hyperMILL MAXX Machining Drilling

MAXXimum drilling

The task: To remove as much material as possible from a circular pocket in an efficient and tool-friendly manner. The solution: 5axis helical drilling.

Simply ingenious

5axis helical drilling involves helical tilt milling. The milling tool is tilted tilted forward in the cutting direction. A second tilt helps to avoid collisions with the hole wall. This strategy is especially suitable for making an opening cut when roughing deep cavities. Material can be removed from circular pockets in a highly efficient and tool-friendly manner. Thanks to this 5axis simultaneous machining strategy, milling tools that are not centre-cutting can also be used. The tool plunges into the material quickly, without the need for any predrilling.

Maximum safety thanks to fully automatic collision avoidance

Features

• Fast and efficient material removal, especially for tough materials
• Excellent for opening deep cavities using large milling heads
• No predrilling necessary
• Tool-friendly
• Safe removal of chips, even in deep drill holes
• Also suitable for milling tools that are not centre cutting
• Strategy is as easy as programming a drill hole

Details

Lead angle

In contrast to conventional 3D machining, a lead angle allows for use of milling tools that are not centre cutting.

Automatic pitch adjustment

In the event of a collision, this function automatically adjusts the pitch until collision-free machining is ensured.

MAXXimum finishing

The finishing module in hyperMILL MAXX Machining is a highly efficient solution for the semi-finishing and finishing of planes and free-form surfaces with various barrel cutters.

Faster and better

As a pioneer in the CAM field, Open Mind has spent time focusing on how to use special milling tools in 5axis machining. This expertise has allowed Open Mind to also use barrel cutters in finishing, for example, and develop a totally unique package for this type of finishing. These strategies allow for much larger step-over distances between paths compared with conventional methods. This results in huge time savings. At the same time, surface quality is the same or even better.

Time saved during plane machining: up to 90%

Open Mind developed its innovative 'tangent plane machining' strategy specifically for machining the planes of steep surfaces and bottom surfaces. The conical barrel cutters used in this strategy make it possible to achieve machining time savings of up to 90 per cent compared with conventional methods. Tangent plane machining takes full advantage of the milling tool geometry in order to achieve perfect surfaces during plane machining. Intelligent automated functions ensure optimum tool orientation and fit. In this way, even hard-to-reach areas can be machined reliably and efficiently.

Time saved during finishing: up to 90%

Features/General information

• Much greater step-over distances with the same theoretical scallop height
• Hard-to-reach areas can now be finished better
• Efficient and reliable finishing strategies
• With these strategies, thermal deformation of machine elements are less likely to leave an impression on the component.
• Reduced number of tools
• Possible applications: tool and mould manufacturing, aerospace, tire moulds, turbine blades and impellers
• hyperMILL MAXX Machining supports barrel cutters. The different cutter types are available in many 5axis cycles:
  • Tangent plane machining
  • Tangential milling
  • 5axis rework machining
  • 5axis machining for impellers, blisks and turbine blades

Features/Tangent plane machining

• Strategy for tangent plane machining with conical barrel cutters for time savings of up to 90%
• Especially for machining steep or flat planes in undercut situations
• Automatic alignment and nestling of the conical barrel cutter
• Simple programming ensures a high degree of user-friendliness

Benefit

• Reduced machining times with time savings of up to 90% during tangent plane machining
• High-quality surfaces
• Extended tool life

Details

Strategies

The following machining strategies are available for tangent plane machining:

1. Machining the face
2. Machining the face with limit
3. Machining the limit

Indexed machining

The face is machined with different orientations in specific areas. A high level of surface quality between the orientations is achieved thanks to a defined overlap.

Simultaneous machining

The entire face undergoes 5 axis simultaneous machining. 5 axis simultaneous machining is especially effective with dynamic machines.

Bottom machining

Bottom surfaces with undercut situations and edge areas of high walls or pocket bottoms can be optimally machined using the strategy for conical barrel cutters.

Barrel cutters in general

Barrel-shaped tools use a section of the circumference, allowing for very large radii. For example, the compact design of the tools allows for a cutting radius of 500 mm. Types:

• General barrel cutter
• Tangential barrel cutter
• Conical barrel cutter

Comparison of barrel cutter and ballmill

Conical barrel cutter

The conical barrel cutter represents a completely new type of milling tool geometry that was developed by OPEN MIND. Thanks to this innovation, faces with minimal curvature can be efficiently machined.

Conical angle greater than 50° for hub finishing

Conical angle of less than 40° for machining steep areas

Advantages

• Greater step over distances during semi-finishing and finishing operations.
• Barrel cutters enable a greater step-over distance with the same theoretical scallop height
• Efficient production thanks to shorter machining times with the same or better surface quality
• Increased tool life while simultaneously reducing the number of tools required
• Tolerance deviations due to heat warping at the tool are reduced to a minimum
• Axial deviations of the machine are smoothed
• Simple tool definition in hyperMILL
• Full mapping of barrel cutters, even during the simulation
• Barrel cutters with ball mill tips can be simultaneously used as barrel cutters and ball mills

MAXXimum HPC roughing

The roughing module in hyperMILL MAXX Machining offers solutions for high-performance cutting (HPC) with spiral and trochoidal tool movements. The package combines optimal milling paths, maxximum material removal and the shortest possible machining times.

HPC tool paths for maxximum roughing results

The roughing module is a comprehensive, high-performance package for creating spiral and trochoidal tool paths. Significantly increases material removal rates allow for extremely fast machining. At the same time, there is much less stress on the tools and machines. The roughing module is based on VoluMill, a tried-and-tested best-in-class HPC technology from Celeritive Technologies.

High performance for all machining situations

Users have maximum programming freedom for 2D, 3D or 5 axis machining Optimal cutting conditions combined with large Z stepdowns ensure extremely efficient 2D machining of grooves, pockets and prismatic workpieces. During 3D machining, hyperMILL MAXX Machining divides the component geometry into different planes. The intelligent design and sequence of these planes ensure time and path-optimised machining. A comprehensive 5 axis HPC package allows spiral-shaped and trochoidal-like paths to be mapped to curved component surfaces.

Features

• Creation of spiral and trochoidal-like tool paths for 2D, 3D and 5 axis simultaneous machining
• Intelligent feedrate adjustment
• Fast repositioning in high-speed mode, with the tool being raised slightly off the bottom
• Full cuts and abrupt changes in direction are prevented
• Intelligent division of cuts during 3D machining
• High-volume material removal in next to no time, even with tough workpieces
• Full control of machining parameters: Machining values can be customised
• Uses proven HPC technology from VoluMill

Benefit

• Reduced machining times
• Extended tool life
• Machining that is easier on the tool and the machine
• Machine potential is fully exploited
• No post-processor adjustments required
• Simple to program

Details

Maxximum reduction in machining times

hyperMILL MAXX Machining reduces milling times significantly when compared with conventional roughing. Intelligent division into spiral and trochoidal tool paths allows for high-volume material removal.

Maxximised tool life

Full cuts are prevented with hyperMILL MAXX Machining. Stress on the tool is reduced, significantly extending tool life, especially when harder materials are involved.

Intelligent feedrate adjustment

Special automated functions analyse the local component conditions – wrapping and speed at the edges – and automatically adjust the feedrates along the toolpath.

Maxximum stock removal rate

hyperMILL MAXX Machining allows users to define minimum and maxximum feedrates for different machining situations such as during the approach, the plunge and for the actual machining in the plane.

Intelligent division of cuts

hyperMILL MAXX Machining automatically recognises a machining situation with different planes and adjusts to the situation optimally. Material is removed with maxximum stepdown depth; the remaining material is then removed from the bottom up in defined intermediate steps. 

hyperMILL MAXX Machining: Performance package for highly efficent roughing, finishing and drilling.

Speed is more crucial than ever these days. It’s for this reason that OPEN MIND developed a high-performance solution for roughing, finishing and drilling – the hyperMILL® MAXX Machining performance package. This unique approach makes it possible to reduce machining times and achieve high standards of quality at the same time.

Overview

The hyperMILL MAXX Machining performance package comprises three separate modules for highly efficient roughing, finishing and drilling. Trochoidal tool paths ensure extremely fast material removal. Milling tools tilted in cutting mode can open holes quickly and easily, even in materials that are difficult to machine and without the need for a predrilled hole.

Benefit

• Highly efficient
• Perfect surfaces
• Tool-friendly
• Simple to program

Possible Applications

• Tool and mould manufacturing
• Production Machining
• Aerospace
• Automotive
• Motor sports
• Energy industries

Download a hyperMILL MAXX Machining brochure9.63 MB

Performance strategies: Roughing, finishing and drilling