hyperMILL 5AXIS Tire

The Tire package

Repetitions for more efficiency.

Whether using positive or negative moulds – the Tire module mills tire moulds more economically than ever before. Automations, milling strategies and special functions guarantee a simplified and efficient programming process, for example for knifecut and stone ejector functions, as well as other details. The recurring arrangement of identical tire sections is usually defined with a tire clock. Each area (pitch) must therefore be programmed only once. The tire utility also copies the tool paths to the relevant positions in the tire. In doing so, the automated segment generation trims the tool paths that go beyond the segment limit. In addition, optimised milling paths considerably reduce the machining time.

Download a hyperMILL 5AXIS Tire brochure2.56 MB

Taking tire machining to the next level.

5axis top milling

In addition to the quick finishing with endmills and bullnose endmills that allow large stepovers, this cycle can also be used for optimising roughing on pre-turned stock. The tool follows the surface curvature. Thus, more consistent remaining material is ensured on the floor and the profile walls.

Arbitrary stock roughing

This ensures that fine points are effectively worked. The exact tracking of remaining material helps to avoid redundant move­ments and guarantees a high degree of process reliability when using slender tools. The individual machining operations can be performed in any direction and in various setups.

Optimised 5axis swarf cutting

Swarf cutting allows a more effective machining of ruled surfaces. This cycle makes milling profile flanks and sharply angled inner corners very easy. Tapered tools can also be employed. The definition of milling and stop surfaces protects neighbouring surfaces.

5axis rest machining

The sharp edges of the tire moulds can be machined precisely with slender tools without having to be reworked. This cycle recognises all rest material areas, even in undercuts. The machining is performed on multiple segments in one collision-free operation. In addition, this cycle also generates especially smooth movements.

5axis contouring

This cycle is for 5axis reworking of edges and efficient programming of sipes. Contours with different tool positions are machined in one step. hyperMILL® combines the indi­vi­dual machining operations automatically with path-optimised, collision-free tool movement.

Simple programming of strongly undercut geometries

The Tube package.

This package is for intake and exhaust tubes for engines as well as pipe inlets and outlets for pumps and condensers. 5axis tube machining makes it possible to continuously machine strongly undercut geometries in one operation, on the basis of the simplest guide curves. Since no special demands are made of the data model, trimming, closing of gaps and surface feedback can all be dispensed with. This easy-to-use package allows the user to achieve quick results without time- consuming tests. The proven collision check and avoidance system ensures safe 5axis milling operations.

Download a hyperMILL 5AXIS Tubes brochure978.58 KB

Quickly programmed. Easily milled.

5axis tube roughing

With this strategy the tube is milled in a continuous machining process from the stock. This 5axis simultaneous strategy is an effective alternative to machining with several axes in fixed positions. There is spiral infeed to the bottom, and work is executed on the plane. Removal can occur from the outside to the inside as well as from the inside to the outside.

5axis tube finishing

With this strategy the tube is finished with a spiral or parallel tool path. The spiral tool path creates a seamless, high-quality surface. With parallel machining, it is possible to avoid unnecessary movements of the rotary axes.

5axis tube rest machining

With this strategy, rest material areas are machined in either a spiral or parallel movement. The areas to be machined are described by a reference curve. The machining width can be limited by defining a value symmetrical to the reference curve.

Optimised milling strategies for complete machining

The Blade package.

The Blade package provides many automations for simple machining definition and incredibly short programming times. These include the rolling ball function for milling transition radii, the best fit function for automatically setting the optimal start position for the finishing cycle or the automatic lead angle correction function for collision avoidance of the tool face with concave surfaces.

Download a hyperMILL 5AXIS Turbine blade brochure854.23 KB

Turbine blade milling – Complete from top to bottom.

3D arbitrary stock roughing

On the basis of a freely definable stock, blades are machined from various directions.

5axis blade top milling

This strategy is for finishing blade surfaces. It is possible to generate spiral tool paths as either 5axis or 4axis simultaneous machining operations using ball-end or bull-nose cutter.

5axis blade swarf cutting

This strategy is used for the swarf cutting of platform surfaces. Swarf cutting can also be used to machine the transitions between the blade and the platform surfaces that cannot be machined using 5axis Top Milling.

5axis blade fillet milling

This function optimises finishing at the transition between the blade and the platform surfaces of the tip or root.

Additional cycles for platform machining

A series of 2D and 3D strategies are available for machining the blade platform and root sections.

As simple as a standard application

The Multiblade package.

Impellers and blisks can be programmed even without special knowledge using this application. Integrated automated functions in the Multiblade package reduce the number of parameters needing to be entered to a minimum. Proven collision checking guarantees a very high level of process reliability. The use of robust tools allows machining with high infeed parameters and feedrates.

Download a hyperMILL 5AXIS Impeller/Blisk brochure1.06 MB

Milling of impellers and blisks made easy.

Multiblade roughing

In the roughing cycle, the blades are machined in a continual process starting from pre-turned stock or a semi-finished workpiece. No time-consuming simulation of the removal of material is required.

Multiblade plunge roughing

Plunge roughing is an alternative if a horizontal feedrate cannot be effectively machined with long, slim tools. This process allows the most rigid tool to be employed to rough open a pocket between blades, and is provided as an optional module.

Multiblade hub finishing

The tool path profile can adjust the hub’s aerodynamic behaviour and appearance to suit individual customer requirements. This machining strategy can also be applied as rest machining near blades.

Multiblade point milling

This HSC strategy is characterised by continuous, spiral machining movements with tool point contact. This allows superb milling of even highly curved blades.

Multiblade flank milling

If the blade surfaces allow for sufficiently precise swarf cutting, the Flank Milling cycle can be used. This reduces machining time. hyperMILL® 5AXIS automatically calculates the optimal tool nestling.

Multiblade edge milling

This machining strategy is used whenever leading and trailing edges cannot be generated together with the flow areas in a single operation.

Multiblade fillet milling

This is the ideal strategy when the radii between the hub and the blade surfaces vary. This strategy also facilitates rest material machining – the basic requirement for choosing an optimal tool for blade and hub machining.

For surfaces and special tasks

Simple programming for the best surface quality.

hyperMILL 5AXIS provides a wide variety of machining strategies for the broadest possible range of manufacturing tasks. Programming is simple and gets you quickly to your goal while achieving the best possible surface quality.

5axis contouring machining

For milling grooves, scribing, engraving, deburring, and chamfering. With 5axis Contouring, the tool is guided on or to the side of a curve with a fixed orientation to the surface. This strategy allows the user to manually change the tool orientation for an entire area or for a specific area, if necessary.

5axis top milling

For machining of large, moderately arched surfaces, top milling reduces cutting time by using greater step-over between adjacent paths. Automatically adapted tool tilt angles ensure high surface quality on concave surfaces. Thanks to multiple infeeds and stock detection, this strategy can also be used for very effective 5axis roughing.

5axis swarf cutting

For machining arched surfaces, swarf cutting machines the workpiece surface with the tool flank. Large step-overs between paths or full-depth cutting reduce milling time and improve the workpiece surface. Multiple axial and lateral infeeds make swarf cutting also suitable for roughing or combined semi-finish and finish operations. Defined stop and milling surfaces, as well as stock tracking, allow precise and simple optimisation of machining operations.

5axis shape offset finishing

Barrel cutter shapes that enable larger infeed are now supported by hyperMILL.
Benefit: Very short machining times and optimised surface quality.
New, spiral movement sequences enable a constant, continuous infeed.
Benefit: Better surface quality.

5axis Strategies for Cavity Machining

For difficult geometries such as deep cavities and steep high walls.

hyperMILL 5AXIS adds 5axis positions to “z level Finishing”, profile finishing, equidistant finishing, free path milling, rest machining and rework machining 3D strategies. These strategies can now be used for 3+2 milling, automatic indexing and 5axis milling. Thanks to the fully automatic calculation of tool positions, 5axis machining jobs can be programmed as easily as conventional 3D tasks.

5axis z level Finishing with simultaneous machining

5axis “z level Finishing” is used to machine steep surfaces as planes or pockets. Flat areas can be automatically excluded in this type of finishing.

5axis profile finishing with automatic indexing

As with conventional 3D tasks, flat or slightly curved areas can be machined using 5axis profile finishing. 5axis collision avoidance allows you to mill near steep walls using a short tool in a single step. Combined with automatic indexing, steep walls can also be machined in the removal direction of the mould.

5axis equidistant finishing with simultaneous machining

5axis equidistant finishing allows you to machine steep and flat areas in a single operation. This strategy generates especially smooth transitions between individual tool paths. It helps prolong the lifespan of tools and machines and ensures the best surfaces possible.

5axis free path milling with automatic indexing

5axis curve machining makes it possible to mill engravings without collisions using short tools, even near steep walls.

5axis rest machining with automatic indexing

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

5axis rework machining with simultaneous machining

5axis rework machining (editor) is used to convert 3D programs into 5axis programs. It also allows 3D tools that have been excluded due to a collision to be machined as 5axis simultaneous machining jobs or with auto­matically calculated fixed positions. All 3D and 5axis toolpaths can also be optimised to improve milling results.

Assured on all sides

Trendsetting 5axis technology.

Depending on the geometry and machine kinematics, the user can choose between 5axis machining with a fixed tool angle, automatic indexing or true simultaneous motion.

Multi-axis indexing with fixed tool inclination

Moving and tipping of the workplane allows parts to be machined from different directions without reclamping. The direction of machining corresponds to the orientation of the tool. Programming times are reduced with trans­for­mation functions to shifted or tilted workplanes.

Milling with fixed option 3+2

For 3D machining with a tool that is tilted relative to the machining direction, milling areas can be programmed easily, defined without overlaps and gaps and checked for collisions. This strategy ensures that all areas including details are completely calculated.

Automatic indexing

Automated 3+2 milling offers an alternative if the milling machine does not fulfil the dynamic requirements for 5axis simultaneous milling. Large areas that require various tool angles are programmed and milled in a single operation. Automatic indexing scans for fixed tool incli­na­tions for the corresponding tool paths. If there are possible holder collisions, the respective path segment can be subdivided automatically into smaller segments with the corresponding tool positions.

5axis simultaneous machining

This 5axis machining cycle is the alternative to conventional 3+2 milling for machining on or near steep walls. Similarly, a tool tilt to the Z-axis is predefined – collision-free, if possible. The continuous movement of the tool around the Z-axis is calculated by hyperMILL either fully automatically or as a result of defined tilt curves. Possible collisions are automatically detected and avoided by changing the tool angle. Optimised tool tilt angles improve cutting conditions when milling surfaces.

Trend-setting 5-axis technology to facilitate economical machining of complex geometries.

The measure of all (milling) things.

The trendsetting 5 axis technology in hyperMILL can typically yield time savings of more than 25 per cent while lowering tool wear and increasing contour accuracy for more cost-efficient production thanks to continuous machining. Challenging geometries such as high and steep walls require many different tool inclinations in precisely delineated milling areas.

5 axis simultaneous machining with hyperMILL 5AXIS is based on what users are already familiar with: milling with a tilted tool. Yet the machining process is now quicker, the surface results are better and programming is much less complicated. Thanks to easy programming with automatic collision checking and avoidance, this technology can also be used as a solution for many standard milling jobs.

Highlights

• Easy programming for milling applications with indexed orientation.
• Process reliability due to proven fully automated collision checking and avoidance.
• Multiple tilt strategies are available: 3+2, automatic indexing and 5 axis simultaneous machining.
• Familiar 3D strategies, such as Z-level machining or rest machining have been expanded to include 5 axis processing.
• A broad spectrum of machining strategies for surfaces, cavities and special machining tasks.
• All 5 axis strategies are available in the hyperMILL® interface.
• 5 axis shape offset roughing and finishing for simple and time-saving programming of shaped and wrapped surfaces.