How do positive rake milling inserts significantly improve the quality of machined surfaces?

In modern manufacturing, milling is a widely used metalworking process, and the quality of its machined surface directly affects the performance and service life of the product. As a key component of milling tools, positive rake milling inserts play an extremely important role in improving the quality of machined surfaces. So, how do positive rake milling inserts significantly improve the quality of machined surfaces?

The uniqueness of positive large rake angle inserts is that their rake faces are at a positive angle to the cutting plane. This special geometric structure fundamentally changes the mechanical state during the cutting process. During cutting, the positive rake angle makes it easier for chips to curl and discharge. The smooth curling and discharge of chips has multiple positive effects, the most critical of which is the reduction of cutting forces. When chips can curl smoothly and quickly leave the cutting area, the friction between the tool and the workpiece is greatly reduced, which in turn leads to a significant reduction in cutting forces. This reduction in cutting forces is one of the core factors for improving the quality of machined surfaces.

The reduction in cutting forces has a direct inhibitory effect on vibrations during the machining process. In milling, vibration is one of the main interference factors affecting surface quality. Excessive vibration will cause relative displacement between the tool and the workpiece, resulting in defects such as ripples and scratches on the machined surface, which seriously affects the surface roughness and dimensional accuracy. The positive rake milling insert effectively reduces the vibration amplitude and frequency during the machining process by reducing the cutting force. From the perspective of mechanics, the reduction of cutting force means that the excitation force acting on the tool and workpiece system is reduced, and the vibration response of the system is also weakened. This is like reducing the weight of the weight on a shaking balance, and the shaking of the balance will naturally decrease. This reduction in vibration allows the tool to act more stably on the workpiece surface during the cutting process, ensuring the stability of the cutting process.

A smoother machined surface is an intuitive manifestation of the improvement of the quality of the machined surface by the positive large rake angle insert. When the vibration is reduced, each contact between the cutting edge and the workpiece is more uniform and stable when the tool is cutting the workpiece. This allows the cutting process to proceed according to the predetermined trajectory, avoiding uneven cutting depth and abnormal wear of the cutting edge caused by vibration. Under a stable cutting state, the tool can accurately remove material from the workpiece surface, making the machined surface appear smoother. This smooth surface is not only more beautiful in appearance, but more importantly, it has a positive impact on the performance of the product. For example, in mechanical transmission parts, smooth surfaces can reduce friction resistance, reduce energy loss, improve transmission efficiency, reduce wear and extend the service life of parts.

Higher dimensional accuracy is another important aspect of positive large rake angle inserts to improve the quality of machined surface. In milling, the guarantee of dimensional accuracy depends on the precise cutting of the tool and the stable machining process. Positive rake milling inserts provide favorable conditions for precise cutting by reducing cutting force and vibration. The stability of the cutting force prevents the tool from offsetting due to uneven force during the cutting process, so that it can be cut strictly according to the preset machining dimensions. The reduction of vibration avoids the slight displacement between the tool and the workpiece caused by vibration, further ensuring the accuracy of the machining dimensions. In the field of precision parts processing, such as aerospace parts manufacturing, medical equipment processing, etc., dimensional accuracy is often required to reach the micron or even nanometer level. With its performance, positive rake milling inserts can meet the needs of these high-precision machining and ensure that the dimensional accuracy of the machined parts meets strict design standards.

Positive milling inserts have a unique geometric structure design that reduces cutting force and vibration during machining, thereby achieving the goal of smoother machined surfaces and higher dimensional accuracy. As the manufacturing industry continues to pursue high-precision and high-quality machining, these advantages of positive milling inserts make them an indispensable tool for improving milling surface quality, playing an important role in promoting the development and progress of the manufacturing industry.