High-performance strategies for roughing, drilling and finishing

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OPEN MIND Technologies AG

In order to collect data for an overall comparison, Neuner now sets the machine to finish all the necessary sides on the sample workpiece. The difference is as follows: Including transition moves, the traditional strategy takes about 5.5 hours to complete, while machining with the 5-axis tangent plane machining process is finished in just under 11 minutes.

The short manufacturing time also offers a number of other benefits. The heat input into the tool is lower – thus significantly reducing the probability of warping – while the tool life is also much longer than that of a ball mill. Furthermore, far fewer tools are required for the new process.

High-performance cutting strategies for faster roughing

In the Hypermill Maxx machining roughing module, the new Open Mind performance package also offers other interesting high-performance cutting (HPC) strategies. By intelligently separating spiral and trochoidal-like tool paths and dynamically adjusting the feed rate to suit the prevailing cutting conditions, this product allows the user to achieve a maximum stock removal rate. Lead Product Manager Damir Petkovic explains: “Practical experience has shown that this technique can deliver to our customers time savings of up to 75%.” And that’s not all: “What makes the high-performance HPC roughing module special is that it can be used for any type of machining operation, be it 2D, 3D or 5-axis. Users will also benefit from our role as a pioneer of 5-axis technology and can use Hypermill for 5-axis machining of uniquely curved parts.”

Petkovic is also very excited about the 5-axis helical drilling cycle, which allows the user to generate helical toolpaths for efficient plunging with just a few clicks. “This is especially useful for materials that are difficult to machine,” he explains. “The strategy reduces wear on the tool, requires no pre-drilling and reliably removes the chips, even from deep holes.” Moreover, the software automatically adjusts the angle of the tool when there is a risk of collision.

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