New functions that reduce programming requirements and optimize machining, both on a large and small scale, can be found in hyperMILL® v9. These functions include improved stock roughing with automatic feedrate reduction for full cutting and path optimization in axis-parallel machining, stock management, easy definition of milling and stop surfaces, and machine and material removal simulation.

Fully developed feature technology represents the ideal way to efficiently process existing machining and geometry information, reducing the amount of programming required in the CAM system. This means hyperMILL v9 automatically recognizes and processes geometry information from surface and solid models. Feature recognition takes place on the whole model, recognizing holes and other geometries, including pockets and plane levels, and storing them in a feature list. Complex machining sequences, in the form of technology macros, can then be assigned to these features, providing a range of intelligent and automated functions to support programmers.

Bidirectionality between the CAD model and the feature list means that features can be identified via the feature list or in the CAD model. Sorting and filter functions, including type, orientation, color, layer, or parameters such as drilling depth and diameter, make it possible to search precisely for the features to be processed. Current model status, including visible elements, orientation, and zoom, can be saved and activated for any feature at any time. Locating smaller geometries, in particular, is now much easier.

New Stock Tracking With Various Tool Orientations

Enhanced stock-tracking in hyperMILL v9 guarantees control of machining status, allowing the user to calculate, as required, current machining status for every job step, any number of selected job steps, or for the entire job. Stock model management can also work with many jobs that have different tool orientations, or with multiaxis machining. Stock management takes place in a separate job list window, providing a clear display of already-calculated stock. Calculated stock is suitable for visual feedback or as a basis for further machining, such as the roughing of any stock.

The range of functions for roughing any stock has also been expanded, now including automatic plane-level recognition, ensuring uniform allowances for subsequent finishing, or enabling surfaces to be completely machined at the roughing stage. Used in conjunction with stock tracking, this cycle makes roughing parts with thin-walled ribs (typical of aerospace parts) much more efficient. The bottom can be processed in one machining cycle, while material remains on the walls for subsequent finishing.

Drilling now includes a retract plane-checking process. In practice, this means every movement can now be checked for collision with the model so that clearance planes within some drilling templates can be placed very close to the part being machined, reducing air time to a minimum. It is also possible to define retract planes between individual drilling templates with various tool positions. As movements between individual machining planes and infeed movements between drill points are both checked for collision with the model, this cycle includes a particularly reliable collision check. If a collision is detected, the cycle automatically repositions to a collision-free plane.

Faster Collision Control and Avoidance

Collision control and avoidance, especially important for 5-axis machining, is also important for many 3D applications. Collision control in hyperMILL® v9 is now more powerful for two reasons:

• Tool heads and holders can now be freely defined. The generated rotational solid is included in the collision control and avoidance; moreover, the rotational solid is managed in the tool database and is always available, once defined.


• Computation time is considerably reduced for the collision-check process despite utilizing more detailed data on tools and holders.