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The machine tool system supplier Haimer is a high-quality partner and supporter of the German Hockey League Augsburg Panthers hockey team. The company took this opportunity to demonstrate the performance capabilities of its tools and tool holders by creating a model Panther. Open Mind's CAM experts used their Hypermill software to undertake challenging programming tasks.
DEL (German Hockey League) member "Augsburg Panthers" is the most famous "Black Panthers" around. Haimer is headquartered in Egenhausen, only 30 minutes from Augsburg, and is a loyal fan and sponsor of the professional hockey team. This family-owned company develops, manufactures and sells high-precision metal cutting products and came up with the idea of milling black panthers with aluminum in its application center. The Panther is a superb part showing that 5-axis milling with its tool holder and solid carbide end mills can rival hockey sports in terms of speed, power and dynamics.
Konstantin Brodowski, head of the Haimer Application Center, sees greater similarities: "Hockey is more than speed and brute force. Every player must have excellent technical skills and contribute to a perfect team. Haimer's The working method is very similar, combining its high-tech products with most modern machine tools and first-class CAD/CAM software."
The Panther model demonstrates how to effectively handle difficult, free-form components. (Source: Haimer/Open Mind)
When looking for "teammates" for the Black Panther project, Heimer turned to Open Mind, a long-term partner and CAD/CAM manufacturer based in Weslin, Germany. Their Hypermill CAM system is widely used in 5-axis machining centers, and the company has extensive experience in programming completely free-form contours. To the question whether application engineers are suitable to program unusual exhibits and join our milling project, they answered "yes" without hesitation. Christian Neuner, Global Engineering Services Manager, explained: “Models like this are an excellent opportunity to test the versatility and flexibility of our software. In many ways, the Black Panther metaphor is very suitable for us. Hypermill has many features that make CAM Users can really use the capabilities of the machine in the final test to achieve the desired goal."
This is why Jakob Nordmann, an application engineer at Open Mind, camped for several weeks in Egenhausen, Germany, where he worked with Haimer application engineer Daniel Swoboda to establish a programming and processing infrastructure. As for the milling machine, they chose the linear 5-axis DMG Mori HSC70 machining center located in the Haimer Application Center, which is very suitable for precision aluminum machining and excellent surface finish.
Facts have proved that the processing of leopard heads is particularly challenging, especially the extremely fine mouth and teeth. The delicate slender shape of the tail is also difficult to grasp because it is extremely sensitive to vibration. More importantly, it is very difficult to access many parts, which is why the person in charge decided to make the statue in two installations, among which the Lang macro fixture 5-axis fixture was used as the fixture.
Limited accessibility also affects the type of tool selected. Although the shortest possible tool has been used, the application specialist still requires a tool length of up to 278 mm. This is why Daniel Swoboda chose to use modular Haimer Duo-Lock tools for roughing applications. The system consists of carbide tips, which are connected to different extensions through extremely stable interfaces. He deliberately chose a four-flute cutter with a fillet radius from the Duo-Lock Haimer Mill Alu series. These finely balanced tools have excellent length repeatability. They provide a certain degree of sharpness and achieve a perfect balance in terms of abrasion resistance and resistance. "We used Haimer Power Shrink Chucks to clamp the coated cylindrical extension of the Duo Lock tool," said Daniel Swoboda. "Compared with the use of standard tool holders, this allows us to achieve higher clamping rigidity and less vibration. This in turn allows us to achieve greater cutting depths and higher metal removal rates."
In the finishing process, they used a full-radius solid carbide end mill from the Haimer Mill Alu series because of its micro-geometric characteristics designed for smoothness and top surface quality. The personnel involved in the project considered very limited space conditions when using the ultra-thin and low-vibration Haimer Power Mini Shrink bracket for clamping.
Faces of the winners: (from left to right) Christian Neuner and Jakob Nordmann from Open Mind MIND, Konstantin Brodowski, Daniel Swoboda and Marketing Director Tobias Völker from Haimer (Source: Haimer/Open Mind)
Open Mind colleague Jakob Nordmann added: “In this project, what I found most helpful to me is that all Haimer brackets and tools are also provided in the form of DXF and STP files. The model can be easily downloaded on the Haimer homepage. They can be entered into the database with just three mouse clicks in our Hypermill Toolbuilder. After that, they can be immediately ready for programming and simulation."
Creating a visually appealing model requires careful and excellent programming. The first core problem we encountered: Panther was presented in the form of an STL data model. Hypermill expert Jakob Nordmann explained: “Because the conversion to a surface model takes a long time, we decided to mill on the STL network-line milling 1 mm, To ensure that the faceted structure is not visible."
"For particularly detailed areas, such as the creases of the mouth and tail or joints, we have generated additional surfaces that can be combined with the STL network in Hypermill." For this purpose, Nordmann used Hyper CAD-S, which is dedicated to Open Mind The designed "CAD for CAM" system can help meet all the needs of programmers.
Processing challenge: The slender shape of the tail section of the gold and silver wire is extremely sensitive to vibration. (Source: Haimer/Open Mind)
Since the limited space requires different inclination of the tools, his focus is to maintain precise line spacing and seamless transition without any visible gaps. "For this, I used the'Edit Tool Path' command, Nordman revealed. "This allows me to determine the entire tool path and divide it into multiple parts, which can then be edited at various tilts using different tools. This saves me a lot of time. "
Also indispensable when milling Panthers is the Hypermill Virtual Machining Center, which is a process-safe NC simulation solution in which the virtual machine motion fully simulates real motion and ensures reliable collision detection.
The team took about three weeks to complete the first standalone Panther. Anyone who is interested can enjoy the model at the Haimer and OPEN MIND booths in the future exhibition. And, of course, the Augsburg Panthers will also receive models of the stadium entrance area and locker room tunnel so that the players always have the correct motivation when going on the ice.
The Panthers will be exhibited at the EMO booths of Haimer and Open Mind.
Flexible CAM solutions make complex tasks easier
Pushing processing to the limit: Open Mind presents the latest Hypermill solution in Italy
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