Maximum precision and fast machining
Automotive supplier Hirschvogel uses the hyperMILL® MAXX Machining performance package to speed up programming and milling operations.
Maintaining maximum precision whilst working much more efficiently is something the Hirschvogel Automotive Group has been able to achieve using the hyperMILL® CAM program from OPEN MIND. The amount of programming required has dropped dramatically and there has been a double-digit percentage reduction in machining times. One important side effect is that there is much less stress on tools and machines.
Based on the motto ‘To stand still is to regress’, the team that is headed by Robert Haug, Head of Planning and NC Programming at the Hirschvogel tool making department in Denklingen, is constantly working to improve the quality and processes.
Haug and his colleagues have taken a great step forward by switching over to hyperMILL® CAM from OPEN MIND. Thanks to the introduction of the hyperMILL® MAXX Machining performance package, the time required for programming the milling machines for many components has decreased, machining times and the load on the machine and tools have been reduced and new manufacturing options have arisen in the 5-axis machining area.
NC programmer Günter Fasching gives an example of how his work has got faster: “In the past, I developed a 5-axis NC program for a toothing stamp; I had to wait for about one and a half hours for the milling paths to be calculated. With hyperMILL®, the paths are calculated in about five minutes.”
The CAM team in Denklingen has also been able to reduce programming times by using the 5-axis-optimised rest material roughing function. A further advantage of indexed 5-axis machining is that shorter tools can be used. This guarantees greater stability and performance. This strategy also allows hard-to-reach areas and cavities to be machined particularly efficiently.
According to NC programmer Thomas Karg, it was necessary in the past, when programming rest material roughing, to work forward manually, tilt angle by tilt angle while watching out for various restrictions. Now, if you choose the ‘Indexing’ function, you can define the tilt angles for the B and C axes easily and quickly using two methods. The ‘Planes’ option allows you generate the tilt angle from the plane normal. In ‘3D mode’, the tilt angles are created automatically within a defined range of angles. All connecting paths between the tilt angles are optimised and fully checked for collisions.
“Thanks to the hyperMILL® MAXX Machining performance package, machining times and the load on the machine and tools have been reduced.”
Robert Haug, Head of Planning and NC Programming at the Hirschvogel tool making department in Denklingen
HPC strategies provided by the hyperMILL® MAXX Machining power package
Roughing during electrode manufacturing is also drastically accelerated. The Hirschvogel tool makers estimate that an average time saving of between 10 and 20 per cent can be achieved with the high-performance cutting strategies of the hyperMILL® MAXX Machining package.
How can this optimisation potential be achieved? It’s very simple: HPC machining takes place in spiral and trochiodal toolpaths. Dynamic feed rate adjustment according to the actual cutting conditions ensures that milling is always performed with the highest possible feed rate. This results in optimal milling paths with maximum material removal and the shortest possible machining times. High-speed roughing of both prismatic and curved component surfaces is supported. Innovative algorithms ensure 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 stress, resulting in roughing speeds that are significantly higher than before. The machining strategy increases the speed and tool life. Stress on the tool and machine is reduced at the same time.