Efficient NC Simulation and Informative Analyses

OPEN MIND developed its hyperMILL® VIRTUAL Machining Center to allow the manufacturing process to be simulated and analyzed in advance. This avoids inefficient operations, costly errors and streamlines throughput.

Machine movements are often simulated before the postprocessor run. The lack of a connection between the postprocessor and the simulation means that it is not possible to fully simulate actual machining situations.

For this reason, OPEN MIND has decided to go one major step further with its hyperMILL® VIRTUAL Machining Center. In the highly efficient and reliable NC simulation solution from OPEN MIND, the virtual machine movements fully correspond to the actual machine movements, as the simulation is based on the NC code after the postprocessor run. The code is simulated line by line, including the link movements. This NC code-based machine simulation guarantees reliable collision detection, making lead-in processes far safer and efficient.


Simulation with maximum safety

The hyperMILL® VIRTUAL Machining Center offers all the classic options for simulation, which is embedded in a highly intuitive user interface. Machine simulation is carried out with a defined machine model and takes into account the workpiece and the tool as well as the tool holder, fixtures and clamps. The axes can be moved manually in the simulation and limitations are indicated and limit switch traversals are detected automatically. Individual machining steps can be simulated separately or used as a starting point for the simulation. The simulation checks each machining operation before the machine setup. This means that the hyperMILL® VIRTUAL Machining Center delivers maximum process safety and stability.

In-depth analysis of the NC program

In addition to efficient simulation, the hyperMILL® VIRTUAL Machining Center includes comprehensive analysis functions. Every machining situation can be examined in detail. The fit-setup function makes it possible to check the machining area reliably. It automatically calculates the optimal placement of the component for the available workspace. In the real world, this can often prevent time-consuming machine adjustments.

Various technical charts provide valuable information about the quality of the machine run. The traverse movements of the different axes, feed rates, and spindle speed are visible to the CNC programmer at all times. This helps to prevent errors and eliminates inefficient operations. The analysis functions provide even more safety and transparency.


  • Simulation based on NC code
  • Bidirectional linking of NC block and hyperMILL® job enables quick comparison of the respective machining job
  • Full simulation of all movements, including transition movements
  • Quick collision check that can be carried out independently of the simulation
  • Interactive placement of workpiece and fixtures
  • Manual movement of the virtual machine
  • Approach of target points with and without Rotating Tool Center Point (RTCP)
  • Display of axis limits
  • Comprehensive analysis functions
  • Fast comparison of the programmed datum points and tools with the actual machine configuration

Details on the analysis functions in hyperMILL® VIRTUAL Machining Center

Workspace monitoringWorkspace monitoring

With the help of a stored machine model, the workspace monitoring checks whether any limit switches are traversed by the 2.5D, 3D, 3+2 or 5-axis simultaneous machining movements. The movements of both the linear axes (X, Y and Z) and the rotary axes (A, B and C) are checked, as well as the clamps and fixturing systems.

Setting breakpointsSetting breakpoints

The simulation can be controlled to stop at certain locations in order to reliably check critical points and estimate the subsequent processes more precisely. The breakpoints are created automatically under certain conditions, such as a tool change or a change from rapid traverse to cut movements. Moreover, breakpoints can also be selected manually through an NC block line or picked up from any point on the toolpath.

Adjusting visibilityAdjusting visibility

The visibility of the individual machine components can be adjusted in order to enable optimal visualization of the simulation. Preset machine views, such as ‘Head and Table’ can be called up at the push of a button.

Safe working space analysisSafe working space analysis

The unique Best-Fit function automatically optimizes the machining operation to match the available workspace. Workspace monitoring is able to indicate instances where the limit switches have been traversed but the actual workspace is still sufficient for machining. In this case, the Best-Fit function automatically determines the optimal setup location for the respective workspace. This does away with the need for unnecessary setup changes and resulting downtimes.