Open Mind Technologies AG, a developer of CAD/CAM software solutions, teamed up with Haimer in Igenhausen, Germany, to perform 5-axis machining of a panther figurine out of aluminum. Haimer is a partner of the German Hockey League’s Augsburger Panther Professional Hockey Team.
Haimer had the tooling aspect well covered, and turned to its longtime CAD/CAM software partner, Open MInd Technologies in Wessling, Germany, for its hyperMILL software suite and programming expertise to program the freely shaped contours required on the panther.
It took the team approximately three intensive weeks to complete the first free-standing panther. Once the machining parameters were in place and optimized, the approximately 20" (500 mm) long panther was machined in just under 13 hours. In addition to being showcased by the Augsburger Panther hockey team, the panther model will be on display in Haimer and Open MInd trade show booths at future events.
“A model such as this one was a great opportunity to put the versatility and flexibility of our software to the test," said Christian Neuner, manager of global engineering services for Open Mind. "HyperMILL has a wide range of functions that allow CAM users to truly optimize a machine’s capabilities to achieve the desired goal, including making intricate, challenging parts.”
Jakob Nordmann, application engineer at Open Mind worked with Haimer applications engineer Daniel Swoboda to develop the programming and machining infrastructure. Due to the extremely detailed mouth and incisors, and the long and thin shape of the filigree tail section, two set-ups were required on a linear 5-axis DMG MORI HSC70 machining center.
A four-flute cutter with a corner radius from the Duo-Lock Haimer mill Alu series was selected for the roughing, and tor the finishing process, the full radius version of the solid carbide end mill from the Haimer Mill Alu series was used because of its micro-geometrical properties, which are designed for smoothness and top surface quality.
“For especially detailed areas, such as the mouth and tail section or with the creases of the joints, we generated additional surfaces that can be combined with the STL network in hyperMILL, said Nordmann. For this, hyperCAD-S, the ‘CAD for CAM’ system specially designed by Open Mind to help meet all the programmers needs was used.
Equally imperative for milling the panther was the hyperMILL Virtual machining center, a process-safe NC simulation solution where virtual machine movements fully mimic real movements and ensure reliable collision detection. The Virtual machining center pre-emptively recognized that the component could not be processed in a basic orientation due to X-axis limited and automatically generated a solution for a workable position.
Related Glossary Terms
- computer-aided manufacturing ( CAM)
computer-aided manufacturing ( CAM)
Use of computers to control machining and manufacturing processes.
- gang cutting ( milling)
gang cutting ( milling)
Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.
- machining center
CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.
Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.
- milling machine ( mill)
milling machine ( mill)
Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.
- numerical control ( NC)
numerical control ( NC)
Any controlled equipment that allows an operator to program its movement by entering a series of coded numbers and symbols. See CNC, computer numerical control; DNC, direct numerical control.