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Hypermill, hypermiling, hypermill vs mastercam, hypermill download, hypermill cost, hypermiling techniques, hypermill cam, hypermile, hypermill training. In multi-axis environement integrated machine simulation already produce a XYZ ABC code adapted to the kinematic and the axis limitations of the machine.hypermill. The new role of the postprocessor is to convert an internal code into the right ISO format. Solutions such as WorkNC, Powermill, Tebis, HyperMILL, TopSolid are using their own generators.
Any exercises collection, PDF or video tutorials to learn HyperMILL with. The following toolpaths are supported: All 2D High Speed toolpaths, Face, Pocket, Slot Mill, Horizontal Area, Dynamic OptiRough, Area Roughing, and Circle Mill.Have you got a tough job ahead, either because your machine is too lightweight or because of challenging geometry on the part (deep pockets, for example)? What about because of a tough to machine material like Titanium? If so, maybe Plunge Milling (also called Plunge Roughing) is the answer. This option is also automatically applied when the ISCAR HEM checkbox is selected.
Or, you may be able to overcome a chatter problem that’s due to a lack of rigidity.Older (or cheaper) CNC milling machines that have more slop in the XY axes, less precise interpolation, or slower spindle speeds may also benefit from exercising the Z-axis more via Plunge Milling. By taking advantage of the greater rigidity your machine will have in the Z direction, you may be able to get higher Material Removal Rates. By changing forces from side forces (XY plane) to axial (Z) up and down forces, we get much more rigid cutting.Taken together, it’s pretty easy to see where Plunge Milling could turn into your Secret Weapon.Perhaps you have a relatively lightweight or less rigid machine. Most CNC Machines have Z as their stiffest axis. Twist drills often have much higher material removal rates than endmills. It is designed to take advantage of two important properties:
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It’s not a total cure, because you’ll still have to manage a finish pass that removes the scallops, but it might allow higher Material Removal Rates without chatter for the roughing pass.In fact, consider Plunge Milling any time chatter becomes a big problem on a job.One last special case for Plunge Milling would be corner clearing. If that’s the case, Plunge Milling is even more likely to give you the best Material Removal Rates.How about machining a tall thin wall? This is a notoriously chatter-prone situation that may be partially amenable to Plunge Milling. But, if your spindle rpm is the limiting factor, you may not be able to take full advantage of HSM. Plunge Feeds and Speeds may be a little slower than straight up high speed machining. Image courtesy of Hypermill.Another way Plunge Milling can help overcome a machine’s limitations is when spindle speed is limited. Sandvik says Plunge Milling is advantageous any time overall Tool Stick out is more than 4 x Tool Diameter.How about a Mill-Turn situation where your live tooling is not nearly as rigid as on a pure milling machine? Here again, you may find Plunge Milling is just the ticket.Plunge Milling can also be just the ticket when your machine’s spindle power is limited, according to Sandvik.Talk about a lack of rigidity–long reach and thin walls make Plunge Milling a natural for this 5-axis turbine application.
Depending on pocket shape, this can clear most of the material without leaving much scalloping.As part of the final finish or an intermediate Semi-Finish pass, we use a much smaller diameter endmill to clear the area of the corner and then we can make an overall finish pass of the entire wall of the pocket or profile. Image courtesy of Sandvik.One could imagine doing most of the roughing with an HSM Toolpath and an endmill that is much to large in diameter to get into the corners. It seems inherently more conservative and less prone to problems like whether coolant is aimed properly or not.Plunge Milling can be applied to help maintain rigidity in these difficult cases:Plunge Milling Corners. That means more profit.I like the idea of Plunge Milling for Lights Out Machining too. They keep their newer machine centers busy on jobs the older machines can’t do, and over shop spindle utilization goes up.
If the tool isn’t center cutting, it also can’t cut on a down slope where the feature gets deeper in some places. Center Cut: The tool used must either be center cutting (leaves out many types of indexable endmill) or the toolpath must allow for a ramp or helix entry to create enough space to start taking partial plunge cuts. If it’s more than a single finish pass can remove, an optional semi-roughing pass will be needed to clean up the scallops before the final finish pass can be applied. Depending on your X and Y stepover amounts, the amount of scallop to be removed could be significant. Scalloped Edges: Plunge cutting leaves a scalloped edge (see diagram above) that will have to be cleaned up by a finish pass. Image courtesy of Sandvik-Coromant.
Suppose we are handed the task of roughing out a pocket that has 1/8″ corner radii, which dictates and endmill no larger than 1/4″ in diameter. Our G-Wizard Feeds and Speeds Calculator has special features to help with Plunge Milling.Let’s work through an example that shows the strengths of Plunge Milling. If you see stalks, you need less stepover in one dimension or the other.Now we need Feeds and Speeds. Keep an eye out so there’s no skinny stalks sticking up in the corners between the holes. 80% of that value is a good choice as well.
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What about Plunge Roughing?Click the “Plunge” button to bring up the Plunge Milling Mini-Calc:G-Wizard’s Plunge Milling Calculator let’s us enter a Step Up (amount to move into material at start of each pass) and a Step Over (amount to move laterally from prior hole on the same pass) and adjusts the feedrate based on those parameters.Here’s a case where Plunge Milling shines…Here’s a case where Plunge Milling shines: our MRR is back in the 3 cubes a minute territory of the original HSM scenario, and while the Deflection error is still red, we can ignore it because we’re plunging and there will be no significant deflection while doing that.Problem solved! Which CAM Packages have Plunge Milling?Here is a list of the most popular software from our last CAM Package Survey that shows whether each package has Plunge Milling or not:As far as differences in Plunge Milling toolpath quality, it’s worth checking on whether your CAM package supports two capabilities. We could probably live with that, but MRR is down to a lousy 1.1 cubic inches a minute.We’re going to lose our shirts on this job if we don’t find another way. This approach is going to chew up tools very quickly with almost 3 thousandths of deflection.We can use G-Wizard’s Cut Optimizer to see how much stepover is allowable to keep things within deflection allowances:Cut is almost impossible without too much deflection…A quick click on the “Cut Width” label has Cut Optimizer taking us all the way down to a Cut Width of only 1.4 thousandths and there’s still a bit too much deflection. Let’s check Feeds and Speeds with G-Wizard and assume we want to use an HSM roughing strategy like Adaptive Clearing or Volumill:MRR isn’t bad at 3 cubic inches/min, but deflection is way too high…The MRR isn’t bad at 3 cubic inches/min, but deflection is way too high.
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