The hyperMILL Virtual Machining Optimiser module automatically generates the optimal path between two operations

Bicester-based CAD/CAM developer Open Mind Technologies will be taking its largest stand to date at MACH 2024, which is taking place 15-19 April at the NEC, Birmingham (Hall 17, Stand 240). The software company will be presenting the innovative technologies of its hyperMILL CAD/CAM suite with live demonstrations of the latest 2024 version that is set for imminent release. The stand will have have no fewer than six CAM workstations manned by experts to talk visitors through the software package.

Pioneering technologies for digital process chains will be demonstrated as well as innovative advancements for connected manufacturing, automation, turning, Hummingbird Manufacturing Execution System (MES), and solutions for additive manufacturing (AM).

One of the latest innovations showcased at MACH 2024, is the new Hummingbird MES which enables users to improve and streamline the planning, control, automation and optimisation of processes across manufacturing operations — too often, the right information, data and materials are not in the right place at the right time. Hummingbird eases entry into the digitalised world of manufacturing for customers with a tailored solution that allows users to choose the modules they require to gain complete control of their processes — and then expand the system step-by-step as and when required.

The Open Mind UK team will also present the latest updates to hyperMILL ‘Turning Solutions’ which have been rapidly expanded since the last MACH show in 2022. The latest updates include technologies for turning, turn/mill and mill/turn machines — making the suite ideal for all corresponding machine configurations.

Turning developments
In version 2024, hyperMILL turning developments will include CAD for CAM functions for rotary contours, finishing paths for grooving, a ‘remove rings’ function, a 2-D stretch command and a new tool turret support that via hyperMILL ‘Virtual Machining’ can create a detailed map of all tools in a turret to create a seamless NC code simulation.

The enhancements will simplify the creation of chamfers, contours, radii and undercuts, create uniform allowances for finishing when grooving, reliably remove ring chips from components, quickly and easily adapt parametric 2-D contours. Furthermore, Heidenhain CNC systems as well as Siemens controls are now supported with the latest mill/turn modules while the ‘Connected Machining’ interface also supports Fanuc control systems. These updates identify the exponential development rate and the associated compatibility of hyperMILL’s ‘Turning’ suite with an ever-increasing range of machine tool types.

Bi-directional communication with machine tool controls is particularly important in networking with other systems along the process chain. At MACH 2024, there will also be demonstrations of hyperMILL ‘Virtual Machining’ that closes the gap between the CAM system and the physical machine environment. If the CAM software can work with a digital twin of the physical machining process, then this opens up new options for generating, optimising and simulating the NC code safely.

HyperMILL ‘Best Fit’ is an impressive example of this. It is a new type of component alignment system for the subsequent processing of cast, welded or AM components. This sees the NC program adapt to what is physically happening in the workspace, rather than the clamping being adapted to the NC program, which has been standard practice until now.

Open Mind UK will also be on hand to discuss hyperMILL ‘Additive Manufacturing’. This technology opens up th possibilities of highly complex five-axis simultaneous machining to the direct energy deposition (DED) and wire-arc AM (WAAM) processes. NC codes can be conveniently programmed and automatically simulated for collision avoidance and as an end-to-end software solution, this enables efficient hybrid machining with additive and subtractive machining on a single machine.