3D Milling

Efficient 3D Machining for Simple and Complex Components
hyperMILL® CAM software offers powerful and precise functions for 3D milling. hyperMILL® also enables the production of simple and complex components with high-quality surfaces generated quickly, reliably and efficiently.

Numerous strategies for roughing and finishing ensure efficient 3D machining. The toolpaths are always calculated with the aim of optimizing manufacturing times. An example of this is the avoidance of unnecessary rapid movements and redundant movements.

Even more performance

The high-performance cutting (HPC) functions in hyperMILL® MAXX Machining help to further improve performance, particularly during roughing. The functions for high-speed cutting (HSC) also satisfy the highest demands for precision, surface quality, tool life and machine dynamics. Gentle infeed movements, spiral approach movements and rounded corners are all features that contribute to achieving high feed rates.

Thanks to its comprehensive automation solutions, hyperMILL® also offers enormous potential for savings in the area of 3D programming.

Strategies for 3D milling

  • Arbitrary Stock Roughing
  • Profile Finishing
  • Z-Level Shape Finishing
  • ISO Machining
  • 3D-Optimized Roughing
  • Z-Level Finishing
  • Free Path Milling
  • Plane Machining
  • Plunge Roughing
  • Complete Finishing
  • Equidistant Finishing
  • Form Pocketing
  • Pencil Milling
  • Automatic Rest Machining
  • Rework Machining
  • Curve Flow Machining
  • Rib and Groove Machining
  • Probing

Any stock geometry can be used as the starting base for the roughing process and the part can then be processed plane by plane. Various optimization options enable extremely efficient machining:

Numerous strategies are available for finish machining and generating perfect surface finishes: This ranges from Profile Finishing to Equidistant Finishing. Profile Finishing allows collision-free milling on all faces close to the contour and across the entire face formation whereas Equidistant Finishing applies a uniform face infeed, even for steep faces.

Special HSC functions have been integrated into hyperMILL® to deliver optimal precision, surface quality, tool life and dynamic machine performance.

  • Filleting of corner radii
  • Smooth plunging
  • Smooth infeed
  • Spiral machining
  • Avoidance of full cuts

This strategy is designed specifically to program negative rib shapes. During rib machining, grooves to be milled are automatically detected with steep areas and floors machined separately from each other. The CAM software selects a suitable roughing strategy based on the geometric situation in order to completely machine neighboring areas. The cycle supports conical and conically reinforced tools.

This cycle generates HSC-optimized toolpaths for rest material machining. A prior roughing operation serves as the starting point and rest material areas are calculated extremely quickly based on the stock and the minimum stock removal value defined by the user. An increased feedrate based on remaining stock guarantees efficient machining.
All 3D machining strategies can also be applied to multi-axis indexing with a fixed tool angle. During this process, the orientation of machining is defined using a frame. Simple frame definition and management assist the user in programming operations with tilted fourth and fifth axes. With transformations in the NC programs, users can easily and conveniently create programs for multiple components clamped within a single plane or in a tombstone fixture, for instance. All traverse movements are checked for collisions and path-optimized.

Benefits of 3D milling strategies

  • Simple and complex parts are machined with remarkable efficiency
  • Collision-checked with precise toolpaths
  • Detailed simulation
  • HSC- and HPC-optimised toolpaths for increased performance
  • Optimal approach and retract strategies for all cycles
  • Simple and fast programming with Customised Process Features (CPF)

3D Plane Machining

With 3D plane machining the user can program single or multiple planar surfaces quickly with full collision checking. All planar surfaces are detected automatically using a boundary. It is also possible to define the milling areas manually via surface selection. In order to machine planar surfaces as quickly as possible, an efficient pocket strategy is used.