Simulation Based on the NC Code Ensures Processes That Are Reliable and More Efficient

hyperMILL® VIRTUAL Machining Center is the CNC simulation solution featured in the hyperMILL® CAM software. A perfect virtual representation of the machine reality based on real NC data, it provides networking between the machine and hyperMILL® to provide an unprecedented level of process control and optimisation. This is an important step to Smart Factory.

Components are becoming ever more complex, yet turnaround times keep getting consistently shorter. As a result, manufacturers must make optimum use of their machine tools. Auxiliary machine processing times, costly machine damage, production downtimes and the resulting critical delays must be effectively minimised.
hyperMILL® VIRTUAL Machining* plays an important and ground-breaking role for NC simulation. The highly efficient NC code-based simulation solution offers three modules: Center, Optimizer and CONNECTED Machining. These modules help to significantly strengthen the close cooperation between the hyperMILL® CAM software and the machine tool. Networking and virtually mapped processes make it possible to evaluate, control and optimise machining operations more reliably, even before the machine runs.

The latest generation of postprocessors

With its hyperMILL® VIRTUAL Machining simulation solution, OPEN MIND has significantly advanced its postprocessor technology* and added numerous innovative functionalities. The NC program generated by the postprocessor and the machine information from the hyperMILL® CAM software can now be linked to each other bi-directionally. The respective machining programs from hyperMILL® can therefore be directly matched to the NC code.

1 | Machine and removal simulation
2 | Networking with the maschine
3 | Remote control for starting and stopping
4 | Each line of code is simulated
5 | Intuitive operation
6 | NC code display

Simulation and analysis allow considerable advantages

Whether in the role of CAM programmer, machine operator or manufacturing planner, the hyperMILL® VIRTUAL Machining Center has both an intuitive and comfortable user interface. The interface has the look and feel of a real, and therefore familiar machine control system. This means that programmers, operators and planners can become quickly acquainted with the new simulation technology.
hyperMILL® VIRTUAL Machining ensures that all processes are transparent to the user and can be analysed in detail. Working with a ‘digital twin’ facilitates significant optimisation without impacting productive machining time. Benefits include optimised workpiece positions and clamping setups, checked tool paths and the reliable prevention of real machine collisions. This results in improved quality and efficiency during subsequent machining with shorter machining times as well as greatly increased productivity.

*Note: hyperMILL® VIRTUAL Machining requires a hyperMILL® VIRTUAL Machining postprocessor.

“The hyperMILL® VIRTUAL Machining Center is key to designing prove-out processes in a far more safe and efficient way.”

Dr Josef Koch, CTO, OPEN MIND Technologies AG

Application areas

  • Checking, evaluating and optimising the machining process
  • Matching a job to available machines
  • Easily shifting job tasks between available machines
  • Supports for the acquisition of new machines
  • More accurate estimation of costs for bid proposals


NC simulation | hyperMILL VIRTUAL Machining | download

hyperMILL® VIRTUAL Machining

NC code-based simulation and
seamless networking with the machine

PDF | 4.8 MB

A closer look at the hyperMILL® VIRTUAL Machining modules

hyperMILL® VIRTUAL Machining CenterhyperMILL® VIRTUAL Machining Center

The hyperMILL® VIRTUAL Machining Center virtually maps actual machining situations, including the controller and PLC. The numerous simulation and analysis options are carried out on the basis of the NC code and following the postprocessor run. hyperMILL® VIRTUAL Machining Center uses the latest postprocessor technology from OPEN MIND.
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hyperMILL® VIRTUAL Machining OptimizerhyperMILL® VIRTUAL Machining Optimizer

The optional Optimizer module offers powerful optimisation algorithms to make multi-axis machining more efficient. The hyperMILL® VIRTUAL Machining Optimizer automatically finds the best tool position for ensuring perfect machining from the wide range of possible tool positions.
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hyperMILL® CONNECTED MachininghyperMILL® CONNECTED Machining

The CONNECTED Machining module enables in-depth networking and synchronisation with the machine. A bi-directional connection is established between the machine tool and CAM workstation. This provides the best possible exchange of information between the generation and execution of programs. A simple click of the mouse establishes the connection with the machine. Moreover, the integrated remote control feature makes it possible to control machining operations on the CNC machine tool easily via a laptop.
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