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Wiper CBN Inserts |
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Higher Performance and Shorter Machining Time in Finishing
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The new wiper idea improves not only the performance but also results in a significant economical advantage by reducing machining time.
It is possible to achieve excellent surface quality, even with relatively high feed rates, using the wiper geometry on WNMG trigon-shaped inserts, the CNMG or DNMG rhombic shaped negative inserts and on the positive CCMT insert configurations.
Figure 5 shows an example of the achieved surface roughness values Ra using the WG wiper type trigon inserts (WNMG) with a 0.8mm nose radius and a standard trigon insert with the same 0.8mm nose radius. From the diagram it can be concluded that when using, for example, the WG insert with a feed rate of 0.4 mm/rev, Ra is about 1µm. This means that an excellent surface finish can be achieved when using this wiper concept. In comparison, when using the standard ISO insert without the wiper at the same feed rate, the Ra value is very poor, reaching only 5µm.
If a finishing operation requires a surface finish of Ra = 1µm, the feed rate with the standard insert would have to be about 0.13mm. However, when using the wiper geometry, a feed rate of almost 3 times the magnitude (i.e. 0.4mm/rev) can be used. This results in a significant reduction in machining time during the finishing phase (about 30%) providing a more efficient and economical process.
Range of Wiper Products
Since the introduction of the wiper concept by Iscar in the beginning of the 1990’s, various insert geometries and corner radii from 0.4 up to 1.2mm have been introduced. The introduction of positive "C" type inserts, like the CCMT and CVD coated grades (IC9015 and IC9025) expanded the scope of applications to a wider range of workpiece materials and includes internal turning. Optimization of the chip deflector design of the wiper inserts, and the introduction of the WG and WF geometries, has ensured good chip control from around 0.5mm depths of cut and a feed rate of 0.12mm/rev. The various wiper inserts can be used with all standard ISO toolholders for facing, external and internal turning applications.
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