Open Mind extends hyperMaxx high performance cutting to 2D pocket milling

Open Mind's hyperMaxx roughing module, fully integrated into hyperMill, is based on the Volumill technology kernel from Celeritive Technologies. It combines ideally distributed milling paths and dynamic feedrate adjustment to existing cutting conditions to ensure that milling always takes place at the fastest possible feedrate. Machining is always performed using climb milling, in a spiral retraction of tool movements that increasingly approximate the required contour as they reach the end. The milling tool generally operates using the entire cutting length. A special system algorithm ensures that an equal volume is removed by each milling tooth. This ensures the optimal capacity of the tool, while ensuring that it is not overloaded, and it generates a large material removal rate, explains Open Mind. The requirement for optimal machining is the dynamic adjustment of the feedrate to the existing cutting conditions. Users do not enter a fixed value for the spindle speed and feedrate. Instead, they provide key data with which the respective machine tool and the tool can operate. The hyperMaxx toolpath is then calculated with regard to the chip volume and balanced movement. The process is not only especially suitable for steel, titanium and nickel alloys, but can also be used for soft materials, such as aluminium. As well as constant load on the tool and machine during the entire machining operation and on the tool, Open Mind says that the strategy also provides the fastest possible safe position of the tool. The strategy features a plunge macro that always creates a complete helix or ramp movement and an automatically generated helix radius; there are no sharp edges or sudden changes in milling direction and there are intelligent automated functions for optimised adjustment of feedrate and infeed for the machining of tight areas with full cutting and long toolpaths (soft material), as well as trochoidal toolpaths that avoid full cutting (harder materials) Up to 100% of the tool diameter can be used without leaving material behind and users have access to a range of more straightforward milling tool qualities which can significantly lower costs. The hyperMaxx 5-axis shape-offset roughing and finishing function was introduced in 2011. This adopts the curved surfaces of a component, such as for turbine housings, structural parts for aircraft or tyre moulds, as the standard surface. The tool operates at an angle of 90º at every point. The strategy works as if it involved 'curved' Z roughing or Z finishing. This makes creating the NC program much easier. Postprocessor adjustment is not required as hyperMaxx is fully integrated into hyperMill.