One of the highlights of the new hyperMILL suite will be the 'MAXX Machining' performance package, consisting of three modules. First, the fast roughing module includes numerous cycles for milling in trochoidal toolpaths, resulting in fast and reliable high-performance cutting machining. With a dynamic feed rate adjustment that performs according to actual cutting conditions, customers are assured of achieving milling cycles with the highest possible feed-rates at all times. This results in optimal milling paths with maximum material removal and the shortest possible production times. High-speed roughing of both prismatic and curved component faces is supported. The feature ensures that a constant chip volume is always removed by each tooth of the milling tool. This delivers high utilisation rates without exposing the tool to undue stresses, resulting in roughing speeds that are said to be 20 to 70% higher than before. Open Mind has made this fast roughing method available for all types of machining from 2D to 5-axis simultaneous.
High-performance-roughing with spiral and trochoidal toolpaths
Second, the finishing module of the hyperMILL MAXX Machining performance package has been introduced for the optimum application of tool characteristics in combination with trendsetting CAM strategies. This module includes pre-finishing and finishing of planes and free-form surfaces with various barrel cutters. Significant time savings can be achieved with a simultaneous improvement in surface quality. These benefits are accomplished with CAM strategies that use the special shape of the tools to best advantage. Larger step-over distances can be realised due barrel cutters’ bigger radius, while achieving high quality surface finish. The finishing module realises fast, high-quality machining jobs with general, tangential and tapered barrel cutters.
Third, with ‘tangent plane machining’, OPEN MIND has developed a special CAM innovation for plane machining. Time savings of up to 90% can be achieved when using conical barrel cutters. Path distances of 6 and 8mm are possible thanks to the large radii of the conical barrel cutters. This results in optimal surfaces and longer tool life. ‘Tangent plane machining’ is equally well suited for straightforward and hard-to-reach planar faces. Tool paths are generated automatically and checked for collisions.
Another new performance strategy to be introduced at MACH 2016, is fresh from its world première at EMO, is the 5-axis helical drilling cycle. This cycle involves helical milling with a forward lead angle. A tilt angle to the side is then used as part of collision-avoidance process. The advantages are that only one tool is needed for different drill diameters. Pre-drilling is not necessary and the strategy is said to be well-suited for materials that are hard to cut. The process features safe chip removal and reduces stress on the tool. Practical tests have shown that the strategy reduces machining time by 20 to 25% compared to conventional drilling.
5-axis helical drilling for an efficient and tool-friendly plunging into the material
