hyperMILL / hyperCAD-S

Release notes 2023

This document is intended for users and administrators. It applies to hyperMILL, hyperMILL SHOP Viewer, hyperCAD-S, hyperCAD-S
Viewer, hyperMILL for SOLIDWORKS, and hyperMILL for Autodesk® Inventor®.

The document is installed in the directory ...\OPEN MIND\doc\[Version number]\PDF... .

Useful information about hardware and software requirements, graphic cards for hyperCAD-S, installation requirements as well as an
installation guide can be found on our website at: Useful information

If you work with third-party software that uses hyperMILL data (such as postprocessors and simulation tools), you should consider the
following: The format of all data generated by hyperMILL can be changed by OPEN MIND without prior notice and at any time for the
purposes of further development. This primarily affects the output of machine- and control-neutral programs (POF format). OPEN MIND
does not offer any guarantee for problems that are due to compatibility issues involving third-party software.

hyperCAD and hyperMILL are registered trademarks of OPEN MIND Technologies AG. Windows and Windows products are registered
trademarks of Microsoft Corporation. Google Chrome is a product of the manufacturer Google Inc. Autodesk® Inventor® is registered
trademark of Autodesk Inc. SOLIDWORKS is registered trademark of Dassault Systems SA.

All other brand and product names are registered trademarks of their respective owners.

OPEN MIND Technologies AG

Argelsrieder Feld 5
82234 Wessling
Germany
Tel.: (+49-8153) 933-500
Fax: (+49-8153) 933-501
E-mail: <[email protected]>
Web: www.openmind-tech.com

Compliance Intelligence
The Software may include a compliance intelligence mechanism for security and reporting purposes ("Security Mechanism") that
automatically collects and transmits data regarding the installation and use of the Software to OPEN MIND Technologies AG, its
licensor and the manufacturer of the Security Mechanism for purposes of verifying End Customer's compliance with the terms of the
applicable EULA, identifying unauthorized use and users, and otherwise protecting and enforcing intellectual property rights. Data
processed through the security mechanism may include, but is not limited to, user, device and network identification information,
location and organizational domain information and software usage information. For more information about the processing of personal
data through the Security Mechanism, please see our privacy policy at https://www.openmind-tech.com/en/privacy/ .

(produced on Fri, Nov 11, 2022)

 hyperMILL / hyperCAD-S

Table of Contents
1. Supported Versions ...................................................................................................................... 2
Operating systems und CAD platforms ........................................................................................ 2
CAD interfaces ....................................................................................................................... 2
Interfaces Tool database ........................................................................................................... 5
Supported EDM formats ........................................................................................................... 5
Interfaces NC simulations ......................................................................................................... 6

2. New commands and additions ........................................................................................................ 7

Basics of CAM editing .............................................................................................................. 7
NC system and frames ..................................................................................................... 7
Corrected output system dialogue page ....................................................................... 7
Calculate and analyse toolpaths ....................................................................................... 10
Distance toolpath-shape ......................................................................................... 10
Probing ............................................................................................................................... 10
Workpiece alignment along edge ...................................................................................... 10
Contours ............................................................................................................. 10
Turning ............................................................................................................................... 11
Finishing ...................................................................................................................... 11
Strategy .............................................................................................................. 11
Drilling ................................................................................................................................ 13
Back Boring ................................................................................................................. 13
Tool .................................................................................................................... 14
Contours ............................................................................................................. 14
Optimisation ......................................................................................................... 15
Process ............................................................................................................... 16
Parameters .......................................................................................................... 18
Boundary ............................................................................................................. 19
Setup .................................................................................................................. 19
3D Machining ....................................................................................................................... 19
Profile Finishing ............................................................................................................ 20
Boundary ............................................................................................................. 20
Z Level Shape Finishing ................................................................................................. 21
Boundary ............................................................................................................. 21
5X Machining ....................................................................................................................... 22
Cavity Milling ................................................................................................................ 22
5X Halfpipe Machining ............................................................................................ 22
OPEN MIND tool database ...................................................................................................... 38
Tool geometry parameters .............................................................................................. 38
Drilling tool ........................................................................................................... 38
Define manufacturer ...................................................................................................... 41
Default settings ..................................................................................................................... 42
Options / properties ....................................................................................................... 42
Selection ............................................................................................................. 42
Data interfaces ..................................................................................................................... 42
General interfaces ......................................................................................................... 42
Point file formats ................................................................................................... 42
Select and snap .................................................................................................................... 42
Select entities ............................................................................................................... 42
Select child entity only ............................................................................................ 42
Analysis .............................................................................................................................. 43
Check ......................................................................................................................... 43
Shape spherical .................................................................................................... 43
Edit and modify ..................................................................................................................... 43
Modify ......................................................................................................................... 43
Continuity curve .................................................................................................... 43
Points, curves and faces ......................................................................................................... 43
Drafting ....................................................................................................................... 43
Projection points ................................................................................................... 43
Curves ........................................................................................................................ 44
hyperMILL / hyperCAD-S

Intersect .............................................................................................................. 44
Compensate ......................................................................................................... 44
Offset .................................................................................................................. 45
Offset on face ....................................................................................................... 46
Shapes ....................................................................................................................... 46
Offset .................................................................................................................. 46
Create solid .......................................................................................................... 46
Solids, features and meshes .................................................................................................... 47
Features ...................................................................................................................... 47
Holes .................................................................................................................. 47
Solid ........................................................................................................................... 52
Difference ............................................................................................................ 52
Design electrodes .................................................................................................................. 52
Electrode options .......................................................................................................... 52
Create reference system ................................................................................................. 53
Modify eroding path ....................................................................................................... 54
User-defined orbit type ................................................................................................... 56
User-defined material list ................................................................................................ 56
NC programming ................................................................................................................... 57
hyperMILL ................................................................................................................... 57
Analyse distance toolpath-shape .............................................................................. 57
Adaptive construction ..................................................................................................... 59
Global fitting ......................................................................................................... 59
Print documentation ....................................................................................................... 59
Quick print ........................................................................................................... 59
Reports ....................................................................................................................... 59
Configure job report ............................................................................................... 59
Export job report ................................................................................................... 60

3. Release notes ........................................................................................................................... 61

Release 2023 ....................................................................................................................... 61
hyperMILL ................................................................................................................... 61
hyperCAD-S ................................................................................................................. 63
 hyperMILL / hyperCAD-S

Starting with this version, the name of releases has been adapted. This version is called 2023. The release
notes for hyperCAD-S and hyperMILL have been summarised in this PDF document. But now let us take a
brief look at the most important innovations ...

We Push Machining to the Limit

hyperMILL 2023 includes improvements for the entire programming process in almost all software modules. It
is particularly worth noting, for example, that the start and calculation times have been significantly reduced –
and all this without any loss of quality!

The measuring and turning strategies have been functionally expanded. The portfolio also includes two
brand new strategies. Easily edit NC-code-checked countersinks using 2D Back Boring. The new 5X Halfpipe
Machining enables quick and easy programming of complex slots. The hyperMILL VIRTUAL Machining
technology makes it easier to program mill-turn machining centres as well as machines with more than 5
axes. And the VIRTUAL Machining Optimizer allows parallel axes to be programmed fully automatically.

Best-Fit technology has been added to the hyperMILL SHOP Viewer. This is practical for machine operators.
It makes aligning the workpieces much faster and increases efficiency. Clamping therefore becomes a safe,
precise and plannable process step that is carried out directly on the machine.

hyperCAD-S brings enhancements to parametric modelling. Boolean operations and hole features can be
incorporated into this elegant approach. Adaptive constructions that can be predicted in advance can be
taken into account and implemented quickly if necessary.

Perhaps the most interesting innovation in hyperCAD-S Electrode is that an electrode can now rotate through
an angle not only at a point, but also synchronously along a path. To conclude this overview, it is important to
point out that it is now possible to manage the electrode materials in the hyperCAD-S material file.

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hyperMILL / hyperCAD-S

1. Supported Versions
Operating systems und CAD platforms
64-bit operating systems 64-bit CAD platforms Server operating systems (Licence
server only)

Windows 10 hyperCAD-S Windows Server 2012 R2

Windows 11 Inventor 2021, 2022, 2023 Windows Server 2016

SolidWorks 2021, 2022, 2023 Windows Server 2019

hyperMILL exclusively supports 64-bit operating systems.

Attention: hyperMILL 2023 is not compatible with any thinkdesign version!

CAD interfaces
The following CAD models can currently be imported and/or exported (depending on the licence purchased):

Product File type Up to version Import Export

Technology up to 31 De- Current technology

cember 2019

CATIA V4 *.mod- 4.2.4 4.2.5 x

el

*.exp 4.2.4 4.2.5 x

CATIA V5 *.CAT- 6R2018 (R28) V5-6 R2022 x

part

*.CAT- 6R2018 (R28) V5-6 R2022 x

prod-
uct

*.CGR Not supported V5-6 R2022 x

CATIA V6 *.3dxm Not supported V5-6 R2022 x

l

PTC Creo Paramet- *.prt 6.0 F000 9 x

ric
*.prt.
*

2
 hyperMILL / hyperCAD-S

Product File type Up to version Import Export

Technology up to 31 De- Current technology

cember 2019

*.asm 6.0 F000 9 x

*.asm.
*

*.neu Not supported 9 x

PTC Creo *.xpr 6.0 9 x

*.xas 6.0 9 x

Siemens NX *.prt NXCR Siemens NX 2206 (June x

2022 major release)

SOLIDWORKS *.sldp 2019 2022 x

rt

*.slda 2019 2022 x

sm

Autodesk® Inventor® *.ipt 2019 2023 x

*.iam

Rhinoceros® *.3dm Not supported 4, 5, 6, 7 x

Solid Edge *.par Not supported V19 - 20, ST - ST10, 2022 x

*.asm

*.pwd

*.psm

PRC (Product Rep- *.prc Not supported All versions x

resentation Com-
pact)

Parasolid *.x_t 31 34.1 x

*.x_b 31 34.1 x

JT-Open *.jt 10.2 10.6 x

IGES *.igs 5.2, 5.3 5.1, 5.2, 5.3 x

*.iges 5.3 5.3 x

STEP *.stp, AP 203 AP 203 E1/E2a x

*.step
AP 214 AP 214b

AP 242 AP 242c

AP 214 AP 214 x

AutoCAD *.dwg 2018 (AC1032) 2019 x

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hyperMILL / hyperCAD-S

Product File type Up to version Import Export

Technology up to 31 De- Current technology

cember 2019
*.dxf
2013-2017 (AC1027) 2019 x

Point clouds *.pt, No version No version x

*.asc

*.xyz

*.txt

*.pt x

Polygon mesh *.stl No version No version x x

*.stla

*.stlb

3MF Reader *.3mf Not supported 1.2.3 x

(3D Manufacturing
Format)

ACIS *.sat Not supported 2021 1.0 x

*.sab

Wavefront OBJ *.obj Not supported All versions x

a(ISO 10303-203) "Configuration controlled 3D design of mechanical parts and assemblies"
b(ISO 10303-214) "Core data for automotive mechanical design processes"
c(ISO 10303-242) „Managed model-based 3D engineering“

4
 hyperMILL / hyperCAD-S

Interfaces Tool database

Tool Required licenses Required software

Management

System

tdm systems TDM Base modul (TDM / TDMGL) TDM Systems - Base Installer

TDM Class / group structure V (CLGR) TDM Systems - Data Installer

CAM Interface TDM - hyperMILL (AME) (iM- TDM Application Server Installer
HYP)
TDM GlobalLine Interfaces Installer (for the
Optional for 3D Tool data transfer: Smart Interface Client hyperMILL)

3D-Solid Converter for hyperMILL (iCHYP)

Zoller TMS hyperMILL v2 Interface first license TMS Tool Management Solutions BRONZE
package
TMS Tool Management Solutions
TMS Tool Management Solutions from ver-
sion 1.17.0

WinTool AG WinTool WinTool 2020 (WT2020.2.1)

hyperMILL Interface Microsoft Server 2012 or higher

Microsoft SQL Server 2012 or higher

hyperMILL Interface (2.13.5)

Hexagon Manufac- NCSIMUL Tool NCSIMUL Tool

turing Intelligence
NCT‐CAM‐HY (hyperMILL interface) NCSIMUL Tool Client

NCSIMUL Tool Server

NCSIMUL Tool Interface

FlexLM

Supported EDM formats

Reports for the following eroding machine types can currently be converted in the EDM converter software.

Machine types from Supported program- Version Note

ming system

Exeron Exoprog 1.6.10 Without rotational electrodes

Exolution In development

With rotational electrodes

5
hyperMILL / hyperCAD-S

Machine types from Supported program- Version Note

ming system

Makino EDCAM 2020 To use the EDCAM simulation, electrodes

and model must be output individually as
*.stp models in the EDCAM folder struc-
ture. The electrode metadata is output by the
EDM converter. The output from the EDM
converter can also be processed without the
3D models.

OPS Ingersoll PowerSPARK Editor From 1.6.4.0

Multiprog All

SODICK On request

Zimmer & Kreim Alpha Moduli

Interfaces NC simulations
VERICUT from version 7.0

NCSimul from version 2020.0

6
 hyperMILL / hyperCAD-S

2. New commands and additions

Information on new commands and additions, as an extract from the software documentation:

Basics of CAM editing

NC system and frames
Corrected output system dialogue page

BEST FIT
More complex part shapes, alternative manufacturing processes (casting, 3D printing,
forged stock) and smaller allowances make manually aligning the part very time-consum-
ing. The hyperMILL Best Fit alignment eliminates the need for time-consuming manual
alignment measures. Positioning is automatic and based on the internal origin shift cap-
tured using the 3D Point Probing cycle. Probing takes place both in the CAM programming
and on the machine, so that the position deviation between the virtual and the real situa-
tion can be determined and corrected. The Best Fit real part position is adjusted in the
hyperMILL VIRTUAL Machining Center and is checked for collisions. An attempt is made
to comply with all machine limits with the help of the NC optimiser.

CORRECTED OUTPUT SYSTEM

In series production or workshop use, OPEN MIND generally recommends Best Fit adjust-
ment via the hyperMILL VIRTUAL Machining Center. For single parts, prototypes or large
toolpath files, the zero point can already be corrected in hyperMILL. The shift is transferred
directly to the hyperMILL VIRTUAL Machining Center which means that the real position
has already been adjusted. After the collision check and release, the NC program can be
executed on the real position.

The Corrected output system dialogue page is only displayed with a licence for the hy-
perMILL VIRTUAL Machining Center. It is not available for origins. It is available for frames
if the Best Fit function has been activated on the Job list → Settings dialogue page.

Active correction: Select the checkbox to create a corrected output system.

From probing log file: Enable if there is a log file that was created using the Best Fit function of the hyperMILL
VIRTUAL Machining Center.

Use frame: Select a frame that was created with the help of the From probing log file function.

Correction to reference system

The deviations of the newly calculated corrected output system from the reference system are displayed as
Angle values for A, B and C and as deviations from the Origin in the X, Y and Z directions. The displayed
values cannot be edited.

Create frame based on correction: This function creates a new frame on the Frames dialogue page of the
hyperMILL browser that was generated using theFrom probing log file function.

Open the Calculate corrected output system dialogue via the Calculate correction function. The following
functions are available:

7
hyperMILL / hyperCAD-S

Select 3D Point Probing report

File: Select a measuring log file generated by hyperMILL in *.ompr or *.log format.

Minimize distance between points

To optimally align the component on the machine, minimise the distance between the model positions
and the real positions on the machine. The distance can be minimised along the surface normals of the
component using the Surfaces (distance along normal) function. Alternatively, this can also be minimised
between the measured values of the points using the Points (3D distance) function.

Fix axis

Axis: Axes of the reference origin table.

Lock: Lock the axes that are not to be moved when calculating the optimal clamping position on the machine.
To do this, click the field for the required axis.

The corrected output system is automatically used when the NC file is created. The job does not need to be
recalculated. The corrected position of the component is not shown in the graphics area of hyperCAD-S. The
component and stock position is checked exclusively in hyperMILL VIRTUAL Machining Center.

8
 hyperMILL / hyperCAD-S

Using the corrected output system – overview

Action CAM Programmer Result

Load Best Fit Protocol Locally stored

from CNC to PC Best Fit file

Calculate new frame system Frame

Enable correction system and choose it Delta values

to reference system

Create CAM program for NC files with

verification, probing and machining corrected output system

Collision check Collision check result

for verification and machining (NC program) OK

Run the NC program for the part Finished part

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hyperMILL / hyperCAD-S

Calculate and analyse toolpaths

Prerequisites, information and options for calculating toolpaths.

Delete, read, update and analyse toolpaths.

Distance toolpath-shape
The distances between a toolpath and surfaces are determined. A subarea of the toolpath can be selected
using a selection area. Two target distances divide the toolpath into three steps. Points can be created at
which the toolpath meets the required distances.

Analyse distances between surfaces and a toolpath. 2023

hyperMILL → Analyse distance toolpath-shape

Probing
Workpiece alignment along edge
Contours

First point / Second point / Mode

The X, Y, Z coordinates of the start point/end point of the contour or the first point/second point are displayed
under Point position.

Shift along edge: Define a value for moving the first/second probing point along the edge (3). Positive values
result in an inwards movement and negative values result in an outwards movement.

Probing direction (4): The following options are available as the probing direction: Y+, Y-, X+, X-, Z- and
Automatic. If you choose the Automatic option, the probing direction will be determined automatically by
hyperMILL.

Offset: (5) Only available for Z-.

+
2 5
Y- 4 4 X- 1
Y
X -
2 Z

Z 2 4
1
Z-
Y X

2 3
+
4 -
3 4
X+ +
- Y+

10
 hyperMILL / hyperCAD-S

Turning
Finishing
Strategy

Smooth overlap

Various tools and orientations are often required to manufacture complex components.
The Smooth overlap function achieves smooth transitions without any visible machining
marks between individual machining areas (jobs). The tool follows the selected contour
beyond the boundary in a gentle lifting movement.

Please note: The selected contour must be part of the turning area.

Use smooth overlap: Activate to enable smooth lifting of the tool in the contour extension. Use Contour length
to define the length of the lifting movement and Distance to define the maximum retract value of the tool for
the extension of the selected contour.

Example: Subdivision into machining areas and overlap using the example of jobs 2 and 3, (1) - (5)
= toolpaths of the jobs

5
3
2 2
3 4

11
hyperMILL / hyperCAD-S

Example: (1) Selected contour, (2) Material to be removed, (3) Contour length, (4) Distance, (5)
Extension of the selected contour, (6) Retract macro.

1
2 6

5
3
4

If the start or end of the selected contour is an interior corner with a radius equal to or smaller than the tool
radius, automatic macro creation must take place.

12
 hyperMILL / hyperCAD-S

Drilling
Back Boring
Machine sinks on the underside of the workpiece.

The Back Boring function requires a machine (VM/postprocessor) that has been prepared
for it.

13
hyperMILL / hyperCAD-S

Tool
The tool type Back Boring Tool can be used.

(1) Diameter, (2) Length, (3) Min. plunge diameter, (4) Cutting edge position .

(A) Mounting direction: Right, (B) Mounting direction: Left.

The Mounting direction parameter indicates the mounting direction of the Insert in relation to the tool axis
and is used to define the spindle orientation. If the mounting direction is Right, the Spindle orientation is
Clockwise. If the mounting direction is Left, the spindle orientation is Counterclockwise.

The Cutting edge orientation parameter is currently not supported.

Example: (C) Back chamfering: (5) Reference point, (6) Hole diameter, (7) Axial position.

A B

4
5
6
3
7
1

The geometry of the tool is not collision checked against the fixture.

Contours
Define the drilling strategy, contour selection for the holes and the vertical machining area (top and depth) of
the holes.

Contour selection
In Lines mode (A), select a contour (1) to define the top (2) and depth (3) of the sink as well as the position of
the drill hole (4). Use the Additional distance parameter to define the depth of the drill hole (5) and specify the
diameter of the sink (6) under Diameter.

In Points mode (B), select a point (1) to define the position of the drill hole (1). Under Top and Depth, select
a point in each case to define the top (2) and depth (3) of the sink. Use the Additional distance parameter to
define the depth of the drill hole (4) and specify the diameter of the sink (5) under Diameter.

14
 hyperMILL / hyperCAD-S

A 1

5
1 2
1 3
4
2
1
5
3
6

The direction of the drill hole is determined by the Z axis of the frame in all procedures.

Optimisation
Drilling point optimisation allows any drilling patterns to be optimised in accordance with various criteria
(not available for the Turning strategy), so that the stresses and heat that are generated during drilling are
distributed as evenly as possible over the entire surface.

hyperMILL generates a graphical feedback of the drilling points that have been selected
for machining. Since a large number of drilling points requires a correspondingly powerful
computer to calculate and display this graphical preview, the preview display is limited to
1000 drilling points by default.

Sorting strategy
Off: Drill holes are machined in the order in which they were selected.

Shortest distance: Machining is carried out starting with the (drilling) point closest to the origin of the specified
coordinate system (frame), followed by the next closest in each case. Select the Use start reference option to
use a start point as the reference for the beginning of the optimisation.

Circular: The drill holes to be machined are divided into concentric circle segments starting from a centre
point.

X or Y parallel: The drill holes to be machined are divided into segments that are referenced on the X or Y
axis of the selected machining coordinate system (frame).

15
hyperMILL / hyperCAD-S

Contour parallel: The drill holes are machined along the outline of the outer contour of the drilling point
pattern.

Process
The movement sequence of the tool is divided into different procedures. Each procedure is characterised by
an event or a movement.

An event is controlled by the following parameters: Spindle speed mode, Spindle speed, Coolant (On / Off),
Dwell time and Program stop (No stop / Opt. stop (M01) ). A movement is controlled by the parameter
Feedrate.

There are ten different procedures for the Back Boring Tool tool type with fixed insert.

Back Boring Tool procedures

(1) Event: The tool is located at the height of Hole security → Clearance distance. The tool
position is eccentric.

The spindle is disabled. The tool’s insert is oriented toward the X+ direction of the job
or feature frame.

Define the coolant, dwell time and program stop.

(2) Movement: The tool moves from the height of Hole security → Clearance distance eccentrically to
the height of Hole security → Retract distance (back side) and then to the position for
Back Boring.

The spindle is disabled.

Define feedrate.

(3) Event: The tool is located at the height of Hole security → Retract distance (back side) in the
position for Back Boring.

The tool spindle is enabled. Define spindle speed.

To modify the spindle orientation of the tool spindle, change the sign for the spindle
speed (positive/negative).

Define the spindle speed, coolant, dwell time and program stop.

(4) Movement The tool moves to the upper edge of the hole (Back Boring).

The spindle is enabled.

Define feedrate.

(5) Event: The tool is located at the upper edge of the hole.

The spindle is enabled.

Define the spindle speed, coolant and dwell time.

(6) Movement: The tool moves to the the retract distance, if the option Move to retract distance is
activated at Final retract (Process #6). The tool moves to the retract value, if the option
Move to retract value is activated at Final retract (Process #6).

The spindle is enabled.

Define feedrate.

16
 hyperMILL / hyperCAD-S

Back Boring Tool procedures

(7) Event: If the Move to retract distance option is activated, the tool is located at the height of
Hole security → Retract distance (back side). If the Move to retract value option is
activated, the tool is located at the upper edge of the hole – Retract value.

The spindle is disabled. The tool’s insert is oriented toward the X+ direction of the
machining frame.

Define the coolant, dwell time and program stop.

(8) Movement: The tool moves to the the retract distance, if the option Move to retract distance is
activated at Final retract (Process #6). The tool moves to the retract value, if the option
Move to retract value is activated at Final retract (Process #6).

The spindle is disabled.

The tool’s insert is oriented in the X+ direction of the job or feature frame.

(9) Event: If the Move to retract distance option is activated, the tool is located at the height of
Hole security → Retract distance (back side). If the Move to retract value option is
activated, the tool is located at the upper edge of the hole – Retract value.

The spindle is disabled.

Define the coolant, dwell time and program stop.

(10) Movement: If the Move to retract distance option is activated, the tool is located at the height of
Hole security → Retract distance (back side). If the Move to retract value option is
activated, the tool is located at the upper edge of the hole – Retract value.

1 2 4 6 8 10

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hyperMILL / hyperCAD-S

Final retract (Process #6)

Move to retract distance: (1) / Move to retract value: (2) The tool moves either to the Retract distance or to
the Retract value before the spindle is switched off (operation #8) and the tool moves eccentrically out of the
hole (operation #10).

2
1

Parameters
Define the machining areas (in addition to definitions on the Contours dialogue page), the infeed and clear-
ance parameters plus other machining parameters.

Machining area
Offset top: The drill depth is enlarged by the specified amount.

Bottom offset: The drill depth is reduced by the specified amount.

Absolute top / Absolute bottom: The defined absolute values are considered in each case. This facilitates
simple machining if the drill hole(s) must be made before the material removal (of the stock model).

Hole security
Clearance distance (1): Distance of the tool to the top of the drill hole that is travelled at the Z feedrate.

Retract distance (2): Distance of the tool to the top of the drill hole (back side) and the start of the retract
movement to the clearance plane (5).

Machining parameters
Pecking depth (3) / Retract value (4): stepdown/retraction of the tool for each drilling stroke.

F2, F4, F6, F8, F10: Feedrate for the respective stage during Back Boring (Process dialogue page).

5 Z

X
Z

1 X

F2
F10 F6 F4
2 F6 F4 3 4
F8 F2

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 hyperMILL / hyperCAD-S

Retract mode
The retract mode defines the Z level at which the infeed movements are executed between the drill holes.
The clearance plane refers to the Z axis of the current frame.

Clearance plane (1): Plane for rapid tool movements. Specification in absolute dimensions Define the
clearance plane by right-clicking on the icon. Select a point and confirm the selection.

(A) = Rapid. (B) = Z feedrate The Z feedrate can be adjusted for the various drilling stages.

A
1 B
Z

Traversing movements on the clearance plane are not checked with regard to collisions.
Therefore this plane must be placed at a sufficient distance above the surface of the
workpiece.

Boundary

Stop surfaces
Use stop surfaces to define the area of the CAD model on which no machining takes place. Always use
stop surfaces whenever you need to ensure that the tool does not touch the stop surfaces.

Offset: the offset of the stop surfaces extends the area excluded from machining by the specified value. Valid
in X, Y and Z direction.

Setup

NC parameters
In addition to activating this function, go to the Machine properties → Program halt dialogue and enter
the command to stop the tool (by means of M function or command chain). Open the Machine properties
dialogue via Job list → Postprocessor → Machine → Machine administration → Edit.

3D Machining

19
hyperMILL / hyperCAD-S

Profile Finishing
Boundary

Milling surfaces
Milling surfaces: Use milling surfaces to define the area to be machined.

Milling surface mode

Standard: Only available for ball mills. Use the Soft bounding option to control the transition between milling
surfaces and stop surfaces.

Extension: Use the Milling surface extension option to protect the edges of the model against rolling move-
ments of the tool. For this purpose, hyperMILL generates extension surfaces that connect to the defined
milling surfaces tangentially or in a curvature-constant manner. This function is available for hyperCAD-S.

Milling surface extension

Advanced option
Check adjacent faces: Without checking, a milling extension is created around all selected surfaces, also
within the model (1) and with checking – only on edges and fillets (2). Optionally handle the fillets differently
when checking adjacency relations depending on the maximum fillet radius (Max. fillet radius). No surface
extension is created if the radius of the fillet is smaller than the entered value (3).

1 2

Wider blending: If a chain of boundaries/edges has been selected and there are usable surface extensions
before and after a gap, an attempt is made to close the gap using the fill algorithm. If this fill surface is
also unusable, further adjacent surface extensions are removed and approximated by the fill algorithm. The
warning ‘Some areas have been replaced by an approximation’ appears. Click the warning to highlight the
approximated areas in colour. To remove the highlighting, click the empty area below the warnings.

Normal direction: Automatically calculate an extension from the direction of the adjacent boundary of the
given surfaces. In a solid, it is the common edge with the adjacent solid surface. As this direction can be
oblique, the width of the extension is often less than the length entered. Activate this Normal direction option
to calculate an extension normal to the selected edge or boundary (1).

Use the Check undercuts option to determine whether a tool’s position direction results in an undercut in the
surfaces to be created due to the orientation of the surfaces to be processed.

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 hyperMILL / hyperCAD-S

Z Level Shape Finishing

Boundary
Milling surfaces
Milling surfaces: Use milling surfaces to define the area to be machined.

Milling surface mode

Standard: Only available for ball mills. Use the Soft bounding option to control the transition between milling
surfaces and stop surfaces.

Extension: Use the Milling surface extension option to protect the edges of the model against rolling move-
ments of the tool. For this purpose, hyperMILL generates extension surfaces that connect to the defined
milling surfaces tangentially or in a curvature-constant manner. This function is available for hyperCAD-S.

Milling surface extension

Advanced option
Check adjacent faces: Without checking, a milling extension is created around all selected surfaces, also
within the model (1) and with checking – only on edges and fillets (2). Optionally handle the fillets differently
when checking adjacency relations depending on the maximum fillet radius (Max. fillet radius). No surface
extension is created if the radius of the fillet is smaller than the entered value (3).

1 2

Wider blending: If a chain of boundaries/edges has been selected and there are usable surface extensions
before and after a gap, an attempt is made to close the gap using the fill algorithm. If this fill surface is
also unusable, further adjacent surface extensions are removed and approximated by the fill algorithm. The
warning ‘Some areas have been replaced by an approximation’ appears. Click the warning to highlight the
approximated areas in colour. To remove the highlighting, click the empty area below the warnings.

Normal direction: Automatically calculate an extension from the direction of the adjacent boundary of the
given surfaces. In a solid, it is the common edge with the adjacent solid surface. As this direction can be
oblique, the width of the extension is often less than the length entered. Activate this Normal direction option
to calculate an extension normal to the selected edge or boundary (1).

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hyperMILL / hyperCAD-S

Use the Check undercuts option to determine whether a tool’s position direction results in an undercut in the
surfaces to be created due to the orientation of the surfaces to be processed.

5X Machining
Cavity Milling
The cycles in the cavity machining package are primarily used for 5-axis machining of cavities and steep
domes without undercuts for which unfavourable process parameters result in 3-axis machining.

With regard to the moving behaviour of the axes, we must differentiate between the following three methods:

1. Fixed inclination: Calculation of NC paths with a fixed tool inclination in the entire machining area.
2. Simultaneous machining: Calculation of NC paths with simultaneous movement of all 5 axes. Depending
on the cycle, the following inclination strategies are available: Automatic, Radial Z, Manual curve and
Offset curve.
3. Automatic indexing: Calculation of NC paths with automatic division into segments with a fixed axis
position as well as simultaneous movement of all 5 axes for the transitions between segments.

5X Halfpipe Machining
Finishing strategy for all kinds of ‘half-pipes’, for example, tube bending or hydro-forming tools along or
across the ‘half-pipe’.

The 5X Halfpipe Machining cycle was in the beta stage for a long period of time and has
been completely revised in the current version. The following documentation describes the
new functionality. Jobs created with previous versions will not be converted to the new
version. They must be created again!

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 hyperMILL / hyperCAD-S

Strategy
To generate the toolpaths, cuts are made along a central curve. Compared to the other tube cycles, the tool
axis does not run along the central curve, but more or less perpendicular to it.

Geometry type
The cycle supports three geometry types: (1) 2 open ends, (2) 1 open end, (3) No open end.

1 2 3

Strategy
Machining can be performed along the groove (option: Along) or across it (option: Across).

Reverse direction: Reverse the cutting direction.

Below is an overview of the machining options for the three geometry types:

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hyperMILL / hyperCAD-S

2 open ends

Graphic Strategy Description / Advantageous as /

To be used preferably with

Across / Oneway outside-in Plunge machining. Especially for

tools with a short cutting edge.

Across / Oneway inside-out Drawing machining.

Small tilt angles result in longer

contact on the cutting edge on the
one hand and less contact with
the tool tip on the other hand.

Across / Zigzag Due to the shorter distances be-

tween the paths, the total length
of the toolpath is shorter.

If drawing/plunge machining does

not play a role.

Along / Oneway outside-in

Layer-by-layer machining with

linking movements across the
Along / Oneway inside-out open ends.

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 hyperMILL / hyperCAD-S

Graphic Strategy Description / Advantageous as /

To be used preferably with

Along / Zigzag outside-in

1 Because of the two open ends,

machining here is first performed
completely on the side with the
starting point and then on the op-
posite side.
Along / Zigzag inside-out
If Climb milling/Conventional mill-
2 ing does not play a role.

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hyperMILL / hyperCAD-S

1 open end

Graphic Strategy Description / Advantageous as /

To be used preferably with

Across / Oneway outside-in Plunge machining. Especially for

tools with a short cutting edge.

Across / Oneway inside-out Drawing machining.

Small tilt angles result in longer

contact on the cutting edge on the
one hand and less contact with
the tool tip on the other hand.

Across / Zigzag Due to the shorter distances be-

tween the paths, the total length
of the toolpath is shorter.

If drawing/plunge machining does

not play a role.

Along / Oneway outside-in

Layer-by-layer machining with

linking movements across the
Along / Oneway inside-out open end.

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 hyperMILL / hyperCAD-S

Graphic Strategy Description / Advantageous as /

To be used preferably with

Along / Zigzag outside-in

As one end of the channel is

closed, Zigzag can continuously
machine the channel from top to
bottom or bottom to top
Along / Zigzag inside-out
If Climb milling/Conventional mill-
ing does not play a role.

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hyperMILL / hyperCAD-S

No open end

Graphic Strategy Description / Advantageous as /

To be used preferably with

Across / Oneway outside-in Plunge machining. Especially for

tools with a short cutting edge.

Across / Oneway inside-out Drawing machining.

Small tilt angles result in longer

contact on the cutting edge on the
one hand and less contact with
the tool tip on the other hand.

Across / Zigzag Due to the shorter distances be-

tween the paths, the total length
of the toolpath is shorter.

If drawing/plunge machining does

not play a role.

Along / Oneway outside-in

Layer-by-layer machining outside-

in or inside-out.
Along / Oneway inside-out

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 hyperMILL / hyperCAD-S

Graphic Strategy Description / Advantageous as /

To be used preferably with

Along / Spiral outside-in

Continuous machining outside-in

or inside-out.
Along / Spiral inside-out

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hyperMILL / hyperCAD-S

Central curves / Boundaries

Top curve: (1) The upper curve corresponds by default to the 0.5 iso curve of a regular surface above the
groove. It is the basic reference for the maximum distance of the ball centre (see Parameters dialogue page).

Bottom curve: (3) The lower curve divides the tube at the line (regular surface) between the upper and lower
central curve into a left and a right side.

(2) = Boundary.

The height of the central curve must be selected so that the tool contact covers the entire
required machining area on the model.

2 1 2

The greater the distance of the upper curve (1) to the edge of the groove or to the defined boundary (2), the
more the tool ‘rolls’ around the edge of the groove.

1
2 2
1 2 2

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 hyperMILL / hyperCAD-S

Boundaries
The selection of Boundaries (1) depends on the geometry type of the groove. Either a closed (A), an open
U-shape (B) or two boundaries, one on each side of the groove, (C) are permitted. (2) = Central curve.

A B C

1
2
1

Start point: Only available for geometry type No open end. Activate to define the starting point of machining
for closed geometries by selecting a point on the boundary. In the case of open geometries (B, C), machining
starts by default at the starting point on the first or only boundary.

Reverse direction: By default, the direction of the machining or the infeed is always the direction of the
boundary. Select the Reverse direction option to reverse the machining direction.

Start opposite boundary: Only available for geometry type 2 open ends. Select to move the start of machining
to the other boundary.

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hyperMILL / hyperCAD-S

Synchronize toolpaths
Synchronization lines Synchronization lines run between the two boundaries or between the boundary and
the upper curve. They are to be used to divide the forming groove into areas and so influence the course
of slicing as well as the course of the paths running across. The interpolation of the slices/paths then takes
place – as with other machining strategies – over the areas limited by the synchronization lines. Slicing
improvements improve the quality of the toolpaths – including those along the channel.

The following pictures show the effect of continuous and one-sided synchronization lines for an example with
a channel open on both sides using zigzag machining.

Examples:

Machining without synchronization lines

(1) = Boundary
1

Machining with synchronization lines at the curva-

2 ture of the forming groove

1 (1) = Boundary, (2) = Synchronization lines

2
1

Machining with synchronization lines at the curva-

2 2 ture of the forming groove and on the course of a
feature

(1) = Boundary, (2) = Synchronization lines

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 hyperMILL / hyperCAD-S

Parameters

Infeed

Lateral infeed (1), Strategy: Across, Zigzag.

Lateral infeed (1), Strategy: Along, Zigzag.

Y
1
X

Max. distance from central curve

Max. distance: (3) Maximum distance of the tool reference

1 point (4) from the upper curve (1). This allows for the machin-
ing of partially open tubes without constructing any auxiliary
2 surfaces. (2) = Boundary,
2

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hyperMILL / hyperCAD-S

Allowance

Allowance: (1) Remaining material on the tube’s outside sur-

1 face to be machined.

Additional shaft allowance: Increases the shank radius for col-

lision check by the value entered. Only available for the Across
strategy to protect the non-cutting part of the tool shank.

Technology: Extend machining outwards

In order to take the stock model into account before machin-

ing, it may be useful to start machining a little higher. Use Start
offset (7) to extend the path outwards.
1
1

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 hyperMILL / hyperCAD-S

Clearance mode / Safety / Rapid Z positions

Define the type of retraction movement and the ranges for rapid movements.

Planar: (A) The retraction movements

are executed in the direction of the Z
A axis of the frame.

The Clearance plane (1) limits the range

for rapid movements. Tool movements
below the clearance distance take place
at the machining feedrate.

Y
Z 1
X

Radial: (B) The retraction movements

are radial to the Z axis of the frame.
B
The Clearance radius limits the range
for rapid movements. Tool movements
below the clearance distance take place
at the machining feedrate.

Start height / end height: (3) Only availa-

ble in Radial mode. Define the height for
Z the beginning (start height) and the end
of the machining (end height).

5 Axes

Tilt strategy
Prefer vertical: Tilt strategy for milling tools and moulds with demoulding in the Z direction. For slight under-
cuts, the machining can perform a 4X or 5X movement locally. This can be suppressed using the Tip check
tolerance (see the Setup dialogue page).

Toward top curve: The tool axis is tilted at the specified angle in the direction of the upper curve. The
connection line between the upper and lower curve corresponds to 0 degrees.

Radial Z: The tool axis is aligned with the specified angle to the Z axis of the frame. If the Fixed tilt option
is activated, the swivel axis remains unchanged during collision avoidance. When the Always radial option is
selected, the tool axis is always aligned radially to the Z axis of the frame.

Ignore any small undercuts with the help of the Tip check tolerance function (see Parameters dialogue page).

Desired tilt angle: Slope angle of the tool to be maintained laterally to the infeed direction of the tool.

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hyperMILL / hyperCAD-S

Automatic indexing
Prefer automatic indexing: If possible, the area to be machined is automatically divided into subareas, each of
which is milled with a fixed tool inclination.

Tilt angle
Max. tilt angle: Maximum permissible angle of the tool to the Z axis of the frame used.

Macros
Additional movements to vertical infeed and retract movements that define a gentle approach and retract
behaviour at the calculated milling paths.

Approach macro / Retract macro

Additional movements during infeed to the first milling path or during retraction after the last milling path of
machining. Radius and Axial offset can be defined separately for approach and retract.

(1) = Radius, (2) = Axial offset, (A) Strategy = Along, (B) Strategy = Across.

A B

Return macro / Linking movement

The retraction of the tool at the end of a path and the approach to the next path is referred to as a return
macro. Retraction and approach take place in one continuous movement. If defining the optional Radius,
small values should be given preference, particularly in narrow channels. If radius = 0, the return macro is not
executed and therefore the tool is not lifted from the component.

The two ends of the return macro are connected with a smooth movement (spline), for which a separate
Feedrate can be defined, which, as a rule, may be larger than the machining feedrate. For safety’s sake, the
increased feedrate is only carried out if the totalLinking movement (1) does not fall below the Min. clearance
to part.

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 hyperMILL / hyperCAD-S

Example: (A) Radius = 0, (B) Radius = 2.

A B

Setup

Model
Specify the model (milling area) required for the current job.

Multiple allowances: If the milling area contains groups with different allowances, these allowances are taken
into account during machining if the function is enabled.

Additional surfaces: temporary safety surfaces to avoid unnecessary rapid travel movements. Surfaces
in the machining area that need to be known to perform a correct collision check.

Check tool
The tool check ensures that all of the components defined for the tool are protected from a possible collision
with the CAD model on the basis of existing material. The tool check is only available if you have defined a
tool and also a model to be checked.

Check on: You must always enable this option if you want the tool to be checked for collisions. If the tool
check is not enabled, the tool used is shown in red in the graphic preview. When this check is enabled, the
defined clearance is used to check all of the components defined for the tool. We recommend that you define
the clearance so that it gets continuously larger, starting with the thick shank in the direction of the spindle.

Tool check setup: the tool check settings are specified in this dialogue box. For further information, see
section ???

NC parameters
Machining tolerance: Enter the required machining tolerance. The value defines the accuracy with which the
calculation for the generation of the toolpath is carried out.

Maximum G1 length(1): maximum length of the G1 movements on planar surfaces which are output in the NC
program. Greater distances are subdivided into a corresponding number of G1 movements of the specified
length. Controlling the G1 length avoids too strong accelerations of the machine on large planar surfaces.

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hyperMILL / hyperCAD-S

Min. G0 distance (1): Distance between two machining areas that can be traversed – without tool contact –
close to the surface with machining feedrate (G1). In the case where gaps are greater than the maximum
gap distance, and depending on the settings for the retract mode in the Machining parameters menu, the
system executes a retraction movement to the clearance distance or clearance plane, with a subsequent
infeed movement to the next surface in rapid.

OPEN MIND tool database

Tool geometry parameters
Drilling tool

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 hyperMILL / hyperCAD-S

Thread mill
(1) Gage length, (2) Tool length, (3) Tool reach, (4) Tip length, (5) Chamfer length, (6) Shank diameter, (7)
Diameter, (8) Tip type – Full thread – fix pitch, (9) Tip type – Partial thread – fix pitch, (10) Tip type – Single
thread – variable pitch, (11) Cutting length, (12) Pitch.

6
8 9 10
6

2
12
5
3

4
11
11
11
7
9

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hyperMILL / hyperCAD-S

Back Boring Tool

(1) Diameter, (2) Length, (3) Min. plunge diameter (4) Cutting edge position.

(A) Mounting direction: Right, (B) Mounting direction: Left.

The Mounting direction parameter indicates the mounting direction of the Insert in relation to the tool axis
and is used to define the spindle orientation. If the mounting direction is Right, the Spindle orientation is
Clockwise. If the mounting direction is Left, the spindle orientation is Counterclockwise.

The Cutting edge orientation parameter is currently not supported.

Example: (C) Back chamfering: (5) Reference point, (6) Hole diameter, (7) Axial position.

A B

4
5
6
3
7
1

Coupling rotation: Rotate the coupling of the tool holder around the Z axis so that the orientation of the holder
corresponds to the orientation of the tool.

Example: (A) Coupling not rotated, (B) Coupling rotated by 45°.

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 hyperMILL / hyperCAD-S

A A B

Import 3D data with the hyperMILL TOOL Builder to create Back Boring Tool types. For
more information on this and on the position orientation of various holder types or exten-
sions see the documenation hyperMILL TOOL Builder.

Define manufacturer
To assign a tool manufacturer to a database, proceed as follows:

1. Right-click on the database entry in the DB browser.

2. Select the Manufacturers... entry in the context menu.
3. Right-click and select the desired manufacturer from the list of available manufacturers at New → [Manu-
facturer name].
4. If necessary, enter a comment and confirm the entry with OK.

The manufacturer can now be assigned to a tool / a tool series or an Extension, a Holder, an Insert a Tool
holder. To assign a manufacturer to a tool / tool series, for example, proceed as follows:

For a single tool in the Tool → Geometry → Common → Manufacturer area or for a tool series in the Tool →
Series definition → Manufacture area, select the manufacturer from the list.

In the Ordering code field, an ordering code can be assigned to a Tool, Extension, Holder, Insert or a Tool
Holder.

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hyperMILL / hyperCAD-S

Default settings
Options / properties
Load and locally modify the defaults for the model, the model structure and the graphical attrib-
utes of the document and the software.

File → Options → Options / properties

Selection
Mesh highlight: Define the highlight for displaying meshes. If Default is selected, the mesh will be highlighted
in colour if the mouse is hovered over it. If Bounding box is selected, a box is displayed around the mesh.
Use No highlight to avoid highlighting a mesh when hovering over it with the mouse.

Data interfaces
General interfaces
Point file formats

Table 1. Options for opening or inserting a point file

Property Description

Load mode Specify how the data is processed when opened:

Approximating: Read in points and approximate curves from them.

If there are only a few points, interpolation makes sense because the
curves run exactly through the points 4 .

If there are many points, approximation is useful if the data is subject to

measurement errors and these should not be reflected. The approxima-
tion tolerance controls the maximum deviation of the generated curves
from the points. The generated curve is smoothed 5 .

4 5

Approximation tolerance The approximation tolerance controls the maximum deviation of the gen-
erated curves from the points. Enter a value.

Select and snap

Select entities
Select child entity only
By selecting an entity inside a closed parent entity (solid, group, V-sketch, feature), the entity is automatically
opened for a selection inside and only the chosen entity itself is selected.

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 hyperMILL / hyperCAD-S

Only select nested entity.

Select a nested feature, that is, a feature within a pattern feature.

Context menu → Select inner feature

Analysis
Check
Shape spherical

Analyse the radii of faces and meshes in relation to a sphere diameter.

Analysis → Shape spherical

The command is based on the tessellation. The lower the values of Tessellation and Edge length, the more
accurate the result, but the longer the calculation takes. Reduce the selected range if a precise calculation is
needed and therefore the entire model cannot be included. Use the Tessellation view to assess the change in
the result based on the selected values.

Sphere size
Check collisions: A collision check of the faces involved with a spherical shape in order to identify the areas
for the correct tool diameter. Conversely, the collision check also makes it possible to detect sharp edges
and corners, for whose production an electrode may be necessary. Without collision checking, each individual
face is analysed for its inherent minimum curvature/radius. With collision checking, all adjacent faces are
additionally taken into account for the diameter/radius.

The analyses in Sphere size and Colour map are separate. The entries do not influence each other.

Edit and modify

Modify
Continuity curve

Modify a transition between two individual curves.

Modify → Continuity curve

More options
Keep attributes: The modified curves adopt the layers and the colours of their respective initial curves.

Points, curves and faces

Drafting
Projection points

Project points onto entities or onto a workplane.

Drafting → Projection points

More options
Keep original: Specify whether the selected entities should be retained.

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hyperMILL / hyperCAD-S

Keep attributes: Colour attributes are retained.

Curves
Intersect

Create a curve along intersecting entities.

Curves → Intersect

Create a curve along intersecting entities. In addition to intersections of faces, it is also possible to calculate
intersections of mesh pairs.

More options
Self-intersection: Create curve where faces intersect themselves 3 . The Shapes B option cannot be selec-
ted.

A1 3
1

Compensate

Compensate for manufacturing deviations using a scanned curve.

Curves → Curves → Compensate 2023

Compensate for manufacturing deviations using a scanned contour curve. A scanned 3D curve is converted
on the basis of the reference curve in such a way that the original manufacturing deviations (of the machine)
are compensated for in subsequent manufacturing.

Select
Curves: Select scanned curves 1 .

Reference: Select CAD target contour 2 .

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 hyperMILL / hyperCAD-S

1
2

More options
Tolerance: Enter the required tolerance for the compensated curve. In the case of long curves, the tolerance
must be reduced in order to obtain the mirrored points of the opposite side in the desired tolerance.

Offset

Create a curve with an offset to an initial curve.

Curves → Offset

More options
Keep attributes: The offset curves adopt the layers and the colours of their respective initial curves.

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hyperMILL / hyperCAD-S

Offset on face

Create offset curves on faces.

Curves → Offset on faces

More options
Keep attributes: The offset curves adopt the layers and the colours of their respective initial curves.

Shapes
Offset

Create faces with an offset from existing faces.

Shapes → Offset

More options
Use the Check radius of curvature option to determine whether the offset is compatible with the curvature
radii. If not, a warning is issued. Unable to create a self-cut 7 . Without checking, self-intersecting offset faces
are permitted 8 .

Create solid

Construct a solid from faces and solids.

Shapes → Create solid

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 hyperMILL / hyperCAD-S

Entity accuracy
Open edges are highlighted in red. The minimum entity accuracy is green, the maximum entity accuracy is
highlighted in blue.

Solids, features and meshes

Features
Holes

Create a hole optionally with further machining (thread, fit, slot, countersink). Solids

Features → Holes 2023

Create a hole (also possible with parametric modelling) optionally with further machining (thread, fit, slot,
countersink). Save the entity as a template in a library and use it again.

A hole configured in Base is marked ‘Base’ on the Model tab. A hole configured in Advanced is labelled
‘Advanced’.

In hyperMILL, select the Keep CAD features option in the settings for Feature mapping
(hole). Activate if a drilling feature created with hyperCAD-S should remain associatively
linked to the hyperMILL feature after feature mapping.

Table 2. Comparison of criteria for selecting Base or Advanced

Base Advanced

Generate quickly Create complex structure

Parametric modelling possible Parametric modelling possible

Max. 2-step (per feature including editing + countersink) Multi-step (up to 15 steps/10 opposite steps)

From one machining direction Possible with opposite machining direction

Several tolerances

As through bore, with flat hole end or pointed hole end Also with hidden through or with spherical hole end

No spot configurable No spot configurable

No bottom offset configurable Bottom offset

No (ring) groove configurable Max. 5 (ring) grooves

Cylindrical only Also conical or with undercut

Use variables from the hyperCAD-S spreadsheet No variables from the hyperCAD-S spreadsheet can be
used

One user library Multiple user libraries possible

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hyperMILL / hyperCAD-S

Configuration

Library
Save a ready-defined CAD feature as a template in a user-defined library.

New
Add a CAD feature as a new template to the user-defined CAD feature library. Enter a name

and save it with . Either the base library or the advanced library is used, depending on the
selection of Base or Advanced.

Base
Create a hole, fit or thread as a CAD feature.

Compose holes
Compose the CAD feature as a hole, thread or fit, with the shape of the end of the hole and any countersink
required.

Select whether a countersink is to be

inserted and, if so, which one.

without countersink Countersink Counterbore

Select machining.

Hole Fit Thread

Select feature end shape.

Conical end shape Conical end shape Through bore

Parameter
Enter the specifications for the selected composition of the CAD feature.

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 hyperMILL / hyperCAD-S

1 1

Use the graphic in the dialogue to enter or change the length of the hole 1 , the diameters and the angles
according to the selected composition.

For threads, take the specifications from the thread table. For fits, take the specifications from the fit table.

Definition: Select a thread type or the tolerance class for a fit.

Designation: Select a thread.

Depth: Enter a length for the thread or fit. The minimum length of a core hole is the length of the thread plus
four times the pitch of the thread.

During creation, a preview is displayed in the form of a cylinder for the thread. The finished thread feature
is characterised by a helical stylisation along the entire length of the core hole. The finished fit feature is
characterised by a striped stylisation.

Browse: In the catalogue selection, change the stored thread or fit table and select from various standards,
such as metric coarse pitch, metric fine pitch, UNC standard pitch and UNC fine pitch.

The thread table omThreadCatalog.xml and the fit table omISOFitCatalog.xml are first searched for
in the default path of hyperMILL specified in the General working space option. This is the C:\Users\Pub-
lic\Documents\OPEN MIND\USERS\FeatTech directory when using the default. If there is no data
there, the installation directory C:\Program Files\OPEN MIND\Shared\[version]\files\featTech
is searched for the data. If there is no data in both places, search in C:\Program Files\OPEN MIND\hy-
perCAD-S\[version]\files\hmfeat\tech.

Thread direction
Select left-hand thread or for the typically used right-hand threads.

Fit / thread
Full depth: Run the length of the thread or fit through the entire feature depth.

Advanced
Create a generic hole as a hyperCAD-S CAD feature. Choose the Feature parameters. Variables from the
spreadsheet cannot be assigned.

Further information can be found in the hyperMILL software documentation under hyperMILL > Feature and
macro technology > Feature catalogue >Generic Hole.

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hyperMILL / hyperCAD-S

Position

Face to be drilled
Face: Select an entity.

Distance from face. The CAD feature is shifted by the specified distance in the feature direction 2 . Enter a
value.

Specify the position reference

In Point definition, select the feature centre position according to the Reference data. In parametric modelling,
the specifications always correspond to the reference entities that may have been changed:

All entries refer only to the area to be machined:

Project onto face

Project the snap point in the direction of the shortest distance onto the selected face
to be machined. This is to be the projected as the feature centre point.

Snap: Snap centre position. The hole is placed on the snap point.

Project: Project the selected snap point as the centre position in the direction of
the shortest distance on the selected face. The CAD feature remains placed on the
selected face to be machined.

Starting from 2 edges

Select two boundaries or edges and determine the distance from each edge.

2 edges: Select two edges and enter the two distances to the edges.

Free point
Select the position using the U and V parameters of the selected face’s domain.

Not assignable using a variable from the spreadsheet. Cannot be

used for parametric modelling.

U: Enter an isoparameter value from 0 to 1.

V: Enter an isoparameter value from 0 to 1.

All entries refer to the face to be machined or, optionally, to another face that is used as a reference.
Initially, the entries are automatically related to the area to be machined. If another face is to be used as a
reference, reset the selection and select again:

With cartesian point

Face: Select a reference face.

Origin: Select the coordinate origin.

Direction: Enter the direction for the X axis by selecting a second point or enter a
position so that a direction results from the line between the origin of this selection.

Enter the coordinate values for X and Y.

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 hyperMILL / hyperCAD-S

With polar coordinates

Face: Select a reference face.

Origin: Select the coordinate origin.

Direction: Enter the direction of the angle flanks as a reference for specified angle by
selecting a second point or enter a position so that a direction results from the line
between the origin of this selection.

Enter the coordinate values for the Angle and Distance from the origin.

Starting from one edge

Select a position along an edge at a distance from this edge.

Face: Select a reference face.

Edge: Select a reference edge or reference boundary.

Along edge: Enter a value for a shift of the feature centre position along the edge.

From distance: Enter a value for the distance of the feature centre position from the
edge.

With cylindrical coordinates

Face: Select a reference face.

Origin: Select the coordinate origin.

Direction: Enter the direction of the angle flanks as a reference for specified angle by
selecting a second point or enter a position so that a direction results from the line
between the origin of this selection.

Enter the coordinate values for the Angle and Height from the origin.

Specify alignment
Select the orientation of the CAD feature.

Normal to face: The CAD feature is aligned at the selected position in the direction of the face normals of the
faces to be machined.

If the CAD feature is not aligned according to the face normals, determine the Direction:

Library (base)
Either the Library (base) or the Library (advanced) is displayed, depending on the selection of Base or
Advanced.

Select a saved CAD feature template from the library. To do so, double-click the required bookmark with the
left mouse button. The files can be set up in such a way that a distinction can be made between user-defined
CAD features and company-wide defined templates for CAD features.

User library: Select a template from the data saved by the user.

Company library: Select a template from the company-wide default settings.

Application library: Select from the generic sample templates provided.

Open the following commands in the context menu of a user-defined entry:

Rename: Change the name of the template.

Remove configuration: Remove the template.

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Edit description: Enter or change information about the template.

Templates are stored under C:\Users\[User]\AppData\Roaming\OPEN MIND\hyperCAD-S\[Ver-

sion]\SmartShapesConfig\Holes in *.xml files. There is a separate file for every template of each
composition of hole type, hole end and countersink. These files can be used for a company-wide preset.

Library (advanced)
Either the Library (base) or the Library (advanced) is displayed, depending on the selection of Base or
Advanced.

The name of the user library, which acts as the default configuration container, cannot be changed. CAD
features, which are saved as templates in the library (advanced), are inserted into this branch library. They
can be dragged and dropped into one of your own branch libraries.

User configurations and user libraries: Select a template from the data saved by the user.
Templates can be moved between user libraries using drag-and-drop operations.

Company library: Select a template from the company-wide default settings.

Application library: Select from the generic sample templates provided.

Open the following commands in the context menu of a user-defined entry:

Add new user library: Create another user library.

Remove library: Remove a user library. The user library (preset configuration container) cannot be removed.

Apply configuration: Apply the selected template to the selected position. Another option is to double-click
with the left mouse button.

Rename: Change the name of the user library or the name of the template.

Remove configuration: Remove the selected user library or selected template.

Solid
Difference

Using a solid, remove the areas of other solids that this solid intersects in the other Solids
solids.

Booleans → Difference

Keep original solids

Solid A: Specify whether the selected entity should be retained.

Solids B: Specify whether the selected entities should be retained.

Design electrodes

Electrode options

Select default settings for electrodes. Electrode

File → Options → Electrode options

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Technology
Electrode material: Select a material for the electrode from the drop-down menu. All materials are displayed
that are entered as electrode materials in the XML file for materials selected in the XML file for materials
option. Also see User-defined material list [56].

EDM
For electrodes without an electrode holder, a machine head is not displayed and not checked.

Orbit type: Select the shape of the electrode orbit type during erosion (for example, sink, sphere, half sphere,
square, widen, linear, sink and widen, sink and sphere, sink and square, injection, ISOG). A dynamically
adapted drop-down menu of orbit types is displayed that are defined in the file selected in the XML file for
orbit types option. Also see User-defined orbit type [56].

Folders
Electrode project: Select a directory for the milling project to undertake milling programming and to create the
derived electrodes.

If an electrode project directory has been entered, a subdirectory with the name of the electrode is created for
each derived electrode.

%HC_CURRENT_DOCUMENT_PATH_NAME% returns the file path and the currently opened document.

Example 1.
C:\66857-1004-004\66857-1004-004.hmc

%HC_CURRENT_DOCUMENT_DIRECTORY% returns the file path of the currently opened document without
including the file name of the document.

Example 2.
C:\66857-1004-004

Export reports: Select a directory to permanently store electrode reports that are generated with the Export
reports command.

%HC_CURRENT_DOCUMENT_PATH_NAME% returns the file path and the currently opened document.

%HC_CURRENT_DOCUMENT_DIRECTORY% returns the file path of the currently opened document without
including the file name of the document.

XML file for orbit types: Select an Electrode_orbit.xml file that has been prepared with the information
on the orbit types. Also see User-defined orbit type [56].

XML file for materials: Select a default.densities.xml file that has been prepared with the information
on materials. Also see User-defined material list [56].

Create reference system

Create a positional reference between the workpiece and electrodes. Electrode

Electrodes → Create reference system

The selected geometry is automatically locked by this command. Unintentional shifting or scaling of the
workpiece is prevented. The lock can be released manually at any time at one’s own risk using the command
Edit → Unlock entities. If manually unlocked, the lock will no longer be set automatically afterwards. Only as
long as the lock is present can the software inform that the workpiece is being used for eroding and should
not be changed.

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It is advisable to lock the workpiece again after making a change. To lock the part again,
reassign the eroding reference to all faces and select the existing name.

Modify eroding path

Make eroding path visible and modify. EDMcon

Electrodes → Modify eroding path 2022.1

If the reference position of the electrode for the target position is on the contact face, no C-axis rotation can
be defined. The axis of the machine does not match the axis of the electrode. The rotation of the electrode is
automatically inserted at the first point of the selected curves at the beginning of the eroding movement when
the curves of the eroding path are selected for Blind or Through.

Blind

Motion
In addition to lines, arcs can also be selected as eroding paths. The arcs must be parallel to the EDM
reference in XY planes.

Add synchronous C-axis rotation

Point: Rotate the electrode continuously at an angle around the C-axis between two positions synchronously
with the forward movement. Select the yellow marker in the middle of the respective curve segment as the
Point 6 .

In the graphic area, enter an angle for the rotation around the C-axis directly at the point in the middle of
the curve segment 7 . The angles of the individual turns are not summed. For example, for a continuous
rotation along six segments by 45° each, enter the angle values 45°, 90°, 135°, 180°, 225° and 270°. The
direction of rotation is determined by the preceding sign + / -. Plus turns in accordance with the right-hand
rule, anticlockwise. Minus turns clockwise.

Tolerance: The rotary movement is implemented in the NC program by subdividing into G1 segments and
partial angles. Control the accuracy of the subdivision with the tolerance (approximate chordal tolerance).

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72°

7 6
72°

Through

Motion
In addition to lines, arcs can also be selected as eroding paths. The arcs must be parallel to the EDM
reference in XY planes.

Add synchronous C-axis rotation

Point: Rotate the electrode continuously at an angle around the C-axis between two positions synchronously
with the forward movement. Select the yellow marker in the middle of the respective curve segment as the
Point 6 .

Tolerance: The rotary movement is implemented in the NC program by subdividing into G1 segments and
partial angles. Control the accuracy of the subdivision with the tolerance (approximate chordal tolerance).

In the graphic area, enter an angle for the rotation around the C-axis directly at the point in the middle of
the curve segment 7 . The angles of the individual turns are not summed. For example, for a continuous
rotation along six segments by 45° each, enter the angle values 45°, 90°, 135°, 180°, 225° and 270°. The
direction of rotation is determined by the preceding sign + / -. Plus turns in accordance with the right-hand
rule, anticlockwise. Minus turns clockwise.

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135° 180°

90° 225°

5 45° 270°

6
4
Y

The curves and points are applied as the eroding path.

User-defined orbit type

Define your own orbit types for a machine.

The orbit types are offered for selection in Create, Create user defined and in Modify EDM parameters as
well as in the Electrode options and are used directly by the EDM converter and forwarded to the eroding
machine.

The selection of an orbit type is based on a user-defined file Electrode_orbit.xml in the directory
%MYDIR%/hyperCAD-S/files/electrode. It contains the displayed name of the <orbit> orbit types
of the name attribute. The description attribute can be used for remarks, such as for the machine in
question.

The T_ORBIT tag is assigned the content of the name attribute that is passed to the EDM converter.

<?xml version="1.0"?>
<EDMOrbits>
<!-- Machine A -->
<orbit name="Sink" description="Machine A" />
<orbit name="Sphere" description="Machine A" />
<orbit name="Square" description="Machine A" />
<orbit name="Widen" description="Machine A" />
<orbit name="Linear" description="Machine A" />
<orbit name="Sink and widen" description="Machine A" />
<orbit name="Sink and shpere" description="Machine A" />
<orbit name="Sink and square" description="Machine A" />
<orbit name="Injection" description="Machine A" />
<orbit name="Half sphere" description="Machine A" />
<orbit name="ISOG" description="Machine A" />
<!-- Machine B -->
<orbit name="Sink" description="Machine B" />
</EDMOrbits>

User-defined material list

Define a separate material list for workpieces and for eroding with electrodes in the file default.den-
sities.xml as a default setting in ...\files\materials\.... The modified file, like all modified
files, should be copied to the roaming or company directory and not modified in the installation directory,

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for example, in C:\Users\[USER]\AppData\Roaming\OPEN MIND\hyperCAD-S\[VERSION]\mate-

rials\default.densities.xml.

Material for eroding electrodes

To specify a group of materials as electrode material set the electrode="yes attribute in <category>.

The materials are offered for selection on the Electrodes menu in the commands Create, Create user defined
and in Modify EDM Parameters as well as in the Electrode options.

Example 3. Material list with graphite as electrode material

<?xml version="1.0" encoding="utf-8"?>

<Materials version="2023">
<categories measureUnit="kg/dm³" context="materials">
<category title="Aluminum - alloys">
<matters>
<matter name="3.0205"
description="EN-AW 1200"
massDensity="2.700" />
<matter name="3.0255"
description="EN-AW 1350A"
massDensity="2.700" />
<matter name="3.0505"
description="EN-AW 3105"
massDensity="2.710" />
</matters>
</category>
<category title="Graphite" electrode="yes">
<matters>
<matter name="ISEM-1"
description="ISEM-1"
massDensity="1.680" />
<matter name="TTK-50"
description="TTK-50"
massDensity="1.800" />
<matter name="TTK-4"
description="TTK-4"
massDensity="1.780" />
</matters>
</category>
</categories>
</Materials>

NC programming
hyperMILL
Analyse distance toolpath-shape

Analyse distances between surfaces and a toolpath. 2023

hyperMILL → Analyse distance toolpath-shape

The distances between a toolpath and surfaces are determined. A subarea of the toolpath can be selected
using a selection area. Two target distances divide the toolpath into three steps. Points can be created at
which the toolpath meets the required distances.

For the analysis, a toolpath calculated with a ballmill is assumed and displayed for the tool centre point. This
is not checked.

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To perform a local analysis, position the mouse at the desired location. A shortest distance to a next face is
calculated, and the value and a line are displayed.

Automatic computation: After selecting all entities, start the calculation for the analysis. The results can be
applied only once the calculation of the preview has been carried out.

Select
Toolpath: Select entities. The number of selected entities is displayed.

Shape: Select entities. The number of selected entities is displayed.

Transparency: Select and set a transparency for the entities selected under Shape.

Inside toolpath
Limit the toolpath analysis to an area inside or outside a selection area.

Window: Analyse distances within a rectangular selection area.

Lasso: Analyse distances within a selection area delineated by a polygonal line.

Circular: Analyse distances within a circular selection area.

Modes
C. + P.: Enter the middle point and point on the circumference of the circular selection area.

C. + R.: Enter middle point and radius.

The number of selected entities is displayed.

Circular sector: Analyse distances within a selection area arranged in an arc.

Select
Centre: Click the centre of the arc with the left mouse button or snap a position or select a point.

Vertices: Click two diagonally opposite corners with the left mouse button or snap positions or
select two points to draw the selection area.

The number of selected entities is displayed.

Invert: Invert the current selection.

Reset: Discard the current selection.

Show: Show toolpath points (within the selection area).

Colour map
Target - max. distance: Enter a presumed maximum distance necessary for the analysis to speed up the
calculation. This can be determined, for example, on the basis of the values used in the tool calculation.

Min. and Max. display the determined minimum and maximum values.

The X axis shows a colour map and assigns a colour to each value in the analysis area. A colour symbolises
the value assigned to the analysed toolpath. The Y axis provides qualitative information about the scope of
the respective value in relation to all determined values. A thin, vertical line shows the analysed distance.

Use Limits to limit the analysis area and find a colour map that is suitable for the analysis. Select a minimum
Min. value and a maximumMax. value. Values below Min. are shown in dark grey. Values above Max. are
displayed in light grey. Use Reset to set a restricted analysis area to its original size. Auto calculates an
optimal analysis area.

The value ‘inf’ is displayed when no result was determined, or if the result goes to infinity.

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Colouring step
Min. and Max. display the determined minimum and maximum values.

It is possible to specify two target distances in the table for the beginning and the end of the middle step. The
toolpath is then displayed with three colours in areas. Double-click with the left mouse button on a colour field
in the Colour column to change the colour. To change the values, double-click the values in the To column.

Extract points: The points at which the toolpath meets the required distances of the centre step can be
created.

Adaptive construction
Global fitting

Join multiple free-form or analytical faces into a face.

Shapes → Global fitting

Parameter
The following options may be active or inactive, depending on the mode selected.

Sampling method: Perform the calculation based on the existing tessellation (option: Tessellation) or based
on a temporarily created grid with evenly sized triangles (option: Uniform sampling).

Print documentation
Quick print

Print using pre-specified layouts or save 2D contours.

File → Quick print

More options
Darken the entities: Entities are darkened for the printout and not coloured.

Reports
Configure job report

Select and configure template for job report.

hyperMILL → Reports → Configure job report

Call up the command and carry out the following steps to make presettings for exporting a job report:

1. Select a template. A job report and a compound job report are available for selection.
2. For two images (Define model view (Graphics 1), Define model view (Graphics 2)) select in which form
the images are generated. The following options are available:
• No screenshot – so no image
• 2D view
• 3D view
• Setting up the view manually
• Manually setting up and changing the view
Use the entries in the Start Excel cell, Width of bitmap and Height of bitmap options to influence the
position and size of the images.
3. If necessary, adjust Folder and File name to use your own logo. The OPEN MIND logo is used by
default.

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4. Set the following options:

• Joblists selection: Select the required job lists
• Each job list in a separate Excel file?
• Automatic clamp display?
• Stock dimensioning?
• Sub joblists separated?
5. Result display: A PDF document or Excel can be optionally opened with the generated job report.

Export job report

Export job report.

hyperMILL → Reports → Export job report

Export job report. To do this, select the options configured in the Configure job report [59] command.

To set up the view manually, place the model in the graphics area accordingly and zoom in.

In a compound job report, the tool from the first job is output in the report! The assumption is that each
compound job contains only jobs with the same tool.

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3. Release notes
Release 2023
hyperMILL
NC Optimizer - Additional axes

Fixed axes
The angle defined in the Virtual Machine configuration (dialog page Machine) for the respective axis is used
as the default angle.

Use preferred angle: Define an angle for the fixed axis. The NC Optimizer can change the defined angle to
achieve an inclination, that is within the machine limitation and at the same time collision free. This is the
default setting when creating a new job.

Optimizing logic:

The defined angle is checked first. If this does not lead to a valid solution, the position of the previous job
is checked. If both positions do not lead to a valid solution, another valid positioning of the rotary axis is
determined by the NC Optimizer. This is iterated in increments between 180°, 90°, 45° and finally 1° steps.

Even if the NC Optimizer is deactivated, this logic is used to search for a kinematically
correct solution. This solution is not checked for collision but only for violation of the axis
limits.

Force: Define a value for the angle of the rotary axis. This will not be optimized by the NC Optimizer and only
checked with active NC Optimizer.

HIRTH GEAR
The fixed rotary axis is also optimized for machines with Hirth gear. Here, the first solu-
tion is selected that is within the defined Hirth deviation tolerance. The Hirth deviation
tolerance is defined in the Virtual Machine Configuration (dialog page NC) under Common
→ Formats. (Attention: This input field is hidden in the standard configuration).

Parallel axes
The position defined in the Virtual Machine configuration (dialog page Machine) is used as the default value
for the respective axis.

Use preferred position: Define a value for the position of the parallel axis. The NC Optimizer can change the
defined value to achieve a position that is within the Machine limitation and at the same time collision free.
This is the default setting when creating a new job.

Optimizing logic:

The defined value is checked first. If this does not lead to a valid solution, the position of the previous job is
checked. If both positions do not lead to a valid solution, another valid positioning of the axis is determined by
the NC Optimizer. This tries to realize a minimum delta between the parallel axes.

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Even if the NC Optimizer is deactivated, this logic is used to search for a kinematically
correct solution. This solution is not checked for collision but only for violation of the axis
limits.

Force: Define a value for the position of the parallel axis. This will not be optimized by the NC Optimizer and
only checked with active NC Optimizer.

DISPLAY OF OPTIMIZATION INFORMATION

The positions or angles optimized by the NC Optimizer are displayed during the generation
of the NC file for the respective job and in the hyperMILL VIRTUAL Machining Center
(postprocessor log). This also applies to optimizations for machines with Hirth gear.

Transformation Pattern Recognition

Use the new Transformation Pattern Recognition function to recognize equal subregions of the CAD model
and transform toolpaths, that have already been created for a subregion to the recognized equal subregions
of the CAD model. To use the function, proceed as follows:

1. Use the context menu in the Feature Browser (Feature lists) to select the Transformation Pattern Recog-
nition entry and open the dialog.
2. In the dialog select the frame at Frame and the surfaces of the already edited geometry at Selection
→ Surfaces. The Sorting → Shortest distance function searches for the same geometry at the shortest
distance from the selected geometry, considering the current frame view. If the Grouping function is also
activated, the same geometries found are grouped within the selected frame and the groups are sorted
according to the shortest distance.
3. As a result of the calculation, a new transformation is created in the Transformation area of the Frames
browser. It contains a correct frame for each geometry found. The frames are automatically used for
machining when using the transformation.
4. For further processing, activate the Transformation function in the job definition and select the newly
created transformation at Selection → General pattern.

Feature technology - Customized Process Feature -Transformation

Transformations are now available in the CPF. To make a transformation available in the cycle using a CPF,
proceed as follows:

1. Use the context menu in the Feature browser (Featurelists) to select the Customized Process Feature →
Machining object or select an existing CPF definition.
2. Set a mark at Selection → Transformation and close the dialog.
3. Open the CPF definition in the feature browser by double-clicking or via the Customized Process Feature
→ [CPF definition] entry, select the desired transformation under Transformation and close the dialog.
4. Select the CPF definition in the cycle via the Feature dialog page. An activated transformation is dis-
played in the lower area of the dialog (Transformation → Active). Double-click on the entry to toggle
between Active / Inactive.

Feature technology - Customized Process Feature - Define Fixture area

In a CPF (Customized Process Feature) you can now also define a Fixture area.

Feature technology - NC Event

A feature can now also be assigned to an NC event. To do this, in the NC event switch to the Feature tab. In
the Select feature dialog double-click the desired feature to move it to the Selected area. The NC event can
thus also be included in a macro.

Feature technology - Pocket Recognition

When using the Pocket recognitiong function, the Rectangle pocket is now also recognized. This means,
that in the Slot-Rib Probing cycle also the parameters Length and Height can be used in the Feature job

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connector. When machining pockets (cycle 2D Pocket Milling, function Use adaptive pocket) and using macro
technology, this improvement allows you to react especially to the rectangle pocket type.

Macros, that only react to the pocket shape General, will not find a match with the newly
recognized pocket shape Rectangle as of version 2023. The Rectangle feature parameter
must be additionally enabled (Free feature parameter) to ensure the usual processing.

Probing - improved user guidance

The user guidance for defining the center tolerance in the cycles Slot-Rib Probing, Circular Probing and
Rectangular Probing has been improved. The options Position → Center X -/+ and Position → Center Y -/+
are used to define the maximum permissible deviation between the actual position and the target position in
the negative or positive X or Y direction.

Thread Milling - Thread Mill

The value for the No. active thread profiles parameter of the tool definition for the Thread MILL tool type is
taken over in the job definition of the Thread Milling cycle (dialog page Parameters) as parameter Number of
thread starts.

Tool databases with older adaptor couplings

If your previous tool database contained Adaptor couplings, you can no longer open them with the current
version of the tool database. Before opening the database, you must convert the older adapter couplings to
Adaptor - ISO 13399 couplings. To do this, proceed as follows:

1. Open the database with version 2022.2 and open the Couplings-Dialog.
2. Select adaptor couplings and convert each adapter coupling to the corresponding ISO 13399 adaptor
coupling.
3. To do this, open the context menu for the adapter coupling and select the correct ISO 13399 coupling
from the Convert to ISO menu.
4. Then restart the conversion to version 2023.

3D Profile Finishing / 3D Z Level Shape Finishing

Boundary dialog page: with the option Milling surfaces → Milling surface extension → Advanced option →
Create CAD surfaces the calculated extension surfaces are generated as CAD surfaces. The faces are
automatically selected and saved on a separate layer OM extended faces.

hyperCAD-S
System check tool

• A warning is given when the energy-saving mode of the operating system is activated.
• The setting of the environment variable HC_SPARSE_FILE_STD_HANDLING is displayed.

In the event of a licence warning:

Please open the licence manager.

Customise context menu: The command has been revised. There are now more commands to choose from.

File

• Temporary data that is necessary when hyperCAD-S files are opened and saved is only stored during the
process and is deleted immediately after the process has ended, including the directories created for this.

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For this purpose, the %temp%\OPEN MIND directory is now used to enable a virus scanner to exclude the
monitoring of hyperCAD-S.
• Open: The error layers (previously from 700) for faces with trim errors have been replaced by a marking
with the hcs_cr_trim_error tag. Filter out the affected faces in the visibility filter for user-defined tags.
The original layers of the faces are now retained.
• Merge: Multithreading is additionally supported for inserting documents. The same technology is now used
when pasting from the clipboard.

CAD interfaces

• PTC Creo: In addition, the file format *.neu is supported.

• SOLIDWORKS: In Solidworks there is no way to select parts that are to be loaded from an assembly. The
configurations may be selected if the model contains several configurations. The ‘Multiple models’ import
setting has been renamed to Different configurations.

Drafting

• Sketch: The line now always snaps into place, even immediately after the first point – in horizontal, vertical
and 45° directions.

Shapes

• Extension faces: Only one single, circumferential face is created at a time if the faces are (coplanar) planar
faces.
• Create solid: Performance when creating open solids has been improved, especially when the data quality
is not optimal.

Features

• Linear slot and Rotational slot: If curves within V-sketches or parametrically created faces are preselected,
the Multishell solid option is automatically activated. It cannot be deactivated and is greyed out. The option
can be switched when there is no preselection or if the preselection includes static entities.

Parametric modelling / Boolean operations

• Parametric modelling is possible for Boolean operations. The Boolean operation used is inserted into the
model structure.
The Boolean operation ‘One solid minus n solids’ can be performed. The Boolean operation ‘B minus A’ is
not possible.

Figure 1. Performing a parametric Boolean operation – example

2 3
a

4
a
a

a=5 a = 12 a = 20
1 Create V-sketches and define the dimensional constraint with a variable from the spreadsheet.

2 Create solids, for example, with a linear extrusion.

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3 Perform a Boolean operation, for example, Difference.

4 Vary the variable in the spreadsheet. The parametric modelling adapts.

• In the model structure, the Roll-back state is indicated by the Roll-back icon even when the tree structure is
closed, for example, for a solid.
• It is not possible to create a parametric feature if the affected entity is in the Roll-back state or if it is the
master of an entity in the Roll-back state.
• The Roll forward and Roll back commands are also available on the Edit pull-down menu.
• Parametric Boolean operations can be changed subsequently. To do this, select the resulting solid again
and call the Change parameters command conveniently on the context menu.
• The ‘Separate multishell solids’ option has been renamed to Separate solids.

Direct modelling

• Several faces can be moved together while maintaining their topological relationships, for example, several
rings and ring grooves including fillets and chamfers along a cylinder.

Modify

• Fill mesh areas, Decimate mesh, Separate mesh clusters and Smooth meshes: The ‘Copy’ option has
been renamed to Keep original.
• Align faces orientation: The calculation algorithm has been revised and now works faster and more reliably.

View

• Global transparency on / off: The switching state of the option was not visible. A second icon has been
added so that the state can be better recognised.

Analysis

• Check quality / healing: Finds boundaries or boundary sections of trimmed faces that are smaller than the
tolerance, for example, small protruding ‘corners’ in the course of the edges at the transition between two
faces. These faces can be repaired using Healing.
A check is made for self-intersecting curves and faces.
Irregular parameterisation is shown in Default and no longer in Advanced, as it is information that is often
needed for hyperMILL.
Most defects on edges (usually in the Advanced mode) have so far appeared in the Curves category. They
have been moved to the Faces category, for example, irregular parameterisation.

hyperCAD-S Electrode

• The eroding path, including information on the C-axis rotation, is written to the file EDM_Converter_sum-
mary_2.0.xml.
• The two Euler angles yaw (alpha) and pitch (beta) have been added as tags for the eroding machines only
for the export of the 3 points eroding path and for its processing in the EDM converter. Accordingly, these
two angles have been added to the EDM_Converter_summary_2.0.xml file.
• Modify EDM parameters: Materials from the default.densities.xml file are offered for selection in a
drop-down menu for the parameter Material for workpiece.
• Print: Materials from the default.densities.xml file are offered for selection in a drop-down menu for
the parameter Material for workpiece.
• The EDM converter is delivered integrated in hyperMILL with the hyperCAD-S installation. A separate in-
stallation is not offered (any longer). The Directories option is no longer necessary and has been removed.
• The <InterpolationTolerance> is no longer maintained in the electrode_machine.xml. It can be
entered directly in the command Modify eroding path.
• A check is made to see whether a CAD entity is part of an electrode with the same reference system, for
example, workplane. A more precise check can be carried out to see whether the target position is on the
contact face. For this purpose, there is the additional (hidden) tag T_ELECTRODE_WORKPLANE_POSITION;
the ELECTRODE_WORKPLANE_POSITION tag is output in full_electrode_summary.xml and in the
other reports.
• Edit → Move / copy: A warning is output when moving and copying a workpiece with electrodes. If a
geometry is moved for which an eroding reference has already been defined, a warning is given indicating

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that this geometry is used for the electrodes. This is because such a procedure can lead to false values.
The aim is to prevent a geometry from being moved unintentionally and without notification.
• Workplanes: Workplanes for the eroding reference system and electrode reference position are linked
to the information in the coordinate labels. They are not linked to the internal tags of the electrode.
A warning is issued if such a workplane is moved and overwritten with the same name, as this could
lead to inconsistencies. The process is not blocked as, for particular reasons, for example, because of
hyperMILL AUTOMATION Center, the workplane should remain movable and it should also still be possible
to manually update it to the correct values.
• Electrode options: A Min. block height of 0 is permissible. If the block height is 0, the correction for rounding
the target position is applied to the linear extension (previously the length was generally added to the block
length). The remaining block height/clamping depth for clamping in the electrode holder remains the same.
The reduction is automatically deactivated. If the reference position of the electrode is set to the reduction
bottom edge or the electrode holder, the reference position is automatically corrected to the coupling of the
electrode holder to the machine axis if the block length is changed to 0.
• The SYSTEM 3R electrode holders have been added. To use them, select the file elec-
trode_blocks_holders_3R.xml in the electrode options, under Folders, in the option XML file for
raw material and electrode holders.

hyperMILL SHOP Viewer

• The PLM Connector functionality is available to an extent aligned with the functional scope of the software.
• The Move / copy command has been added.

hyperCAD-S Viewer

• Extended by the Compare and merge command.

• Extended by the Move / copy command.
• In order to be able to use the software better for production, numerous base commands have been added
to the Drafting, Curves and Modify menus.

hyperMILL related

• The setting for the entities of the mesh type are used for stocks. The bounding box is then available for
selection and makes it quicker to preselect a large stock. Selecting can also be switched off as a result of
this.
• PDF export: The default has been changed from A4 to the main screen resolution that has been set.
• The menu structure has been slightly adapted for tool reports. They can now be found under hyperMILL →
Reports → Export tool report or hyperMILL → Reports → Configure tool report. The functionality has been
revised.
• The icon has been updated for the hyperMILL → Utilities → Import WinTool tools and Export WinTool tools
commands.

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