Influence of micro-geometry of wiper facet on the performance of a milling insert: an experimental investigation and validation using numerical simulation
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The wiper facets are incorporated between the corner radius and cutting edge of the inserts to achieve a higher surface finish and improve the overall efficiency of the metal cutting process. However, it also results in higher friction between the tool and workpiece (due to the larger contact area between the tool and workpiece and wiping action) which increases the cutting force and sometimes even results in an unstable cutting operation. Numerous studies highlight the benefits of different micro-geometries on the cutting edge, whereas the effect of micro-geometry on the wiper facet (or wiper edge) is not known. Hence, the objective of this study is to provide an insight into the effect of different micro-geometries on wiper facet on cutting power, specific cutting energy, surface roughness, forces, and wear rate in face milling. Milling inserts with chamfer onboth cutting and wiper edge, and chamfer on cutting edge, hone (radius) on wiper edge were exclusively designed and precision manufactured for the study. The study reveals that the inserts with chamfer on wiper facet gave 67 to 225% superior surface finish, whereas the insert with hone on wiper facet gave around 5% lower forces, cutting power, and specific cutting energy. The tool wear study revealed the superior edge stability of the insert with chamfer on the wiper facet. The experimental results were validated using numerical simulations.
Volume 48, 2023
Continuous Article Publishing mode
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