Turning milling hours into minutes – Part 3

By oldbac 13.05.2021

How does the software take account of the milling bench?

Selecting the right software is just as important because sometimes software can limit the number of details that can be cut with a single operation. If the detail is sufficiently complex, it may prove necessary to perform the final cross-sectional operation using a particularly sophisticated cut that simply cannot be solved in certain programmes. Many programmes also lack detailed control over the performed cut.

The Hypermill software that we use supports automatic machining angle detection and hyperMILL® detects collisions and offers efficient solutions to avoid them. Fully automatic collision avoidance includes different strategies. A collision-free tool angle is calculated automatically if five axes work simultaneously.

Efficient milling is often achieved by dividing components into different machining areas

and using different tools and feeding for machining. The “Smooth overlap” command improves the surface quality of transition areas, making transitions near undetectable to the naked eye and hard to measure.

Under regular circumstances, a simulation of the CNC mill is run before the postprocessor. Lack of connection between the postprocessor and the simulation indicates that real machining situations cannot be simulated in full.

For this reason, OPEN MIND has decided to take things one step further with the hyperMILL® VIRTUAL Machining Center used in OLDBAC. OPEN MIND’s super efficient and reliable NC simulation solution represents virtual machine movement completely in line with machine reality because the simulation is based on an NC code after initiating postprocessing. The code is simulated on a line-by-line basis and this includes movement between operations. This NC-code based machine simulation ensures reliable collision detection.

Cutting with a single operation reduces the principal expenditure, i.e. time.

Time is one of the most costly elements when it comes to milling. Milling benches are expensive, the cost of keeping it up and running are not actually that substantial. It follows that the number one priority for all milling bench owners is to make sure their expensive piece of equipment is constantly in use. Otherwise, the machine will depreciate and the investment made to purchase it will diminish over time without any return.

Milling with a single operation enables considerable time savings per detail. If this means work translates into minutes instead of hours, we would be able to produce quite a few details in the same amount of time. It is therefore more expedient to produce details at a smaller time and financial cost with a single operation rather than going through the trouble of repeated mounting and machining.