© All rights reserved, OPEN MIND Technologies AG, Wessling, Germany. Published December 2008.

All information subject to change. No reproduction allowed without the consent of the publisher.
The CAM solution for more efficient processes
© Alle Rechte bei der OPEN MIND Technologies AG, Wessling. Stand Dezember 2008. Änderungen vorbehalten. Nachdruck nur mit Genehmigung des Herausgebers.
Die CAM-Lösung für effizientere Prozesse
Optimise processes,
secure investments,
succeed in production

OPEN MIND Technologies AG enjoys an outstanding

international reputation based on future-oriented CAD/
CAM solutions, reliable customer support and arguably
the best CAM development team in the world. We have
made a name for ourselves as a pioneer in 5axis tech-
®
nology. Today, OPEN MIND and our hyperMILL CAM
software stand for trendsetting manufacturing solu-
tions, long-standing NC experience and comprehensive
technological know-how. Companies in the automotive,
tool and mould making, mechanical engineering, aero-
space and medical technology industries choose OPEN
MIND because they know our products lead to more
cost-effective and efficient manufacturing.
 ®
hyperMILL — a CAM system
that offers you new opportunities

Market requirements change. Workpieces are becoming increasingly complex, pro-

cessing times need to be reduced and the ability to make changes on short notice
is essential. New machines, tools and materials are leading to alternative manuf-
acturing methods. All of these factors are creating new challenges time and time
again. Featuring a host of new innovative functions and manufacturing strategies,
®
hyperMILL gives you the opportunity to leverage change as a way to increase your
company‘s success.

®
Process-oriented: hyperMILL tion functions. It allows you nent today, for example, you
is designed to meet the to implement requirements can easily add 5axis strate-
production requirements of down to the smallest detail gies or the mill/turn module
your company. It assists you in order to manufacture on the following day. The
in implementing continuo- parts of extraordinarily high operating philosophy is the
us processes, optimising quality. The CAM system same for every module. This
workflows and reducing also comes with a variety of makes it easier to learn and
machine runtimes. Integra- options for optimising indi- use the system on a daily ba-
ted automated functions vidual machining operations sis and provides you with the
minimise programming time. based on the requirements flexibility to quickly respond
The option to structure jobs of the machinery currently to new requirements.
based on a job list provides being used.
more transparency and helps
®
minimise errors. Flexible: hyperMILL is a
modular system. All strate-
®
Practical use: hyperMILL gies can be accessed from a
offers a wide range of machi- single user interface. If you
ning strategies and optimisa- choose a 2D or 3D compo-

®
hyperMILL
allows you
to create conti-
nuous processes:
starting with the
product idea,
design and CAM
programming and
ending with simu-
lation and final
production.

2
With optimised
processes, lower
programming
times and reduced
machine run-
®
times, hyperMILL
guarantees efficient
and economical
production.
 Everything you need

®
hyperMILL combines 2D, 3D, HSC and 5axis milling strategies, powerful special
applications and a mill/turn module under one easy-to-use interface. This interface
provides everything you need for efficient CAM programming in a single CAM system.
Users do not need to switch between two or more programs, which in turn simplifies
operation, offers more ease of use and ensures the highest programming reliability
possible.

Special functions ®

such as slope-de- Comprehensive: hyperMILL milling or 5axis swarf cutting The concept: By integrating
pendent machining, is a comprehensive CAM so- are also included. The all modules and strate-
plane detection and lution. It offers powerful 2D mill/turn module and special gies with shared collision
the software’s HSC strategies including feature applications for blade, multi- checking and stock and tool
functions allow you
to optimise machi- technology and control cycle blade, tube and tyre mould administration, you can now
ning for milling at support. For 3D applications machining have been added freely combine all turning
high feed rates. it features intelligent add-on to the concept as well. and milling strategies as
functions that can be used to needed. This also applies to
optimise specific programs. the special applications. Not
Thanks to 5axis technology, only does this concept pro-
users can choose from a va- vide programmers with the
riety of 5axis tool positioning greatest possible freedom
solutions ranging from tilted of action, but it also allows
milling and automatic inde- them to master both stan-
xing to 5axis simultaneous dard and special tasks using
milling. As a result, common a single CAM system.
3D strategies such as profile
finishing or rest machining
are now available for 5axis
machining. Special 5axis
strategies such as 5axis top
4
 ®
hyperMILL
includes a wide
range of powerful
CAM strategies
from 2D milling to
5axis machining.
Now you can program in record time

Automated data entry functions, plausibility checks, feature technology, user-defined

machining rules, a technology database, functions such as mirroring or transformation
®
– hyperMILL offers a wealth of features that minimise programming time.

Secure data entry:

®
hyperMILL supports the
user with graphical dialog
boxes. Only data relevant to
the function selected can be
entered. Thanks to integra-
ted plausibility checks, data
entry errors are detected,
flagged and then described
in an error message. The soft-
ware also detects incorrect
feed parameters or incorrect-
ly dimensioned tools.

Feature techno-
Automated programming: feature with a simple mouse parameters, you can descri-
®
logy can be used
hyperMILL includes a click and then stored in the be dependencies and thus for all 2D, 3D and
number of functions for cre- technology database. Once make associative changes 5axis strategies.
ating CAM programs almost production know-how is to the geometric data. Even
automatically. For instance, created, it will be available at variants can be programmed
feature recognition is able all times and thus minimises this way, which is almost as
to extract geometric objects programming time. simple as a mouse click.
such as holes and pockets
from surface models and so- Time saving: Recurring
®
lids. hyperMILL can process geometries or components
these objects very efficiently with identical elements can
by sorting and grouping be easily reproduced with
them based on specific cha- ®
hyperMILL . By copying a
racteristics. machining operation (trans-
The ability to define machi- formation), for example, NC
ning rules that link strategies programs for multiple setups
and tools for characteristic or tombstones can be cre-
geometries makes standar- ated very quickly. Mirroring
disation and automation can be used to program sym-
possible. The machining metrical or partially symmet-
rules can be assigned to a rical parts. By working with
6
The operating prin-
®
ciple of hyperMILL
is based on what
users are already
familiar with. The
Windows-based
user interface and
generous data
entry assistance
simplifies the task
of programming.
Continuous processes make
production more flexible

®
hyperMILL offers perhaps the most comprehensive CAM concept for more flexibility,
continuous processes and cost-efficient production. It helps you create seamless
workflows, increase process reliability and access resources.

CATIA V4®/V5®

Pro/ENGINEER® thinkdesign

Autodesk®
SolidWorks® hyperCAD® hyperMILL® Inventor™

Parasolid® SolidWorks®
®
hyperMILL is
NX™ available both as
(Unigraphics®)
an integration into
a variety of CAD
systems and with
powerful direct and
standard interfaces.
Seamless: CAD-integrated
solutions provide an excel-
lent means for implementing
continuous processes. The Reliable: A wide range of di-
®
user interface of hyperMILL rect and standard interfaces
is a part of the CAD system, are available for importing
which means the user works data from different CAD sys- A reputation for efficiency: switching. This is why OPEN
in a familiar environment. tems. In particular, the direct OPEN MIND Technologies AG MIND postprocessors are
The CAD and CAM systems ®
interfaces to CATIA V4 and is known for its excellent always custom designed to
both access a single data- ®
CATIA V5 , Pro/ENGINEER , ®
postprocessor technology. ensure compatibility with the
base. The CAM programmer ®
NX™ (Unigraphics ), Para- The postprocessors transfer machine, the controller and
can easily switch between ® ®
solid and SolidWorks allow the power and quality of the range of workpieces to
CAD and CAM systems if, you to reliably import additi- the CAM programs to the be used.
for example, the program- onal information for feature- controller and machine in
ming requires surfaces supported programming with an optimal manner. They
to be optimised. Training geometric data from the CAD are capable of, among other
time is reduced and daily system, for example. things, using the intelli-
operation is made easier. gence of the active controller
®
hyperMILL is integrated into such as controller cycle,
®
the hyperCAD , thinkdesign, tool radius compensation,
® ®
SolidWorks and Autodesk subprograms, program part
Inventor™ CAD solutions. repetition or workplane
8
 The well-designed
postprocessor tech-
nology converts the
calculated toolpaths
into NC programs, in-
cluding the machine
kinematics and con-
troller intelligence.
Everything under control – with a
structured work plan

A well-organised system with transparent workflows ensures seamless and efficient

®
production. To this end hyperMILL provides you with functions and tools for
planning and preparing work in a structured manner. Workspace monitoring, the
OPEN MIND tool database and job list based programming are provided as well.

Transparent workflows: The OPEN MIND tool Easy-to-understand pro-

Clearly defined structures database provides a clear grams: One special feature
®
and management combined means of managing tools in of hyperMILL is the job
®
with easy-to-follow work- hyperMILL . It allows you to list. Sorting functions and
flows provide an excellent systematically organise tool bookmarks provide a struc-
basis for cost-effective management with respect tured method of working. By
production. Machining and to machines, groups or grouping jobs according to
material removal simulations single applications. CAM manufacturing processes,
not only let you evaluate a programming and production geometries or tool positions,
program you create, but also workflows can be optimised for example, you can create
represent critical tools for with the structured storage clear and easy-to-understand
planning machine alloca- of tools. This means, for ex- programs.
tion by means of workspace ample, that cutting data can
Analytic monitoring. Hence, time lost be stored for specific tools or
functions can due to multiple setups can materials and then auto-
be used to
accurately be avoided from the very matically calculated during
evaluate com- start. programming.
ponents and
thus optimise
work planning.

10
 ®
hyperMILL enab-
les systematic and
transparent manuf-
acturing planning
thanks to its ma-
chining strategies,
structured job lists
and administration
tools.
Get all you need from a single source

Deciding which CAM solution to choose involves many issues for users. Can it be
used to cover the entire range of manufacturing processes? Does it make sense
economically? How reliable is the data transfer from different CAD systems? We can
give you the right answers. Seeing this as an important service offering, OPEN MIND
Technologies AG provides personal consulting and support throughout the course
of a customer relationship.

We will happily
provide bench-
mark tests
to prove what
®
hyperMILL
is actually
capable of.

Comprehensive service Service engineering: The The upgrade agreement of

during the decision-making development and application OPEN MIND Technologies AG
stage guarantees that the departments at OPEN MIND offers numerous benefits for
customised product you Technologies AG work closely customers. These include
receive perfectly matches together under the same roof. regular software updates and
your requirements. Consul- Short paths literally mean new versions as well as free
tation plays a decisive role. our employees can exchange access to our service hotline.
This includes an analysis information very quickly, and
of the manufacturing tasks, create decisive advantages in The training concept: Our
process flows and the uses terms of time for our custo- training seminars are desi-
of the milling machines. mers. Our flexibility allows gned for either beginners or
Benchmark tests can be us to assemble a competent advanced users. The courses
carried out, if needed. team to help you when ques- have been specifically
tions arise. developed for use in real-
world conditions. We also
offer workshops on specific
topics.

12
Specialised
knowledge, for
example, on
milling blades
or multiblades,
is offered in
workshops.
2D machining – program more
efficiently than with any controller

®
The 2D strategies of hyperMILL feature a variety of intelligent functions that can
be used to achieve better production results and reduce programming times. They
include functions such as contour milling with optimised traverse path and the fully
integrated mill/turn module. Equipped with these intelligent functions, 2D machi-
ning offers the potential for even greater production efficiency.

®
2D milling: hyperMILL
comes with 2D strategies for
face milling, contour milling,
pocket and rest machining,
drilling and playback milling
(interactive collision-free tool
guidance with simultaneous
viewing of the material remo-
val). In particular, feature-ba-
sed programming of pockets
and holes can greatly reduce
programming times.

®
Mill turning: The hyperMILL
millTURN module allows you
to machine entire workpieces
on a mill/turn machine with
only one CAM application.
The module is seamlessly
®
integrated into hyperMILL :
all turning and milling cycles
can be freely combined.

For 2D machining,
®
hyperMILL relies
on the intelligence
of the controllers
to minimise pro-
gramming time.

14
Simple milling
tasks can
easily be
programmed
using playback
milling.
3D milling – providing the
best strategies for every application

®
hyperMILL integrates proven strategies with a new level of quality. These strategies
are supplemented by intelligent add-on functions that improve production results.
Hence, 3D and HSC technologies offer significantly more than what is currently
available on the market. Both simple and complex parts can therefore be machined
very efficiently and with the highest level of quality.

For 3D machining,
Efficient: The strategies Optimisation functions: A ®
hyperMILL offers
are designed so that the broad spectrum of strategies a wide variety of
toolpaths are automatically ranging from arbitrary stock machining strat-
optimised during calculati- roughing to slope-dependent egies, ranging
from roughing and
on. Unnecessary rapid travel finishing is available for 3D profile finishing to
movements or redundant applications. Moreover, each Z level machining,
movements are thus strategy includes add-on and slope-dependent
avoided, which is a critical optimisation functions that machining
and complete
factor in reducing production can be used to adapt each finishing.
times. machining job to meet your
specific requirements.
Solutions such as arbitrary
stock roughing ensure ma-
ximum accuracy when using
these functions. The func-
tions for HSC milling satisfy
the highest demands for pre-
cision, surface quality, tool
life and machine dynamics.
Gentle infeed movements,
spiral approach movements
and rounded corners all
contribute to achieving high
feed rates.

16
Even in the case of
hard metal machi-
®
ning, hyperMILL
offers suitable ma-
chining strategies
that you can use to
meet the specific
material hardness
requirements.
 ®
The measure of all things: hyperMILL 5AXIS

®
The trendsetting 5axis technology in hyperMILL can typically yield time savings of
more than 25 per cent while lowering tool wear and increasing contour accuracy for
more cost-efficient production. Thanks to easy programming with automatic collision
checking and avoidance, this technology represents a real alternative today – even
for many standard milling jobs.

Common 3D stra-
tegies such as
Z-level finishing,
profile finishing,
equidistant
finishing or rest
machining have
now been upda-
ted with 5axis
tool positions.

Process-reliable: Reliable Automatic indexing:

collision checking and avoi- With automatic indexing,
®
dance is necessary for secure hyperMILL automatically
5axis machining. It serves as divides the tool paths into
®
the basis for hyperMILL 's individual segments, each
fully automatic calculation with collision-free fixed tool
of tool inclinations and angles. Simultaneous 5axis
positioning. Optimised tool movements are only perfor-
inclinations also improve med between the segments.
cutting conditions. One of the advantages of this
is that rest machining beco-
Challenging geometries mes more efficient; multiple
such as high and steep walls milling areas with different
require many different tool fixed tool angles can be
inclinations in precisely machined in a single job. The
delineated milling areas. results are fast programming
5axis simultaneous machi- and machining and excellent
®
ning with hyperMILL 5AXIS surface quality.
is based on what users are
already familiar with: milling
with a tilted tool. Yet the
machining process is now
quicker, the surface results
are better and programming
is much less complicated.

18
Thanks to the fully
automatic calculati-
on of tool posi-
tions, 5axis machi-
ning operations can
be programmed as
easily as conven-
tional 3D tasks.
Programming complex geometries
made easy

Geometries such as blades, multiblades, tubes and tyres pose special requirements
®
that standard strategies cannot satisfy. With this in mind, hyperMILL offers special
user-friendly applications that allow users to easily program without special know-
®
ledge. Since they can be integrated seamlessly into hyperMILL , special and standard
tasks can be programmed with only one CAM system.

can be altered easily to meet

specific technological re-
quirements when necessary.

Tubes: The Tube package

contains optimised machi-
ning strategies and functions
specifically developed for
this type of machining.
Thanks to integrated auto-
mated functions and auto-
matic collision avoidance,
the programming time for
these geometries is reduced
by a significant amount.An
easily constructed central
curve is used to guide the
tube machining cycles. Work
can be done directly on the
The special appli- digitised surfaces.
cations are based
on the innovative
5axis technology Tyre moulds: The Tyre
of OPEN MIND package offers enormous
Technologies AG. For blades: The Blade packa- Multiblade: Optimised time savings by optimising
ge offers optimised machi- machining strategies makes the processes used to create
ning strategies for complete programming more user- tyre moulds. In this package,
machining from tip to root friendly and reliable at the dialog boxes of all 2D,
and the blade in the middle. the same time. Integrated 3D and 5axis strategies have
Special functions such as the automated functions mini- an additional parameter
‚rolling ball‘ feature allow for mise the number of process that allows you to assign a
easy definition of the machi- parameters that need to be pitch (identically constructed
ning job and greatly reduce defined. Parameters such as section) to each machining
programming times. feed rate and spindle RPM strategy.

20
In contrast to
special systems,
no special know-
ledge is required
to use the multi-
blade package.
„OPEN MIND Technologies.
Our name is what we’re all
about. Our passion goes into
every new development, every
new project and each and
every product we manufacture.“

Werner Schwenkert
is the founder and CEO
of OPEN MIND Technolo-
gies AG. He is also one
of the main share-
holders of the parent
company Mensch und
Maschine Software SE,
where he is the director
of the company‘s re-
search and technology
management board.

22
Innovative CAM technolo- Intelligent broad thinkers Worldwide success: The Successful cooperation in a
gies: OPEN MIND Technolo- don‘t miss any opportunity to company was incorporated worldwide network: OPEN
gies AG is one of the most play out alternative strate- in 2001 and has been a MIND Technologies AG works
successful developers and gies. Practical, pragmatic full subsidiary of Mensch in technological alliances
providers of CAD/CAM soft- and technologically perfect, und Maschine Software SE together with renowned
ware for programming milling our experts transform their since 2002. More than 9,000 providers of CAD systems,
®
machines. We are at home knowledge and experience hyperMILL installations machine tools, tools and
wherever challenging work- into CAM solutions that are worldwide are testimony to controllers. We pursue
pieces are produced. The easier for the user to handle. both our competence and dialogue, gather informati-
overarching product concept In this way we can offer our experience. They represent on and expand our base of
comprises CAD solutions, customers economical and a large number of satisfied experience through contact
CAD integrations, interfaces demand-led CAM solutions customers who are able to with many manufacturers
and postprocessors for much quicker than the rest. compete successfully against and other market players.
implementing a continuous With patent applications in tough competition on the This collaboration is taking
process from design to final Europe and the US, we don’t international scene. place both globally and at
production. The platform and just set high standards – we the national and local levels.
component strategy guaran- are the technological leaders Home field advantage in The product of these efforts
tees quick and seamless in- in digital manufacturing. all the key markets of the includes excellent CAD inte-
tegration in the IT landscape world: OPEN MIND establis- grations, optimal interfaces
of your company. The world‘s The advantage of produc- hed subsidiaries in markets and ultra high performance
leading 5axis technology can tion experience: Before important to us across Euro- postprocessors.
be used to optimise the most establishing OPEN MIND, the pe, Asia and North America.
demanding milling techno- company founders gained To best meet the specific
logy of today. It provides a extensive experience in requirements of each coun-
unique competitive edge production automation. try, OPEN MIND Technologies
that is reflected in the suc- They participated in the AG has always recruited local
cess enjoyed by OPEN MIND development of the Dialog employees. This means we
customers. 4 and 11 DECKEL controllers can provide our customers
as well as the first PC-based with optimum advice and
Theory and practice: Those and workstation-oriented support while observing the
who know what they are NC programming system. As different national practices.
talking about get to the heart lead development partner of We are also supported by re-
of the matter. In addition Daimler-Benz Aerospace, the liable and effective partners
to their actual profession, current core team of OPEN in countries where we do not
our developers are experts MIND played a significant have an actual subsidiary.
in milling on the machine. role in designing the first
‚What if we tried it this way?‘ UNIX-based and open MK 21
CNC controller. On the basis
of the experience gained in
that area, we founded OPEN
MIND Software Technologies
GmbH in 1994.

23
Headquarters OPEN MIND Technologies AG
Argelsrieder Feld 5 • 82234 Wessling • Germany
Phone: +49-81 53-93 35 00
E-Mail: [email protected]
[email protected]

UK OPEN MIND Technologies UK Ltd.

John Eccles House • Robert Robinson Avenue
Oxford Science Park • Oxford OX4 4GP • UK
Phone: +44-18 65-33 80 26
E-Mail: [email protected]

USA OPEN MIND Technologies USA, Inc.

39111 W.Six Mile Road • Livonia MI 48152 • USA
Phone: +1-888-516 1232
E-Mail: [email protected]

Japan OPEN MIND Technologies Japan Inc.

KS Building • 1-31-11, Kichijojihoncho
Musashino-shi • Tokyo 180-0004 • Japan
Phone: +81-4 22-23-53 05
E-Mail: [email protected]

Asia/Pacific OPEN MIND Technologies Asia Pacific Pte. Ltd.

10 Ubi Crescent • #05-22 Ubi Techpark
Singapore 408564 • Singapore
Phone: +65-67 42-95 56
E-Mail: [email protected]

China OPEN MIND Technologies China Co. Ltd.

Suite 1507 • Le Kai Tower • 660 Shang Cheng Road
Shanghai 200120 • China
Phone: +86-21-5887 6572
E-Mail: [email protected]

Taiwan OPEN MIND Technologies Taiwan Inc.

3F, No. 153, Hwan-Pei Road • Chungli City 320
Taiwan, R.O.C.
Phone: +886-3-4613125
E-Mail: [email protected]

India OPEN MIND Technologies India

1109, 11th floor, Barton Center • #84, M.G. Road
Bangalore 560001 • India
Phone: +91-80-30504647
E-Mail: [email protected]

www.openmind-tech.com

OPEN MIND Technologies AG is represented

in Germany, Italy, France, Switzerland, UK,
USA, Singapore, China, Japan, Taiwan and India
and a member of the Mensch und Maschine
technology group, www.mum.de.
© Alle Rechte bei der OPEN MIND Technologies AG, Wessling. Stand Dezember 2008. Änderungen vorbehalten. Nachdruck nur mit Genehmigung des Herausgebers.
Die CAM-Lösung für effizientere Prozesse
© Alle Rechte bei der OPEN MIND Technologies AG, Wessling. Stand Dezember 2008. Änderungen vorbehalten. Nachdruck nur mit Genehmigung des Herausgebers.
Die CAM-Lösung für effizientere Prozesse