Maximum material removal - shortest possible production time

With hyperMAXX®, OPEN MIND Technologies AG blazes new trails in roughing. The optional roughing strategy, fully integrated with hyperMILL®, combines optimal milling paths, maximum material removal and the shortest possible machining times. By calculating ideally distributed milling paths and dynamically adjusting the feedrate to existing cutting conditions, this strategy ensures that milling takes place at the fastest possible feedrate.

With hyperMAXX®, OPEN MIND presents an optimisation strategy for stock roughing, which is based on Celeritive Technologies Inc.’s VoluMill solution.

OPEN MIND has fully integrated this software into hyperMILL®. As a result, there is no need to launch a second system to utilise the new roughing options. Plus: No adjustments are required during postprocessing.

Very special algorithms

Special algorithms help to ensure superb performance levels when generating the milling paths. In addition, they also help to protect machines and tools. The reason for this lies in the ideally distributed milling paths that are managing the material removal and cutter engagement.

This results in a host of advantages:

- Automatic adjustment of the feedrate to the current cutting conditions.
- Constant load on the tool and the machine during the entire machining operation.
- Reduced machining times based on larger axial depth of cut and better path layout on each cutting level
- The fastest possible safe positioning of the tool.
- The plunge macro always creates a complete helix or ramp movement.
- No sharp edges or sudden changes in milling direction.
- Intelligent automated functions for optimised adjustment of feedrate and infeed for the machining of tight areas with full cutting and long tool paths (soft material), as well as trochoidal tool paths that avoid full cutting (harder materials).
- Up to 100 percent of the tool diameter can be used without leaving material behind.

New version with more improvements

The new version of hyperMAXX® facilitates milling with even higher feedrate averages. This is possible thanks to an optimised feedrate control developed by OPEN MIND. Previously, the system calculated the feedrate as a linear value between 0 and 100% of the maximum feedrate. Now, the user can specify a minimum feedrate in addition to the maximum feedrate.

If the user enters a minimum value of 50% of the ideal value, for example, this increases the average feedrate value. In this case, the feedrate will be interpolated between 50% and 100%. Next to improving the working feedrate, the extended feedrate definition also has the advantage that it helps to avoid feedrate speeds that are too slow for the tool to cut properly.

The optimised plane detection provided by hyperMAXX® further shortens machining times. This strategy helps to prevent step formation during roughing with large stepdowns, and also to create a uniform allowance on the stock. The strategy automatically detects the different planes and then starts with the largest stepdown depth (as opposed to constant-Z plane-by-plane machining). Planes with a low stepdown depth are then machined with a reduced stepdown, step by step, from bottom to top.

The “Intermediate Steps” function is available for defining additional steps to enable smoother machining of flat transitions and inclined walls. This not only creates a contour cut but also processes entire planes or pockets that were not included in the primary cutting levels. Such an approach enables machining that is optimised for both paths and for machining times. The tool’s cutting width is used more efficiently and tool life is increased.

Process reliability

For axial infeeds, the process is absolutely reliable up to the maximum cutting length of the cutter. The software is suited for machining soft as well as hard materials that are difficult to cut, such as titanium, nickel-based alloys or stainless steel. Both large machining and micro-machining jobs can be handled quickly and efficiently. The high-performance strategy also includes a collision check that accounts for tool lengths, as well as plane detection in automatic mode.

Process reliability furthermore entails the aforementioned adaptive adjustment of the cutter settings. This simplifies the user’s work greatly. The user can set the optimal values for stepdown, feedrate, spindle RPM and the cutting tool without having to worry about worst-case scenarios. The system automatically adjusts the values in areas where the maximum permitted values are exceeded (e.g., tool engagement in case of excess material in the corners).