Programming machine tools: It's all about the software

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Open Mind: Complete end-to-end software solution for CNC production

A universal all-in-one system instead of different software solutions: With Hypermill Virtual Machining, Open Mind closes the gap between CAM system and real machine environment. CNC manufacturers are thus given the opportunity to obtain absolute process control by having all steps mapped virtually. This includes programming, NC code generation and optimisation, simulation of the NC code and networking with the machine.

At Open Mind, the development of a safe simulation solution begins long before the NC code. The CAD/CAM developer relies on in-house solutions for an integrated system with close interlocking of NC code generation and simulation. NC codes that are generated are extensively tested and take machine limitations into account. All process-relevant data are available in the NC code simulation and ensure maximum accuracy and safety, according to Open Mind.

Three modules for merging the virtual and real worlds

Three modules are available in Hypermill Virtual Machining for merging the virtual and real worlds:

• In the Center module, real-life machining situations are virtually mapped using the machine and control system and simulated based on NC code.

• The Connected Machining module enables in-depth networking and synchronisation with the machine. The simulation software can, for example, detect deviations in the zero point or tool positions.

• With the Optimizer module, optimisation algorithms ensure an efficient design of multi-axis machining. The best solution for perfect machining can be identified automatically. Users can now proceed with the CAM programming of portal milling machines in exactly the same way as with a 5-axis milling centre. The Optimizer automatically adds the rewinds required by rotary and linear axis limits and by collision on the basis of the machine's digital twin. When combining jobs with the same tool (“linking”), 2D and 3D machining steps now also form a flowing movement. The Optimizer can also distinguish between roughing and finishing operations.

Intelligent component alignment at your fingertips

Another tool for more efficiency and economy in machining is the intelligent component alignment function in CAM with Hypermill Best Fit. Using a 3D measurement, the unaligned component is probed on the machine and the measurement points are sent back to the CAM system in the form of a measurement log. Hypermill Best Fit then adapts the NC code exactly to the real component position. The adapted NC code is subsequently simulated in the virtual machine on the actual clamping situation and automatically optimised.

To ensure safe and accurate machining, the machine setter then performs a verification measurement. He can then start machining without having to align the component in the machine beforehand. This saves a lot of time and leads to reliable machining and plannable processes.

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