CAM Soft­ware for the Aero­space Industry

The hyperMILL^® CAM soft­ware helps manufacturing companies in the aero­space sector gain a critical edge in the face of tough competition.

Complex work­pieces, difficult-to-machine materials, and tight time windows are constant companions in the aero­space sector, one of the most demanding industries when it comes to technology. Perfect NC pro­gram­ming across all machining processes is there­fore a key pre­requisite for companies if they wish to remain com­pe­ti­ti­ve in the complex environment of structural, engine, and non-structural aero­space parts.

Innovative Solutions Designed to Meet Tough Challenges

Be it aluminum structural parts, engine components, or non-structural parts for actuation and flight control systems: The hyperMILL^® CAM software can solve the challenges of the aero­space industry with ease. hyperMILL^® is a comprehensive solution that features intelligent methods and strategies ideally suited to typical aero­space tasks. OPEN MIND is a true innovator and has developed numerous functions that result in perfect component sur­faces while also accelerating programming and machining. Complex work­pieces, free-form surfaces, deep cavities, and the like can be reliably programmed in the shortest possible time using the HPC, HSC, and 5‑axis solutions provided in hyperMILL^®. Even difficult cast and forged parts made of titanium, Inconel and other super-alloys can be machined efficiently and in a tool-friendly manner based on proven HSC and HPC strategies.

The Right Strategy for any Application

hyperMILL^® offers a comprehensive range of high-performance machining strategies for every application. The name says it all: The hyperMILL^® MAXX Machining performance package offers the perfect strategies for high-performance roughing, finishing, and drilling. For example, exceptionally high metal removal rates can be achieved when roughing thin-walled structural parts. hyperMILL^® provides specially developed app­li­ca­ti­ons for the efficient manufacture of special aero­space components such as impellers, blisks, and turbine blades.

Complete Machining Is the Baseline

5‑axis machining centers and hybrid machines are the accepted standard for manufacturing companies in the aero­space industry. In addition to other components, a power­ful and versatile CAM solution is required to fully exploit the potential of these machines. hyperMILL^® combines power­ful milling and turning strategies in a single user inter­face to ensure efficient programming and machining. Required setups are reduced to a minimum, setup times are shortened, and at the same time accuracy is increased.

Fast, Reliable, and Automated Programming

OPEN MIND’s feature and macro technology lays the foundation for automated NC programming. Feature technology can automatically recognize standard geo­metries such as bores, grooves, and pockets together with all their machining properties. The information obtained is then reused for manual or automated pro­gram­ming by means of stored machining sequences – so-called machining macros. Feature and macro technology not only significantly reduces programming times; this type of standardization also helps to avoid operating errors. If required, programming projects can be executed in a fully automated manner.

Reliable Simulations Ensure Error-free Processing

‘Safety first’ is of particular importance when producing for the aero­space industry. The hyperMILL^® CAM soft­ware comes with a power­ful NC simulation to ensure that everything will run safely on the machine tool. Collisions are detected in advance and avoided. The advantages are obvious: improved process re­li­a­bi­li­ty and fast set-up processes.
The NC code-based simulation of hyperMILL^® VIRTUAL Machining allows for the virtual mapping of real ma­chi­ning situations, including the programmable logic controller (PLC) and the machine environment. The si­mu­la­ti­on already captures and shows users the exact machine movements that will be later performed on the machine tool. The user inter­face is based on the familiar machine control and is thus very easy to o­pe­ra­te. The solution also supports quick familiarization with the simulation. Based on the NC code, hyperMILL^® VIRTUAL Machining offers numerous options not only for simulations, but also for analyzing and optimizing the machining processes. CAM soft­ware that is tightly integrated with the machine tools is an important pre­requisite for realizing Industry 4.0-grade production.

Seam­less hyperMILL^® PLM Integrations

For aero­space companies that want to combine all product and process data (including NC manufacturing data) into a central PLM environment, hyperMILL^® offers corresponding inter­faces to leading PLM systems such as Teamcenter, Windchill, or SAP PLM. The CAM system thus enables the net­working of the relevant manufacturing disciplines as well as the integration of all CAD, CAM, and NC processes.

OPEN MIND – A Long-standing CAM Partner of the Aviation Industry

In numerous successful projects, OPEN MIND has proven its extensive know-how and shown how com­po­nents in the aero­space industry can be programmed and processed efficiently. hyperMILL^® has also es­tab­li­shed it­self as a CAM system that stands for programming the most complex parts with un­precedented ease, such as impellers and blisks, turbine blades made of high-strength nickel-based alloys, engine hou­sings, and structural parts.