Hypermill教程

pr ev ie w Trendsetting Technologies and Novel Functionality 2009.1 New paradigm in manufacturing hyperMILL® 2009.1 off ers innovative functions and a new multi- dimensional, process-oriented CAM platform. This is a unique platform which, with comprehensive features for planning, organising and implementing machining processes, al- lows users to organise these processes with a view to the future. Users can aggregate manufacturing expertise and thus safely and fl exibly implement complex tasks and reduce production times. This is made possible through the following features: – Associative linking of geometries, tools and technology macros – Automatic inclusion of modifi ed external data – Defi nition of processing standards using customized process features – Automated programming associated with the above – Ability to defi ne individual diff erences between similar geomet- ries by simply editing/deleting individual constraints – Process-oriented workfl ow with signifi cant reduction in auxiliary processing times Here, hyperMILL® 2009.1 is building on past experience. As a benefi t, users need not relearn how to program. Since users can continue to work in the same manner as previously, they can gra- dually learn this new comprehensive method of programming. 1 Customized Process Fea- tures: CPF allows users to defi ne various characte- ristic geometry sequen- ces using freely defi nable machining processes. 8 page Transformations: Trans- formations allow users to move and/or copy a program across spatial coordinates. 9 page Job linking: This feature merges machining ope- rations using a common tool into a single machi- ning job. Production mode: This feature automatically optimises all transiti- on moves to minimize processing times for standard parts.Mirroring: This function mirrors input data across a plane and calculates an independent toolpath on the basis of the mirrored geometry. 11 page 12 page 10 page 3 System requirements: Windows XP, Windows Vista. hyperCAD® 2008.1, thinkdesign 2008.1 Software languages: D, E, I, F, ESP, J, NL, PL, CZ, RU, CHIN page Management functions and tools 5 General functions 9 Rotate 13 2D machining 15 3D machining 17 5AXIS machining 21 Contact 24 Contents 4 Analysis functions ➜ Parts verifi cation for effi cient job planning and CAM programming The new modelling and surface analysis tools allow users to quickly and easily determine which element properties in a component are relevant for machining tasks. By simply clicking on a surface, users receive impor- tant information on the surface type (radius, plane, free-form surface), minimum and maximum radius, position and angle as well as picking point coordinates for the selected frame system. When selecting two elements, the minimum distance between the two surfaces is displayed. In addition to analysing individual surfaces, hyperMILL® can automati- cally search for all planes and radii on a component and also mark their positions and sizes accordingly. Various machining data, such as machining type or tolerances, are often compiled into standardised colour tables. These can be stored in hyperMILL® so that users have easy access to tolerance and fi t data for holes or other geometries to be machined in a component. Manual positioning of any tool allows users to quickly and easily check whether areas that are diffi cult to access can be machined and, if so, at which angle. To do this, any tool defi ned in hyperMILL® can be moved to any position and freely rotated around all axes. Analysis of existing radii on component Model analysis Integration of standar- dised colour tables Compound jobs help users to improve their project organisation and management. A job list consists of several compound jobs. Users can structure these jobs according to aspects such as machining process, geometry, 3D position or tool orientation. Thus, it is possible to create structured lists containing many hundreds of jobs. Furthermore, the various jobs can be shown or hidden as a group. A compound job can be assigned to a transformation that is then valid for all corresponding job steps. M an ag em en t f un ct io ns a nd to ol s Compound job ➜ For well-structured job lists Associative jobs permanently link all parameters with the original. Changes to the job template are automatically copied to the associated jobs. Any individually defi nable parameter for a job step can be disas- sociated from the template by a simple mouse click so that it can be defi ned diff erently for this job step. This new functionality allows users to work more fl exibly and quickly edit common machining strategies where only few parameters diff er across several steps in a job. All parameters that have been disassociated from the job template are displayed in a separate window of the job step where they can be edited. Associative job copies ➜ For associative copying Input screen Clear structuring according to job group 5 6 Global editing ➜ Fast and easy editing The redesigned user interface allows additional options to edit seve- ral steps in a job. Next to central parameters such as surface, depth, allowance or infeed, various other geometry selections such as milling or milling surfaces and even macros can be changed globally across multiple jobs. Extended setup ➜ Improved management of data and fi les used in hyperMILL® This function simplifi es the handling, entry and confi guration of di- rectories containing essential hyperMILL® data such as postprocessor information, machine defi nitions and NC fi les. When saving a CAD model, a backup copy can be created automatically. The storage location and number of backup copies are freely defi nable. Editing screen Setup defi nition In addition to a holder, thicker shaft and head, tools can now also be defi ned with extensions. For optimum processing, the required length of a tool is calculated during the entire collision check. Here, the software calculates the required length. After the calculation, hyperMILL® returns the length by which the defi ned tool should be extended or shortened in order to perform the step without colliding. ➜ Extended tool defi nition and collision checks Tool defi nition 7 M an ag em en t f un ct io ns a nd to ol s Tool length calculation hyperMILL® 2009.1 comes equipped with a fully redesigned high-perfor- mance tool database. Tools can now be defi ned with greater versatility and much more realistically. To fully assemble a tool, freely defi nable tool extensions are now available with corresponding coupling systems. By entering the technology data for tool extensions, copying tools into a job list automatically changes the corresponding technology values. In addition to the material-specifi c cutting data, users can also create various profi les for each tool defi ned in the database. Thus, diff erent applications can be predefi ned and selected in the job steps – even for the same workpiece and cutting materials. ➜ Extensive defi nitions of tools using technology data Tool database Freely defi nable tool extensions … ... Corresponding coupling systems Freely defi nable tool holders 8 CPF – Customized Process Features (optional) ➜ Automation of CAM programming and defi nition of company- specifi c machining standards Extended feature technology allows users to defi ne any type of complex machining sequence and store it as a technology macro so that it can be quickly and easily applied to various similar machining tasks. This is based on process-oriented links between characteristic geometries with freely defi nable sequences of various machining strategies – from 2D, 3D and 5AXIS milling to turning. The same elements can be used in various work steps for diff erent tasks. For instance, a surface selection can be used as a stop surface in one step and a milling surface in the next step. The various geometry elements can be selected manually in the model or selected automatically by defi ning selection rules. Thus similarly struc- tured external data can be used to quickly program similar components or for making design changes later on. Selection script Operating screen for Customized Process Features 9 G en er al fu nc tio ns Using transformations, it is possible to reproduce programs for ma- chining identical or similar geometries within a component or several identical components that are clamped together. By freely transforming machining steps across spatial coordinates, users can simplify their pro- gramming workload and reduce costs. In other words, multiple copies of machining steps can be placed along the X and Y axes or rotated around a freely defi nable axis. With transformations, users can easily and conveniently create programs for multiple components clamped within a single plane or in a tombstone fi xture, for example. Since the “copies” are associated with the job temp- late, modifi cations to a program or geometry can be implemented quickly and easily. Any changes to the job template are copied automatically by hyperMILL® to the associated jobs. Furthermore, each parameter can be modifi ed individually. Since users can make local changes or even delete parameters and dependencies, workfl ows remain highly fl exible (see also “Associative job copies”, page 5). Another powerful feature is that users can perform collision checks relative to the fi nished part for programs that have been off set or rotated. This means that jobs involving tombstones or multiple setups can be programmed effi ciently and reliably. Transformations can be applied to all job steps. Transformations ➜ For reproducing machining jobs on identical or similar geometries Spatial copies of programs Copies of program sections for components with identical elements 10 Mirroring ➜ Creates symmetrical geometries or geometrical planes in components and determines entire machining programs for mirrored components In contrast to simple mirroring actions performed by machine controllers, hyperMILL® does not merely mirror the NC paths but also the entire step. This requires recalculating an independent toolpath for the mirrored geo- metry. Here, hyperMILL® automatically adapts the required technologies so that climb milling movements remain intact. Automatic approach and retract strategies, curve orientations and optimised infeed movements are taken into consideration in mirrored jobs. Mirroring automatically creates an associated element in a browser. Any changes to the original are automatically applied to the mirrored versi- ons. Again, every parameter can also be modifi ed individually if required. Mirroring can be applied to all job steps as well as to the entire job list. Geometry and boundaries are mirrored 11 G en er al fu nc tio ns Job linking ➜ For intelligent links between jobs and eff ective reduction of transition moves Multiple job steps to be machined with the same tool can be combined into a single step using job linking. Here, each of the job steps remains unchanged. hyperMILL® calculates the NC toolpaths between these steps with respect to the workpiece and performs a collision check. Each job link is established independently of the type of machining (2D, 3D and 5AXIS machining) and machining direction. Even undercut areas can be approached safely with job linking. This new unique function allows users to combine multiple strategies into a single processing cycle. The benefi t is that there are no transition moves to safety planes between these jobs, saving much non-cutting time. And the job linking moves are collision controlled. With and without job linking Collision-checked link 12 Production mode ➜ Automatic optimisation of transition moves for shortest possible machining times of standard parts Production mode is a new function that lets you minimise all transition moves within a job. hyperMILL® automatically optimises fast travel move- ments according to the path length by stepping over or sideways around the geometry to the starting point of the next path. Lateral movements prevent unnecessary plunging movements. By including the stock in the collision calculation, hyperMILL® ensures that transition moves remain reliable. Extended collision checks ➜ Better process reliability, improved surface quality The safety allowances for tool collision checks can now be defi ned in even higher detail. Each of the various tool components (spindles, holders, extensions) can be defi ned with separate allowances for checks against the model. Next to collision checks, the required length can also be calculated. Depending on the entry, the tool is not only extended but the shortest possible tool is also calculated (see also “Tool defi nition”). Machining without production mode Machining with production mode Defi nition with safety allowance Ro ta te Advanced stock defi nition ➜ Convenient and easy defi nition of turning stock hyperMILL® provides users with various options for defi ning stock for turning processes: 1) The user chooses the stock contour as a 2D sketch. 2) Relative to a rotational axis, the software automatically calculates a rotationally symmetrical stock that contains the entire CAD model. 3) The user generates the turning stock on the basis of 3D milling stock or STL model. Here, the new function for defi ning the bounding geometry makes the workfl ow very easy and user-friendly. The corresponding surfaces are simply selected by clicking them with the mouse. Next, users can enter a stock allowance applicable to all contours or defi ne separate allowances for each contour. hyperMILL® automatically creates the corresponding geometry. Furthermore, a parallel stock allowance can also be defi ned as an off set to the contour – as required for cast components, for instance hyperMILL® automatically suggests a minimum size for the stock. Based on these values, users can defi ne global or separate stock allowances or even defi ne the fi nal dimensions. 13 Slope-dependent turning ➜ For optimised cutting conditions during fi nishing These new functions are specifi cally intended so that users can machine fl at and steep regions. To defi ne the areas to be machined, the user fi rst selects the entire contour. Next, the user defi nes the areas that are to be machined and the maximum slope angle to be used in the single-step process. Slope-dependent turning deactivated Steep regions Flat regions Defi ning the bounding geometry 14 Feature recognition for pockets ➜ Detection of breakthroughs Pocket feature recognition has been extended to include breakthroughs. In addition to closed pockets, pockets with islands and pockets with open sides, hyperMILL® now also detects breakthroughs. In automatic mode, any closed breakthroughs within the model are detected in the frame direction. In manual mode, users can specify the start and end points to also detect open areas or separate breakthroughs. Open pockets without fl ooring Pockets without a bottom surface Playback ➜ Simple creation of toolpaths Toolpaths can be generated manually by moving the tool across the mo- del with the mouse. Once defi ned, hyperMILL® performs a collision check for the tool against the model. If a collision is detected, the software mo- difi es the tool paths to place them at collision free points on the model. Easy generation of NC toolpaths Reliable programming of machi- ning processes With collision checks 2D m ac hi ni ng 15 2D contour milling ➜ Unique potential for optimisation with reductions in programming and machining times hyperMILL® 2009.1 provides new functions for optimised 2D machining of contours. The “Automatic orientation”, “Fast travel optimisation” and “Contour sorting” functions mainly assist users while programming mo- dels with multiple contour areas or for machining automatically detected pocket features. The automatic search feature for starting points can be used together with new intelligent approach and retract macros to ensure the transition moves are always performed in the most suitable areas for the technolo- gy in use. Other functions such as automatic step-down levels, multiple infeeds in the vertical and horizontal machining directions, and defi niti- on of additional fi nishing allowances allow users to make eff ective and reliable use of their tools. As an added benefi t, the surface quality also improves. The new production mode allows the created milling paths to be checked against the current stock material. Any traversing or other redundant mo- vements that are detected are reduced to a minimum. Using a collision check, fast travel movements can be performed directly within a model or in its vicinity. This eliminates the need for repeated, time-consuming positioning movements along the clearance plane. As a result, machining times are reduced and the process becomes more reliable. Automatic cut division Trimming against the model Fillet outside edges… ... with extended edges Complex deep holes with various steps and cross-holes can be pro- grammed separately using hyperMILL®. The infeeds, drilling speeds and coolant can be controlled separately for diff erent areas and geometry elements such as guide bushings, pilot holes or cross-holes. Here, the strategy automatically detects cross-holes in the specifi ed stock. Optimised peck drilling ➜ Drilling deep holes 16 Automatic detection of cross-holes Input screen for optimising process Cross-hole/breakthrough Pilot hole F1, S1, M9 F2, S2, M8 F3, S3, M9 F4, S4, M9 F5, S5, M9 F2, S2, M8 3D m ac hi ni ng 17 Stock roughing ➜ Optimised and reliable stock roughing with high milling quality and precision To improve milling paths and prevent empty cuts and/or very short movements, “minimum material removal” can be defi ned to optimise NC toolpaths. Here, hyperMILL® fi lters out small areas of material. Using the new parameter “Force contour cutting”, stock roughing can also be used for machining rest materials as well as for preliminary fi nishing. As early as during the roughing phase, an allowance is applied equally across the entire component. After entering the new tool parameter, “core diame- ter” and “core height”, hyperMILL® provides the best possible plunge movement. Here, the infeed is calculated automatically and adapted to the tool. Use for preliminary fi nishing With minimum material removal Without minimum material removal 18 For higher precision 3D radius compensation ➜ Precise machining 3D radius compensation reduces programming workloads for users and makes it possible to achieve high machining tolerances – for instance, when a tool is used for milling multiple electrodes. A bullnose endmill can be used to detect rest material areas as well as for actual machining. A rest material area that has not been machined due to potential collisions can be used as a reference for a subsequent machi- ning step with modifi ed tools (e.g., longer tool lengths). This ensures that only the areas that could not be completed during the fi rst step are machined in this next one. With the new machining strategies for cavities, it is now possible to create grooves, ribs or deep, narrow grooves in a single machining step. Deep areas containing large amounts of material can be cleared comple- tely and eff ectively using a constant infeed. ➜ For effi cient machining and milling ribs and grooves Automatic 3D rest material Previous job as reference 3D m ac hi ni ng 19 Bullnose endmill as reference tool Visualisation of non-machined area Milling grooves 20 Drill point optimisation ➜ More eff ective machining with minimised tool path lengths Dri