OPEN MIND Technologies AG has released its new optimization strategy for stock roughing titled hyperMAXX. The high-performance roughing module is powered by the Volumill toolpath layout engine from Celeritive Technologies (and is fully integrated in hyperMILL 2010. It combines optimal milling paths and maximum material removal with minimized machining times. With features like constant radial depth of cut and fully automated dynamic feedrate and infeed adjustment, the results are significantly improved productivity and cutting conditions.

The optional hyperMAXX module generates ideally distributed 3D milling paths for stock roughing, reducing wear and tear on both milling machine and cutting tools. This is achieved by establishing and maintaining ideal cutting conditions throughout, regardless of part shape. Milling parameters are set based on best-case scenarios, rather than the usual worst-case situations like cornering, entry moves, and connection paths. Feed rates are also adjusted dynamically in special machining conditions to ensure constant volume removal.

Roughing time savings of 50 percent or more are typical. As the new strategy is fully integrated in hyperMILL, there is no need to open any additional software tools, change the program, or adjust the post-processor, further boosting productivity while optimally complementing the other roughing strategies in hyperMILL. The Celeritive Volumill toolpath kernel has been successfully used in the market for years within standalone versions and other integrations. This is matched with proven hyperMILL analysis for slicing, stock management, collision detection, and more. Increasing service life and reducing milling times.

As hyperMAXX performs all machining jobs in a predictable, consistent manner, tools and machines are subjected to an even load, resulting in increased service life. Tool paths are completely free of abrupt changes of direction and other extreme tool movements, thus providing the basis for a high surface quality. hyperMAXX ensures maximum material removal and the fastest possible safe positioning of the tool, resulting in reduced machining times and more efficient production.

The high performance of hyperMAXX is made possible by intelligent automated functions, such as a feature that accounts for the material and dynamically optimizes both feedrate and infeed during 3D arbitrary stock roughing to control the volume of cut. This option is seamlessly integrated with hyperMILL's roughing procedure to simplify learning and implementation. There are also two selectable functions. The "first opening cut" is suited for full-cut machining of areas that are difficult to reach, and is highly effective in softer materials, such as aluminum. The "side cutting only" option enables opening via lateral infeed movements without full cutting, and is designed for machining harder materials.

The plunge macro always creates a complete helix or ramp movement and automatically determines the helix radius. Up to 100 per cent of the tool diameter can be processed by infeed without any rest material remaining between adjacent paths. For axial infeeds, the process is absolutely reliable up to the maximum cutting length. hyperMAXX is suited for machining soft as well as harder materials that are hard to chip, such as titanium, nickel-based alloys, or stainless steel. Both machining large parts and performing micro jobs can be handled quickly and efficiently using hyperMAXX. The function range also includes a collision check that accounts for tool lengths as well as plane detection in automatic mode. In addition, the residual geometry can be defined as a stock for subsequent job steps.