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KYOCERA SGS Precision Tools Group
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KYOCERA SGS Precision Tools Group
As machinists and shop managers/owners, achieving a good surface finish is more than a matter of aesthetics—it’s essential for functionality, fit, and overall product quality. Whether it’s a crucial aerospace component or a precision mold, a smooth and consistent finish can reduce friction, enhance performance, and even extend the lifespan of the final product. But getting that perfect finish often requires optimizing your tooling and approach. Enter wipers: a small change in your tooling setup that can lead to substantial improvements in finish quality and machining efficiency.
Imagine your standard cutting tool, designed with a primary edge that does the brunt of the cutting. A tool with a wiper flat—whether it’s an indexable insert or a solid round tool like an end mill—has a wider section behind the primary cutting edge. This wiper flat smooths out the surface left behind by the cutting edge, producing a finer finish. It’s like following a painter with a broader brush, ensuring that the strokes blend seamlessly. The result? A surface that shines under the scrutiny of a machinist’s trained eye.
For machinists, time is money—and finish quality is a point of pride and necessity. Wiper flats, whether on inserts or solid round tools, bring multiple advantages to your operations:
Wiper technology isn’t limited to one type of tool. While indexable inserts in milling cutters and turning tools are often the focus, solid round tools like end mills can also feature wiper flats. This versatility expands the range of applications where wiper technology can be leveraged, allowing machinists to optimize both broad-area and detailed finishing operations.
When deciding between these options, it’s essential to consider your specific machining requirements. Indexable inserts with wiper flats excel in situations where you need consistent, high-quality surface finishes over large areas. On the other hand, solid round tools with wiper flats shine in scenarios requiring intricate details and precision, such as pocket milling or when achieving smooth floor finishes is crucial.
Choosing the right tool with wiper flats depends not only on the application but also on the material and setup. If your focus is on achieving a fine finish across a broad surface, an indexable milling cutter with wiper inserts might be the best choice. However, if you’re working on detailed features or internal pockets, a solid end mill with wiper flats can be the more precise option. Both types of tools benefit from wiper technology, but each offers unique strengths that can be leveraged for specific needs.
For instance, if you’re tackling long, uninterrupted cuts on flat surfaces, wiper inserts on a face mill can help maintain consistency. Conversely, for internal features, solid end mills equipped with wiper flats can leave floors and walls with an improved finish in fewer passes (like the XPR pictured above). Understanding the strengths of each tool type and how wiper technology enhances them can help you make the most of your operations.
One aspect that often sparks debate among machinists is how tools with wiper flats impact tool life. On one side of the argument, these tools allow you to increase feed rates, which in turn reduces the time each tool spends in the material. In theory, this shorter contact time should mean less heat exposure per revolution, which can potentially extend tool life. Justin highlights this point: “In some cases, because a wiper allows you to feed an insert through the workpiece faster, it spends less time in contact with material, which in theory can increase your tool life, and it has in some cases.”
But there’s a flip side. Due to the larger contact area and the inherent increase in cutting pressure, wiper flats also generate additional heat—something every machinist knows is the enemy of cutting tools. Increased temperatures can accelerate wear, offsetting any gains in tool longevity achieved by the reduced contact time. Justin Wilkes, a technical sales engineer at KYOCERA SGS Precision Tool acknowledges this risk: “But at the same time, because of the natural amount of increased contact that each wiper insert has with the material and the extra heat that comes generated from that increased contact, we all know that heat is the enemy of cutting tools. It can also pull cutting tool life away from your operation as well.”
This double-edged sword means that machinists need to carefully consider their material and application to find the balance that works best.
Let’s talk shop. In a demo turning operation, two sections of a workpiece were run at the same input feed rate using both a standard insert and a CA115P wiper insert with a DCLNR turning holder for 1/2″ IC insert. At 0.012” per revolution, the standard insert left a noticeably rougher surface, while the wiper insert produced a much finer finish. Keep in mind, this was achieved without coolant—showcasing just how effective the wiper insert can be. Introduce coolant, and the results improve even further. Solid end mills with wiper flats achieve similar results, leaving pocket floors with improved finishes.
The story doesn’t end with turning. Wiper technology also brings its advantages to milling. In a side-by-side comparison using a MB45 face mill, the difference was clear. The side milled with a standard insert had visible tool marks, while the section finished with the PR18 wiper insert was markedly smoother and more consistent.
If you’re looking to boost finish quality and cut cycle times in finishing operations, tools with wiper flats are your new best friend. However, knowing when not to use them is equally important. Here’s the takeaway:
As machinists, we live for the details—those fine nuances that separate a decent part from a masterpiece. Wiper technology is a prime example of a seemingly small change that can lead to significant improvements in both efficiency and final product quality. Whether you’re taking on turning or milling tasks, with indexable inserts or solid round tools, consider where wiper flats could enhance your operations and save you time on each job.
If you’re interested in adding tools with wiper flats to your toolkit or have specific questions about integrating them into your operations, reach out to your Kyocera sales representative. And as always, keep those chips flying!
Q: Can wiper flats be used effectively on all types of materials?
A: While wiper flats work well on harder materials like steel and cast iron, they may not be ideal for softer materials, which can smear or experience poor surface quality. Test wiper flats on your specific material to ensure they’re suited to your application.
Q: How should I maintain or inspect tools with wiper flats?
A: Regular inspection for wear is essential, as wiper flats rely on a precise geometry to achieve a smooth finish. Any chips or uneven wear on the wiper flat edge can impact finish quality. Tools with wiper flats should be replaced or reconditioned when they show signs of wear.
Q: Do wiper flats require different programming or toolpath adjustments?
A: Yes, because wiper flats allow for higher feed rates, you may want to adjust your toolpath settings to optimize speed without compromising quality. Proper feed and speed adjustments are key to getting the most out of wiper technology.
Machinists require reliable solutions to tackle intricate tasks efficiently. Indexable tooling provides exceptional flexibility, quality, durability, and delivers high-performance results. Customize your tooling for specific tasks by choosing the ideal combination of inserts and holders to optimize performance.
Explore our SGS branded high-performance and versatile solid round tooling options. Our quality tooling not only ensures precision but also minimizes downtime, allowing for increased material removal per hour. Explore a range of options including end mills, drills, routers, countersinks, and more to find the perfect tools for your specific needs.
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KYOCERA SGS Precision Tools, Inc.
(330) 686-5700
150 Marc Drive
Cuyahoga Falls, OH 44223
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