Programming interface eliminates 'dummy' roughing

New at MACH 2002 will be the pre-release version of a new user machine programming interface for easier operation and quicker access to individual functions as well as an upgraded browser.

New at MACH 2002 will be the pre-release version of hyperFORM 7, offering a new user interface for easier operation and quicker access to individual functions as well as an upgraded browser.

Extra functionality includes enhanced Z-level rest machining whereby it no longer needs to be referenced to a roughing cycle.

It is now possible to calculate remaining material from the previous rest machining job, so time consuming 'dummy' roughing is no longer necessary.

The interface allows the user to display the input data in large or small windows and choose between modal and non-modal dialogue, the latter enabling direct switching between jobs and calculation with the dialogue window open.

hyperFORM 7 saves job lists directly in the model drawing.

It is now also possible, for the first time, to define multiple job lists in one drawing.

The user can conveniently swap individual jobs or complete lists between different models using the import/export interface or using copy and paste.

When exporting, the entire list or individual jobs can be selected.

It is possible to specify whether to save tools and geometries such as boundaries and contours as well.

Not only can hyperFORM 7 import job lists from version 6, it can also import hyperMILL AMD V6 export files.

Tools may be defined complete with holder, cutter and technical data; or imported from an external database.

Then, using an internal tool list, they can be assigned to a new job.

Data is stored in the tool list or locally in the job.

This enables global modification for all jobs, and also local adaptation to individual jobs.

The tool display in the model offers quick feedback on the size relationship of the tool to the part.

Visually checking NC paths is now easier, especially when multiple jobs have been calculated, with menu features to view and hide, delete or highlight the milling paths, as well as customisable display colours for each job.

All boundary, profile and 2D contours are referenced to the original contour.

Thus when the user moves, rotates or makes geometric changes, the system automatically detects them and updates the job during the next calculation.

Traditionally, converting entire models or only parts of models into a 3D file, especially if it involves various tasks with different tolerances, is not just a time-consuming activity but managing all the different files can also be very tedious.

New automated functions not only simplify handling but also optimise calculation times by optimally matching the polyhedral data to the milling cycle.

In hyperFORM V7 only the surfaces need to be selected, so individual jobs may now be assigned to a surface set.

Open Mind's CAM modules for fully interpolative 5-axis machining will again be in evidence within hyperMILL and hyperFORM and there will be a demonstration of the most recent innovation - software specifically for tube machining that may equally be used in 3- or 4-axis mode.

Expected to find numerous applications in automotive manufacture, it permits undercutting as well as machining in both spiral and parallel type motion.

Spiral is useful for roughing when entering a solid port whilst the parallel motion is ideal for finishing.

Special 'lollipop' tools are supported as well as the ball and 'woodruff', with full collision avoidance for the tool as well as the toolholder.

One of the first users, Liechtenstein-based PAV, has reduced programming times by 10 per cent and machining times by 50 per cent in the small scale production of cylinder heads, clutch pedals and racing car components.

Segment Optimisation, for which world patents are pending, takes the technology a stage further by allowing some areas of a component to be milled faster by interpolating three or perhaps four axes simultaneously and clamping the others.

The ability is retained to revert during a cycle to 5-axis machining as often as is expedient, such as for undercutting, finishing complex components or rapidly re-orientating the tool for the next cut.

There are also accuracy implications in that, if a 5-axis machine tool is not particularly rigid, better tolerances and surface finish can be achieved by 3- or 4-axis rather than 5-axis milling.

This 'best of five' approach is what segment optimisation enables.

Each 5-axis tool retraction, automatic collision check and repositioning followed by 3+2, 4+1 or 5-axis machining of the next segment in the tool path are calculated automatically within the Open Mind software using special NC programming algorithms.

Many factors are taken into account such as machine construction, kinematics, control technology and the degree of look-ahead especially for high-speed machining.

Five-axis simultaneous machining with segment optimisation guarantees the same high process safety as 3-axis machining with hyperMILL and hyperFORM.

When calculating the tool paths, the entire surface model is included in the collision-check.

This enables the user to enjoy all the advantages of 5-axis machining while also benefiting from uncomplicated NC programming, for which preparation times are considerably reduced as the collision check is carried out automatically and without the time and cost penalties of using third party products.

Until recently a computer-aided manufacturing (CAM) software provider, Open Mind will demonstrate at MACH 2002 its first, fully-featured CAD/CAM system, hyperFORM S.

Combining the attributes of the Think3 CAD kernel with Open Mind's existing hyperMILL CAM software, the system provides users with a highly capable, single-source solution for component design and manufacture.

Designers are given a flexible range of options when developing component geometry.

These include direct creation of drawings using parametric shapes, objects and commands; development of 3D geometry from 2D drawings; reading in existing 3D geometry and creating parameterised variations using the source data; and generation of 2D drawings from 3D model data.

hyperFORM S contains specific features for creating surface intersections, draft angles and split lines for toolmaking and tool design applications.

In addition there is a surface closing capability to fill in missing surface data from imported CAD geometry.

A start-up library is included of 'smart objects' representing commonly required components or features.

The end user can add to the library to provide a system that allows partial automation of the detailed design process, as the entities can be customised before being dragged and dropped into new designs.

Latest additions include new third party libraries and specialist tools for mould / die applications.

Customisation of imported model data is assisted by a new tool, Global Shape Modelling, that allows metamorphosis of existing geometry into a revised form.

hyperFORM S provides Global Modelling Bend in which the selected geometry is bent around one axis; Global Modelling Twist which twists the selected geometry around one axis; and Global Modelling Advanced which allows the user to define fixed and variable sections of the existing geometry.

The CAD capability provides a highly effective front end for Open Mind's hyperMILL CNC program development software.

The latter provides comprehensive toolpath generation facilities including multiple infeed strategies, support for taper cutters, collision detection and avoidance, rework cycles based on an existing tool path, and machining strategies intended to provide optimum finish.

The rework cycle capability works in conjunction with the automatic machining analysis of hyperFORM S, which separates areas of a workpiece that can be machined quickly and easily with minimal clamping from those that require a more considered approach.

Partners on the Open Mind stand at MACH 2002 will be Toolbox and Roland.

ToolBox is an Open Mind partner and a premier Autodesk System Centre specialising in mechanical CAD and CAM solutions based upon AutoCAD, Mechanical Desktop and associated products.

It is a major reseller, also authorised to supply the new adaptive technology modeller, Inventor.

Complete systems, software and a full range of support and training services are provided.

Based in High Wycombe, Toolbox has over 250 customers within the Thames Valley and beyond, and provides support for engineering, CAD and CAM requirements.

Roland is a leading manufacturer and supplier of 2D and 3D digital input and output devices.

Key markets for these products include CAD, project management, business graphics, graphic design and education as well as rapid prototyping, mould making, sign manufacturing, digital colour printing, three dimensional modelling, engraving and general design applications.

MACH 2002 - NEC Birmingham.

April 29 - May 3.

Hall 5.

Stand 5557.

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