hyperMILL^® end-to-end CAM solution is now even more powerful

hyperMILL^® VIRTUAL Machining is all about generating, optimizing, and simulating NC code reliably. Through a collection of targeted solutions, Virtual Machining can be used to map all process steps in CNC manufacturing for perfect process control. The modular technology now also supports additive machining programs. The Optimizer module, which delivers powerful optimization algorithms for efficient multi-axis machining, also features the “Optimized Table-Table Logic” function for easy programming and reduced air time between cuts. The user selects a distance value, and the Optimizer automatically calculates the safety distances using the raw part, component, and clamps selected in the job list. The defined distance is maintained from all components and the movement sequences are automatically optimized. Generating ideal linking movements is even easier as a result. Also, the new feature of direct data transmission in the CONNECTED Machining module provides additional safety during tool input. Instead of the traditional manual input, the parameters are transferred directly from hyperMILL^® to the controller.

Seamlessly merging the virtual and real world

The three hyperMILL^® VIRTUAL Machining modules for the seamless merging of the virtual and real worlds form the core of the safe simulation solution. The Center module virtually maps real machining situations for the machine and controller and simulates these based on the NC code. The Optimizer module provides powerful optimization algorithms that ensure efficient multi-axis machining. It also automatically identifies the best inclination for top machining results. The CONNECTED Machining module enables in-depth networking and synchronization with the machine.

Intelligent component alignment at the touch of a button

Another tool for ensuring greater efficiency and cost-effectiveness in machining is the intelligent component alignment in CAM in real time using hyperMILL^® BEST FIT. The unaligned component is probed on the machine using 3D probing, and the probing points are sent back to the CAM in the form of a measuring log. hyperMILL^® BEST FIT then precisely adjusts the NC code to the actual component position. The adapted NC code is subsequently simulated in the virtual machine on the actual clamping setup and optimized automatically.

5-axis radial machining

Machining strategies for 2.5D, 3D, HSC, mill-turn and 5-axis applications offer the ideal solution for any machining situation. In the area of 5-axis radial machining, the new improvements in the CAM software raise the bar in blow mold machining. The new “Flow Equidistant” infeed strategy is the first of its kind that supports the generation of toolpaths with a constant infeed for vertical and challenging surfaces. This means these surfaces can be integrated into the overall machining sequence and processed in a single step. Seamless machining with a very high surface quality is guaranteed.
New undercut detection automatically identifies undercuts and makes the corresponding machining adjustments, if desired. This means that undercut areas can now be skipped with no manual intervention necessary. As a result, users do not need to generate additional surfaces.
A dedicated 3-axis machine mode greatly simplifies the use of radial machining on these machines, and the “Smooth Overlap” function can be applied to the general milling area without selecting a boundary curve. For instance, the “Smooth Overlap” function blends the transitions between two surfaces that have been milled in different machining directions. This results in perfectly transition-free surfaces.

Programming turning processes even faster and easier

The two new feature types make programming turning processes much easier and faster. Component areas for turning or plunging are reliably recognized, structured, and displayed. During this process, hyperMILL^® automatically divides the recognized features into several areas that can be turned, faced, groove machined, or machined with a combination of these technologies. This saves users a lot of time in contour selection and programming, while giving them full access to all recognized contours. With macro technology, components can thus be programmed automatically with just a few mouse clicks.
hyperMILL^® now offers convenient programming for two-sided machining on machines with a main and counter spindle. The machining jobs are simply programmed under the “Main Spindle” and “Counter Spindle” containers, which assigns them to the respective machining side. The component or bar material, with or without parting, is transferred with the new transfer job. NC output from the main side, opposite side, and component transfer are realized in one end-to-end NC program with a machine model and a post-processor. DMG MORI CTX machines with Siemens control are supported starting in release 2022.1. More manufacturers and machine types will follow.

Time-saving erosion path changes with hyperCAD^®-S Electrode

Time-saving erosion path changes with hyperCAD^®-S Electrode Thanks to the simple creation and subsequent modification of traverse paths during the EDM process with hyperCAD^®-S Electrode, users no longer need to program on the controller. Three new modes are available to users for creating the traverse paths.