With the latest release of its leading CAM system, OPEN MIND Technologies AG is setting the direction for future-oriented CAM programming. The NC programming system benefits from more process reliability, a better user interface and short manufacturing lead times – all with less programming effort even for complex workpieces. Once again, the new hyperMILL® 2009.1 from OPEN MIND Technologies AG sets the benchmark for the efficient and comprehensive CAD programming ranging from 2D to 5-axis applications.

As the link between design and production, the CAM system represents a major factor in process streamlining. hyperMILL® software from OPEN MIND Technologies AG implements a consistent process chain with uninterrupted workflows and reduced cycle times. The CAM expert offers a broad spectrum of CAD-integrated solutions and direct interfaces as well as powerful post-processing technology that is customized for each machine. The new release hyperMILL® 2009.1 impresses with improvements and innovations in all areas ranging from 2D to 5-axis processing, including improved deep-hole drilling with feed motion reduction for cross-hole drilling, 3D roughing with minimal metal removal and as an all-in-one finishing process, an optimized rapid motion concept, the intelligent job link as well as new functions for simultaneous 5-axis milling. The new release makes all CAM programming steps even more efficient than before.

With hyperMILL® 2009.1 components can be checked quickly and easily for optimum job preparation and seamless CAD programming, and with the new analytical tools the user can easily recognize manufacturing-relevant properties of design elements. A simple click brings up information about surface types, radii, coordinates and selection points. By clicking two elements, the user can check the distance between surfaces and points or the angle between two surfaces. Depth measurements are possible, too.
Production-relevant information such as tolerances or process types are displayed as standardized and color-coded tables which can now be stored in hyperMILL® 2009.1. They provide the user with easy access to information about the drilling or other geometrical tolerances in the workpiece.

Efficient programming with a mouse click

Transformations provide new ways of reproducing the processing of identical, similar or symmetrical shapes quickly and easily. Any changes in the original are instantly reflected in all “copies”. In addition, each parameter can be adjusted individually. As a special feature, the shifted and/or rotated programs can be checked for collisions with the finished part, which simplifies the programming of tombstone fixtures or multiple fixtures.
Mirroring is suitable for completely symmetrical parts such as left and right workpieces as well as for parts where only certain shapes are mirrored. Synchronized processes are maintained in the mirrored operations, and any changes in the original are automatically reflected in all mirrored versions. Individual parameter adjustments are possible too.

Reusing manufacturing know-how

The expanded job list in hyperMILL® 2009.1 makes it possible to arrange jobs in groups based on work steps, geometries, special positions or tool orientations. You can even combine or hide work steps. This feature makes managing projects with long job lists a lot easier.
With the new OPEN MIND tool database, you can map tools even more accurately than before. The graphical user interface ensures reliable definitions. You can map complete tools and even take connector types into account for a comprehensive collision analysis.  Depending on the tool construction, the processing strategy and the material you can also store different technology parameters. The new tool database provides a comprehensive solution for efficient tool management. It also includes interfaces for connections to the databases of leading tool manufacturers.

The new 2D contour milling offers significant potential for faster programming and shorter machining times. The automatic transportation strategies always select the best available path and the optimum starting point. A special feature is the automatic trimming of tool paths against the unmachined part, which optimizes the travel paths and avoids deadhead trips. In addition, the collision check against the milling area ensures maximum process reliability.
With playback milling you can execute very simple milling procedures by guiding the mouse pointer across the corresponding areas. The system displays the material removal for the selected cutter diameter and checks the milling path for collisions.
The perforation detection expands the pocket feature detection: In addition to closed pockets, pockets with islands and pockets with open sides, hyperMILL® 2009.1 now recognizes open pockets as well.

The production mode is a new function that minimizes the travel movements within a process. If certain areas are not machined, the production mode makes sure that they are circumvented along the shortest path and without collisions. This can shorten production times considerably, particularly for large parts on relatively slow machines.
For processing residual materials, a reference job can be selected instead of the reference tool. Afterwards, the system processes only those residual material areas that the reference job was unable to work on due to collisions. Another search for potential residual material areas is no longer necessary. These areas can be processed with 3D, simultaneous 5-axis simultaneous processing or fixed 5-axis processing. Since the calculation is based on the areas previously determined by the reference job and only the toolpaths are recalculated, a different tool can be selected at any time. Additional restrictions with boundary of milling surfaces are no longer needed.
New functions in 3D residual material processing also provide speed improvements in hyperMILL® 2009.1. One of these involves defining a radius cutter as a reference tool for machining ribs and grooves. Deep sections with lots of material can now be cleaned out completely and effectively with a constant depth setting.
The 3D radius correction reduces the programming effort and makes it possible to maintain high tolerances, for example when a tool is used to mill multiple electrodes.

October 2009

John Hart Pty Ltd has expanded its range of 3D design software with the announcement that it is now an agent for the integrated 3D CAD/CAM/CAE solution Pro/ENGINEER, from PTC. Accompanying the CoCreate (PTC) software package also available from John Hart, Pro/ENGINEER is the standard in 3D product design, featuring productivity tools that promote best practices in design while ensuring compliance with your industry and company standards.

Pro/ENGINEER’s powerful, parametric design capabilities allow superior product differentiation and manufacturability, while the fully integrated applications allow you to develop everything from concept to manufacturing within one application. Automatic propagation of design changes to downstream deliverables allows you to design with confidence and Pro/ENGINEER’s complete virtual simulation capabilities enable you to improve product performance and exceed product quality goals.

The latest Pro/ENGINEER package, Wildfire 5.0 is available now and offers numerous enhancements that enable users to overcome the key barriers to design productivity. With real-time, dynamic editing and disruption-free design, Wildfire 5.0 is designed to help users overcome the traditional barriers to flexible and easy design modification. New user experience enhancements such as graphical browsing, intuitive UI enhancements, streamlined tasks and faster performance have also been included to improve design efficiency and increase your design productivity.

July 2009

Products for the medical industry benefit from the high manufacturing quality offered by hyperMILL ® – injection moulds for medical products as well as implants made from hard metal or titanium, for example. The high-precision machining offered by OPEN MIND Technologies AG’s powerful CAM solution is essential for achieving the high surface quality that is crucial for the compatibility of implants. The fully automated hyperDENT® programming system is available to users in the dental industry.

hyperMILL® : Integrated all-round solution
OPEN MIND’s powerful hyperMILL® CAM software for demanding and complex geometries is one of the leading CAM solutions for 5axis simultaneous milling. The company’s software package offers an extensive range of machining operations for use in medical engineering that are particularly useful for the complex milling and mill/turn processes required for implants as well as the manufacture of injection moulds. hyperMILL® ’s 5axis technology enables the use of shorter and therefore more stable tools. Improved cutting conditions and less risk of chatter and tool breakage translate into better milling results. Tool wear can also be reduced to increase the performance of the machining process.

hyperMILL® CAM software offers 2D, 3D, HSC, 5axis milling and mill/turn strategies. All the programs can be generated in the intuitive and consistent user interface. The millTURN module is integrated seamlessly so that stock tracking, collision avoidance and the tool database are available for all operations. This ensures quick and easy programming as well as superb process safety. Thanks to fully automated collision checking, programming is very easy. Tool angles and positions are largely generated automatically. Depending on the part geometry and the machine kinematics, users can choose between “3+2”, “automatic indexing” and “5axis simultaneous machining”.

Milling in 5axis simultaneous machining avoids approach and retraction marks often found in 3+2 machining. The comprehensive 5axis strategies provided by OPEN MIND’s solution, such as 5axis swarf cutting with barrel-shaped tools, result in a significant reduction in machining times. Furthermore, the precision and high finish of the machined free-form surfaces created by hyperMILL® reduce the often expensive and time-intensive manual rework to a minimum. The CAM solution thus combines a high level of performance and machining efficiency with an excellent surface quality of the individually manufactured product, which is crucial for ensuring the compatibility of implants in the human body.

Widely used standard CAD interfaces and direct interfaces allow seamless CAD data imports to hyperMILL® from CATIA V4 and CATIA V5, Pro/ENGINEER, NX™, Parasolid and SolidWorks, for example. The CAD-integrated hyperMILL® solutions, which are available for thinkdesign, SolidWorks, Autodesk Inventor™ as well as OPEN MIND’s own hyperCAD application, provide even greater convenience for users. They allow users to carry out their CAM programming directly within their familiar CAD environment removing the need to export/import CAD data between software platforms.
Error-free from CAM to NC program: The postprocessors from OPEN MIND Technologies AG generate optimised NC programs from the machine- and controller-independent toolpaths created with hyperMILL®. Each NC program is tailored to the machines and controllers used by the customer. OPEN MIND’s expertise and many years of experience make it possible for the company to develop an individual solution for each system that optimally satisfies all existing requirements.

hyperDENT®: Open system specially developed for dental engineering
OPEN MIND Technologies AG’s new hyperDENT® software is a fully automated CAM programming system for manufacturing customised dental solutions. The programming system is closely geared towards dental technology processes and allows the digital precision manufacturing of crowns, multi-unit bridges, abutments, caps or implants, for example. As the open CAM system is integrated seamlessly in the process chain comprising scanner, CAM software and milling machine. hyperDENT® allows dental laboratories and dental technicians to flexibly set up solutions or easily modernise existing solutions to suit their own requirements.

hyperDENT® guides users through the entire programming process in a well-structured manner, so that even users who are new to CAM programming can generate complete NC programs with only a few mouse clicks. Once the machine and holder have been specified, the stock has been loaded and the part has been placed by clicking the mouse, the parts are simply and optimally aligned with the help of gouge control, and tooth preparation limits are automatically detected. Connectors are set automatically while sintering pins are set simply by clicking the mouse. In addition, hyperDENT® provides experienced CAM users with additional options for manually optimising and controlling individual programming steps.
The toolpaths are calculated automatically. The comprehensive collision check and avoidance feature, which also incorporates the fixtures, ensures maximum process reliability. Likewise, the machining simulation feature performs a thorough and detailed check of the generated programs before these are released for machining. (Where required, each step can be checked individually.) All of these features offered by hyperDENT® ensure exceptional high-quality parts and reliable production in dental technology applications.

July 2009