On a Mazak INTEGREX i-100H turning-milling center, a workpiece inspired by aerospace components was manufactured with precision through turning and milling.
The 102 mm long demo part with a diameter of 135 mm made of high-strength aluminum (EN AW 7075) is produced using 5-axis technologies and the hyperMILL TURNING Solutions from OPEN MIND. During the demonstration, a variety of functions and strategies for milling-turning, turning-milling, and turning are showcased, which have been further expanded in the current release hyperMILL 2025. Initially, machining operations programmed with the performance package hyperMILL MAXX Machining can be seen.
Trochoidal roughing is used in both turning and milling. The HPC finishing with 5-axis tangential machining is performed, like almost all finishing operations in the demonstration, with conical barrel cutters from Ceratizit. These ensure the best surface qualities in the shortest time.
New functions
OPEN MIND takes the opportunity to present newly added functions in the current release.
For 3D-optimized roughing, the pocket milling algorithm has been newly developed to achieve higher efficiency in roughing, especially with large lateral engagements. Tool path rounding can be better controlled through the separate definition of contour and path radius.
The new, user-friendly deburring functions are also utilized. 5-axis deburring is an effective solution for breaking sharp edges of a component. After selecting the edges, the strategy automatically calculates all tool paths. The strategy supports both a 5-axis mode, where machining is indexed as much as possible, and a 3-axis mode. The same applies to the strategy for deburring edges at holes, which is also employed.
Another innovation that can be demonstrated is the automatic raw part chain. Especially for the transition between turning and milling operations, it provides security. hyperMILL automatically creates all raw parts in the correct order – even with changes in the job sequence.
What the digital twin can do
The EMO demonstration by OPEN MIND also provided an opportunity to experience the latest status of hyperMILL VIRTUAL Machining. For the first time, a machine with a main and counter spindle and a milling head was simulated. New is that the component handover is programmed and simulated. Previously, only programming could be simulated, now the handover as well. Machining with main and counter spindle can be conveniently programmed in a job list, and the machining process can then be accurately simulated.
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