Roughing Module Offers 2D Cutting Optimization

Open Mind’s hyperMaxx roughing module for hyperMill, initially designed for 3D arbitrary stock-contour machining and five-axis shape-offset roughing, now offers its high-performance cutting optimization strategy for 2D pocket milling. The process is suitable for soft metals such as aluminum, as well as steel, titanium and nickel alloys.

Based on the Volumill technology kernel from Celeritive Technologies, the hyperMaxx adaptation in hyperMill combines optimal milling paths with maximum material removal for shorter cycle times. The module is fully integrated into hyperMill, eliminating the need for postprocessor adjustment.

The program distributes milling paths and dynamically adjusts feed rates to existing cutting conditions, ensuring that milling takes place at the fastest possible feed rates. Climb milling with spiral retraction of the tool movements increasingly approximates the required contour as the end is reached. According to the company, as much as 100 percent of the tool diameter can be used without leaving material behind. An algorithm ensures that the same volume is removed by each milling tooth for optimal capacity and a large material removal rate, the company says.

The hyperMaxx tool path is calculated for balanced movement and chip volume based on data about the machine and tool, rather than on user-entered fixed values for spindle speed and feed rate. With no sharp edges or sudden direction changes, the process is said to maintain constant load on the tool and machine, reducing cycle times and ensuring fast, safe positioning of the tool. The plunge macro creates a complex helix or ramp movement, automatically generating a helix radius. Intelligent automated functions optimize feed-rate adjustment and in-feed for machining tight areas, with full cutting and long tool paths for soft materials, as well as trochoidal tool paths that avoid full cutting in harder materials.