Product Details Supplier Info More products

The Productivity Centre at Dormer Tools has installed a Hypermaxx CAM roughing module from Open Mind to enhance the productivity benefits that the cutting tool manufacturer provides to its end users.

Since relocating to its new facility more than two years ago, Sheffield-based Dormer Tools has invested considerable time, resources and expertise into selecting ’Technology Partners’ to enhance the capabilities of its Productivity Centre department.

Among the technology partners are Sandvik Coromant, Kelch, System 3R, Heller, Hexagon Metrology and Open Mind.

This culmination of manufacturers enables Dormer to solve the cutting tool and production issues of its customers and the partners’ customers by implementing a combination of technologies from each partner.

Dormer decided to take on Open Mind as a technology partner after being impressed by the demonstration of the company’s Hypermaxx package.

Engineers from Dormer were invited by Open Mind to supply tooling for a demonstration piece at Warwick University and witness the Hypermaxx package in action.

Using Open Mind’s Hypermill, the previous machining time for the 18mm-deep pocket in the 316 stainless steel part was 25 minutes.

Engineers from Dormer supplied the company’s S356 solid carbide end mill and changed the cutting parameters to slightly reduce feeds and speeds, but to machine the full 18mm depth in one pass as opposed to the previous programme that used three 6mm-deep passes.

This strategy reduced the cycle time.

Then an Open Mind engineer turned on the Hypermaxx roughing cycle and asked a Dormer engineer to treble the recommended Dormer feed and almost double the speed rates for the cutter.

Most cutting tool manufacturers measure productivity benefits by calculating the QMax value for the machining cycle – this cubic (cm/min) value is the depth of cut x step over x feed divided by 1,000.

In this demonstration, using the Dormer 12mm cutter at the recommended parameters resulted in a QMax value of 30ccm/min.

However, when the Hypermaxx module was turned on, it produced a value of 108ccm/min, representing a 280 per cent improvement on the combined use of Hypermill and Dormer tooling.

This speed increase did not reduce tool life – on the contrary, cutter wear was less than on the slower cycle.

Hypermaxx tool paths are generated to reduce stress on the cutting tool while continually calculating the optimal speed and feed for each cut.

It reduces the forces on the cutting tool by eliminating sharp directional changes in the tool path.

According to Open Mind, it is the directional changes in alternate CAM packages that cause stress and contribute to the sudden failure of cutting tools.

Producing a structural aerospace part, one of Dormer’s aerospace customers was taking 40 hours to machine two sides of a component.

Using Hypermaxx, Dormer has reduced the machining time to 10 hours.

Open Mind Technologies

OPEN MIND Technologies AG is a leading developer of CAD/CAM software and postprocessors for designing and manufacturing complex moulds and parts. OPEN MIND offers an extensive range of products, from 2D feature-oriented solutions for milling standard parts through to software for 5axis simultaneous machining. With their hyperMILL software, which is used in the automotive, tool and mould manufacturing, mechanical engineering and aerospace industries, OPEN MIND Technologies AG is represented in all the important markets in Asia, Europe and North America.  

OPEN MIND’s solutions feature a user-friendly interface and the largest range of 2D, 3D and 5axis modules available to users. In addition, the company delivers a fully integrated product concept encompassing CAD solutions, plug-ins, interfaces and postprocessors that cover the entire manufacturing process from design to manufacture. We take our innovative ideas, long-time CAD experience and milling expertise and create technologically sound CAM strategies. OPEN MIND has made a name for itself internationally as a pioneer in innovative 5axis technologies. What makes OPEN MIND and its products special is the unique blend of computing and production expertise, experience and vision, and international character and individual service. This combination of qualities results in a constant stream of new ideas that help companies optimise their production processes.  

View full profile