hyperMILL CAD/CAM software: What’s new in 2024?

hyperMILL as Innovative CAD/CAM Complete Solution

OPEN MIND has always offered an innovative CAD/CAM solution whose CAD functionalities are seamlessly linked to CAM programming. This leads to enormous time savings in workpiece preparation.

This alone makes it clear that CAM without CAD is no longer an option today. From version 2024, hyperMILL now combines CAD and CAM under one name (instead of hyperCAD-S), thus consolidating “CAD for CAM” for the future. The familiar CAD functionalities remain the same, only their names change.

By separating topics into the new sections – CAD, CAM, and Technology – we hope to provide an even better overview of our variety of products.

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Current version

hyperMILL^® 2024 | Update 4

Import model-based definition

hyperMILL supports the import of PMI and MBD data in various formats such as STEP, CATIA V5, SOLIDWORKS, Creo, and Siemens NX. A model-based definition (MBD) is assigned to faces, and PMI symbols are assigned to dimensions, tolerances, and surface finishes. This data can be evaluated with the help of the AUTOMATION Center for faster processing.

Benefit: Model data available during CAM processing.

Create faces from grids

hyperMILL now offers the option of generating both open and closed faces from a variety of grid curves. Even non-intersecting curves are taken into account within a tolerance, allowing faces to be generated effortlessly, even in the most complex areas.

Benefit: Simple face creation for milling or 3D modeling.

Creation of three-dimensional electrode paths

Two-dimensional machining is no longer sufficient for some erosion processes. With hyperMILL Electrode, you can now generate machining paths along a 3D curve with simultaneous C-axis rotation. Retract movements are automatically created in the opposite direction to ensure an efficient machining process.

Benefit: Simple erosion process for complex electrodes.

Electrode generation for open surfaces

Deviations in faces and tolerance values often make it very time-consuming to create electrodes. hyperMILL Electrode simplifies this process by allowing electrodes to be created even with open or overlapping faces.

Benefit: Improved user-friendliness.

Optimized Deep Hole Drilling

We have revised the deep hole drilling process and developed a new strategy. A user-friendly interface makes programming easier, with all process-relevant parameters now clearly displayed on the new process tab. The new strategy offers all the functions required for safe and reliable deep hole drilling. Coolant and dwell time can now be defined for each stage or phase of the deep hole drilling process. New functions also make it possible to integrate a chip break into the drilling process.

Thanks to the various parameters, the drilling process can be perfectly adapted to your machining. This increases process reliability. Optionally, programming can be carried out independently of the stock, which is a particular advantage when there is extensive model data. In parallel with the new strategy, we have introduced a new type of tool, namely, the single-lip gun drill. The simulation includes a precise collision check and detailed visualization of the stock removal.

Benefit: Improved programming of deep hole drilling tasks, reliable machining.

3D Automatic Rest Machining

A new algorithm for rest material detection ensures complete detection of all rest material areas. In addition to this detection, we have also optimized the algorithms for path calculation. Toolpaths are now optimally divided to ensure more efficient machining. The detection of intersection areas where paths meet has also been improved. Thanks to a new toolpath layout, the rest material in these areas is machined perfectly.

Benefit: Improved machining of rest material areas.

3D Cutting Edge Machining

This strategy offers you new functions and a large number of improvements. These include optimized collision avoidance that works on the basis of a reference job during machining. Machining is carried out with as little collision risk as the tool reach allows. The “Smooth overlap” option offers the opportunity to smoothly blend the entry and retract moves with the surface and thus almost completely avoid visible approach and retract marks. Zigzag machining can now be selected for the “Plunge” machining mode, and cutter radius compensation can also be used. We have also revised the user interface for this strategy and arranged all important functions on a new strategy tab.

Benefit: More extensive machining options, more user-friendly programming.

5-axis Rest Machining

We have revised and improved this strategy from scratch. A new algorithm for rest material detection ensures comprehensive detection of all rest material areas. In addition to the new rest material detection, we have also updated the functions for indexed approach calculation and path calculation. This is reflected in a faster calculation time and better approach calculation for the automatic 5-axis “Indexing” mode. The optimized detection of intersection areas where paths meet, combined with a new toolpath layout, ensures perfect machining of the rest material.

Benefit: Improved machining of rest material areas, simplified 5-axis programming.

Read back measuring points

Measuring points can now be read back in hyperMILL to ensure and log the component quality. You can see at a glance which measuring points are within or outside the tolerance both on the 3D model and on the “Measured” panel. This allows you to analyze inaccuracies, tool wear, or deviations/trend after milling and compensate for them simultaneously on the CAD and CAM side. This saves time, provides security, and increases quality. This new function can also be used directly on the machine tool with the hyperMILL SHOP Viewer. In addition, reading back the points can be used in conjunction with hyperMILL BEST FIT to visualize the results of the new alignment.

Benefit: Improved quality and process control.

hyperMILL VIRTUAL Machining postprocessor required. Available controls on request.

Turret support for lathes

We have taken a big step forward with hyperMILL 2024 and further enhanced our turning functionalities. The turret technology^* we have implemented now allows you to program lathes with a turret and a main spindle. Thanks to hyperMILL VIRTUAL Machining, the machine and all tools are mapped in detail and used for NC code simulation. The turret is equipped conveniently with turret holders and tools in the machining planner of the virtual machine.

^*Available for machines with a turret and a main spindle with Siemens control system. Further controls to follow.

Convenient use of multiple turret setups

The user can create several setups and select them via the job list. A turret setup is defined as standard. However, several setups can also be exported to the global working space and reused in other hyperMILL projects.

All tools at a glance

The setup status of each tool is immediately visible in the hyperMILL browser. Two new icons indicate whether a tool is mounted on the turret or not.

✓ Tool is mounted on the turret
✗ Tool is not mounted on the turret

Tool breakage check

It is now possible to activate a tool breakage check for tools in the tool database. This information is processed during NC generation with the virtual machine. The generated NC program contains the respective call of the control macro. The breakage check is called before a tool change and at the end of the program. The movements required for breakage control are simulated and checked for collisions. The virtual machine must be adapted to support breakage control.

Benefit: Tool breakage check option, improved process reliability during machining.

Milling with rotation axis

The Optimizer now offers you the option to transform X- and Y-axis movements into one movement with the rotation axis in the table. By swapping axes, for example, an XY movement is transformed into a simultaneous CX movement. This allows, among other things, machining operations to be generated without rewind movements. This is particularly useful for machines that cannot move over the center of the table, or when machining components that take up most of in the workspace. The axis change can be carried out by the Optimizer for 3D and 5-axis jobs.

Benefit: Simple generation of NC programs with axis change and optimized use of the workspace.

Programming assistance: CAM Plan

With version 2024 of hyperMILL, we are introducing a new generation of programming assistance called CAM Plan. This takes over various tasks for you during the programming process. With our first release of CAM Plan, we have focused on simplifying daily tasks and eliminating possible sources of error that occur during programming.

Easier programming thanks to automatic process steps

Thanks to predefined workflow steps, you are guided safely through the process, while the geometries and features required for programming are created automatically. One example of this is the fully automatic generation of cover surfaces for drill holes. In addition, after analyzing the geometry data, you are notified of possible errors, such as double surfaces or gaps in the model surfaces.

Assistance with precision machining

A particular highlight is our new, innovative analysis function, which analyzes the component topology. This topology information is then used to calculate perfect toolpaths with an optimized point distribution for milling.

Toolpaths
hyperMILL calculates the optimum point distribution based on the topology information for the component

Cappings
hyperMILL automatically creates cappings for holes, even on complex geometries with multiple surfaces

Connected Manufacturing

TURNING Solutions

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hyperMILL CAD/CAM software: What’s new in 2024?

hyperMILL as Innovative CAD/CAM Complete Solution

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Version 2024