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Simulation Based on the NC Code Ensures Processes That Are Reliable and More Efficient


hyperMILL® VIRTUAL Machining Center is the CNC simulation solution featured in hyperMILL® CAM software. A perfect virtual representation of the machine reality based on real NC data, it utilizes networking between the machine and hyperMILL® to provide an unprecedented level of process control and optimization. This is an important step to Smart Factory.


➤ Components are becoming ever more complex, yet turnaround times keep getting consistently shorter. As a result, manufacturers must make optimum use of their machine tools. Auxiliary machine processing times, costly machine damage, production downtimes and the resulting critical delays must be effectively minimized

➤ hyperMILL® VIRTUAL Machining* plays an important and groundbreaking role for NC simulation. The highly efficient NC code-based simulation solution offers three modules: Center, Optimizer and CONNECTED Machining. These modules help to significantly strengthen the close cooperation between hyperMILL® CAM software and the machine tool. Networking and virtually mapped processes make it possible to evaluate, control and optimise machining operations more reliably, even before the machine runs.

The latest generation of postprocessors

With hyperMILL® VIRTUAL Machining simulation solution, OPEN MIND has significantly advanced its postprocessor technology* and added numerous innovative functions. The NC program generated by the postprocessor and the machine information from the hyperMILL® CAM software can now be linked to each other bidirectionally. The respective machining programs from hyperMILL® can be directly matched to the NC code.


1 | Machine and removal simulation
2 | Networking with the machine
3 | Remote control for starting and stopping
4 | Each line of code is simulated
5 | Intuitive operation
6 | NC code display

Simulation and analysis allow considerable advantages

Whether in the role of CAM programmer, machine operator or manufacturing planner, the hyperMILL® VIRTUAL Machining Center has both an intuitive and comfortable user interface. The interface has the look and feel of a real and familiar machine control system. This means that programmers, operators and planners can become quickly acquainted with the new simulation technology.

hyperMILL® VIRTUAL Machining ensures that all processes are transparent to the user and can be analyzed in detail. Working with a ‘digital twin’ facilitates significant optimization without impacting productive machining time. Benefits include optimized workpiece positions and clamping setups, checked tool paths and the reliable prevention of real machine collisions. This results in improved quality and efficiency during subsequent machining with shorter machining times as well as greatly increased productivity.

*Note: hyperMILL® VIRTUAL Machining requires a hyperMILL® VIRTUAL Machining postprocessor.

Application areas

 Checking, evaluating and optimizing the machining process

 Matching a job to available machines

 Easily shifting job tasks between available machines

 Supports for the acquisition of new machines

 More accurate estimation of costs for bid proposals



hyperMILL® VIRTUAL Machining

NC code-based simulation and seamless networking with the machine

A closer look at the hyperMILL® VIRTUAL Machining modules

hyperMILL® VIRTUAL Machining Center

The hyperMILL® VIRTUAL Machining Center virtually maps actual machining situations, including the controller and PLC. The numerous simulation and analysis options are carried out on the basis of the NC code and following the postprocessor run. hyperMILL® VIRTUAL Machining Center uses the latest postprocessor technology from OPEN MIND.

hyperMILL® VIRTUAL Machining Optimizer

The optional Optimizer module offers powerful optimization algorithms to make multi-axis machining more efficient. The hyperMILL® VIRTUAL Machining Optimizer automatically finds the best tool position for ensuring perfect machining from the wide range of possible tool positions.

hyperMILL® CONNECTED Machining

The CONNECTED Machining module enables in-depth networking and synchronization with the machine. A bi-directional connection is established between the machine tool and CAM workstation. This provides the best possible exchange of information between the generation and execution of programs. A simple click of the mouse establishes the connection with the machine. Moreover, the integrated remote control feature makes it possible to control machining operations on the CNC machine tool easily via a laptop.

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