Winning teams design and manufacture premium, optimized components to meet a wide array of challenges.

Speed and reliability matter on the race­track – and for machine tools, too. Manufacturers interested in producing high-end components should choose a high-end CAM system.

Whether they’re riding in race­cars or in motor­cycles, winning teams design and manufacture premium, o­pti­mi­zed components to meet a wide array of challenges. On the race­track, vehicles battle to out­pace one a­no­ther by hundredths of a second – there’s virtually no room for error. Similarly, component manufacturing calls for achieving the greatest dimensional accuracy, the highest sur­face qualities, and contour accuracy for free-form sur­faces, with­out making any compromises.
Motor­sport involve a particular challenge: Changes to vehicles must be quickly and flexibly implemented so that the teams riding them can start off the next race with better systems on board.

 
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Industry Challenges

  • Extremely high levels of surface quality

    Grooves and ridges are taboo; this industry requires milling surfaces that are as smooth as possible to serve as the ideal starting point for sub­sequent polishing and grinding

  • Large material removal rates

    Large amount of material must be removed from the stock of thousand individual parts

  • Dimensional accuracy

    Uphold the most stringent tolerances

  • Contour accuracy

    Absolutely precise milling of free-form surfaces is required for optimal aero­dynamics and to reduce the weight of premium, optimized com­po­nents

  • Hard-to-machine material

    Covers everything across the board – from composites to titanium and Inconel

Videos: CAM software for Motorsport

5-axis Machining: Formula 1 Front Wing
hyperMILL® MILL-TURN Machining: Motorsport front wheel hub
5-axis Machining: Formula 1 Front Wing

Manufactured by OSG - programmed with CAM software hyperMILL®.

hyperMILL® MILL-TURN Machining: Motorsport front wheel hub

hyperMILL® MILL-TURN Machining is a powerful mill-turning solution that is completely integrated in hyperMILL®.
This machining of a front wheel hub was made in cooperation with Mazak UK: on a Mazak Integrex I400.

 

High-end milling

Racing-related applications typically involve challenging geo­metries for which a great deal of material needs to be machined. hyperMILL® offers sophisticated high-speed cutting (HSC) and high-performance cutting (HPC) strategies that guarantee optimal roughing and finishing processes, even for material that is difficult to machine. This in turn ensures tool- and machine-friendly machining with high material removal rates. The unique 5‑axis HPC strategies from OPEN MIND make it possible for even the deepest cavities to be roughed as quickly as possible and with­out collisions using short clamped tools. The high-performance finishing mo­du­le of hyperMILL® MAXX Machining achieves time savings of up to 90 percent, thanks to the use of barrel cutters. It also delivers perfect surfaces.

CAM Strategies for Industry-specific Components

High-Feed Cutting
Rest Machining
hyperMILL® MAXX Machining
Special Applications

Adaptive pocket/High-Feed Cutting (HFC)

hyperMILL® offers a large number of functions for HSC and HFC ma­chi­ning. Using a freely definable tool geo­metry makes it possible, for example, to precisely map high-feed cutters, which are then taken fully into account during collision checks and rest material com­pu­ta­ti­on. Machining times can be reduced in connection with the ‘a­dap­ti­ve pocket’ function, where­by circular or rectangular pocket geo­met­ri­es are automatically adapted in the area to be machined.

Rest machining

5‑axis rest machining offers all the options of 3D rest machining in ad­di­ti­on to the 5‑axis tool positions. Automatic indexing independently determines the positions and areas that allow the work­piece to be completely machined in a single operation.

hpc roughing | motorsports –

HPC roughing
Trochoidal toolpaths enable efficient roughing of pockets and open areas with large material removal rates. The particularly high axial infeeds and low lateral infeeds ensure tool-friendly roughing with a peeling cut.

5-axis helical drilling | motorsports –

5‑axis helical drilling
Using this strategy, the material is milled from a circular pocket based on helical tilt milling in a 5‑axis simultaneous movement, which is par­ti­cu­lar­ly efficient and tool-friendly, even when handling difficult-to-machine materials.

finishing with barrel cutter | motorsports –

Finishing with Barrel Cutters
This method allows users to achieve time savings of up to 90 percent during tangent plane machining. The use of conical barrel cutters al­lows for larger line increments while delivering a better surface quality at the same time, compared to conventional finishing methods.

Tube package

The ideal solution for intake and exhaust tubes for engines as well as pipe inlets and out­lets for pumps and compressors: 5‑axis tube machining makes it possible to machine strongly under­cut geo­metries on the basis of the simplest guide curves. The proven collision check and avoidance system ensures safe 5‑axis milling operations.

Automation using feature and macro techno­logy

Feature and macro techno­logy plays an important role in CAM automation that makes daily work easier for all programmers. hyperMILL® recognizes features such as holes, threads and fittings automatically. These features can be used manually or automatically for NC programming. Macros that can be used to save en­ti­re machining sequences enormously reduce the amount of programming required. Programmers’ ma­nu­fac­tu­ring know­ledge is stored in the macro data­base and can be retrieved by all employees at any time. Users can quickly respond to geo­metry changes using this data­base. Thanks to standardization and automation, programmers also avoid possible application errors.

 

References

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Beechwood Engineering Ltd

Read more
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Carbon Fibre Technologies

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Erode All

Read more
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GE Precision Engineering Ltd

Read more
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MK Precision Engineering Limited

Read more

Maximum process reliability is a key to success

As it is for delivery times, so it is for race­tracks: Speed is decisive in motor­sport. Efficient manufacturing with absolute process reliability is necessary in order to uphold tight delivery dead­lines and deliver just in time.
When tool­paths are calculated with the hyperMILL® CAM soft­ware, the collision check is already in­cor­po­ra­ted, and reliable simulation techno­logies make it possible to master the machining of complex 5‑axis integral components at any time.

 

Advantages at a Glance

  • Innovative roughing and finishing strategies

    Particularly efficient as well as tool- and machine-friendly machining, even when handling materials that are difficult to machine

  • Best-in-class 5‑axis strategies

    Safe machining of complex components and deep cavities using short, stable tools

  • Complete machining

    All machining strategies integrated into a single user inter­face

  • High degree of automation

    From feature and macro techno­logy through to fully automated programming

  • High process reliability

    Simulation and collision avoidance for safe processes

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