FLY-CUTTING SYSTEM AND METHOD, AND RELATED TOOLING AND ARTICLES

• US 20100218650A1
• Filed: 05/11/2010
• Published: 09/02/2010
• Est. Priority Date: 08/06/2007
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Ehnes, Dale L., Campbell, Alan B., Burke, James P., Wertz, Daniel S.
• Granted Patent: US 8,443,704 B2
• Time in Patent Office: Days
• US Class Current: 82/1.110
• CPC Class Codes: B23C 2226/125 cubic [CBN]
• CPC Class Codes: B23C 2226/31 Diamond
• CPC Class Codes: B23C 3/30 Milling straight grooves, e.g. keyways
• CPC Class Codes: B23C 5/08 Disc-type cutters
• CPC Class Codes: B23Q 15/007 while the tool acts upon the workpiece
• CPC Class Codes: B29C 2793/0009 Cutting out
• CPC Class Codes: B29C 37/0057 Moulding single grooves or ribs, e.g. tear lines folding lines B29C53/06
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: G02B 5/1852 using mechanical means, e.g. ruling with diamond tool, moulding
• CPC Class Codes: G05B 19/182 characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control G05B19/21 - G05B19/40 take precedence
• CPC Class Codes: G05B 2219/50213 Grooving of different forms or parallel to each other, grooving cycle
• CPC Class Codes: Y10T 408/03 Processes
• CPC Class Codes: Y10T 408/909 Having peripherally spaced cutting edges
• CPC Class Codes: Y10T 409/108745 Cutting action along work axis
• CPC Class Codes: Y10T 409/303752 Process
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 82/10 Process of turning
• CPC Class Codes: Y10T 82/2529 Revolvable cutter heads
• CPC Class Codes: Y10T 82/2587 Turret type holder [e.g., multiple tools, etc.]

Abstract

Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.

Claims

1. A method of forming features in a surface of a cylindrical workpiece using a fly-cutting head, comprising the steps of:

(a) providing a fly-cutting head having a cutting element;

(b) providing the cylindrical workpiece;

(c) using the fly-cutting head to form an initial feature in the surface of the workpiece while the workpiece is rotated around a central axis of rotation, the initial feature having a major axis extending generally parallel to the axis of rotation for less than the length of the workpiece;

(d) rotating the workpiece around the central axis of rotation; and

(e) using the fly-cutting head to form a subsequent feature in the surface of the workpiece, the subsequent feature having a major axis extending generally parallel to the axis of rotation, wherein the subsequent feature is in predetermined location relative to the initial feature.

2. The method of claim 1, wherein the subsequent feature is aligned with and adjoins the initial feature such that the two features approximate a single continuous feature.

3. The method of claim 1, wherein the method further comprises, after forming the initial feature and before forming the subsequent feature, the step of forming additional features in the surface of the workpiece and around the perimeter of the workpiece, wherein at least some of the additional features have a major axis extending generally parallel to the axis of rotation.

4. The method of claim 1, further comprising the steps of:

(f) applying a viscous polymeric material to the workpiece such that the material substantially conforms to the surface of the workpiece; and

(g) removing the material from the workpiece.

5. A method of forming adjacent longitudinally-extending features or grooves in a cylindrical workpiece, comprising the steps of:

(a) forming, beginning near a first end of the workpiece, an initial portion of each feature or groove; and

(b) forming subsequent portions of each feature or groove during successive revolutions of the workpiece, the subsequent portions being substantially aligned with the initial portion of each feature or groove, the subsequent portions being formed progressively closer to a second end of the workpiece.

6. The method of claim 5, wherein the initial portions of the features or grooves formed near the first end of the workpiece are relatively sharper than the subsequent portions of the features or grooves formed closer to the second end of the workpiece.

7. A method of forming features in a surface of a cylindrical workpiece using a fly-cutting head, comprising the steps of:

(a) providing a fly-cutting head having a cutting element;

(b) providing the cylindrical workpiece;

(c) using the fly-cutting head to form an initial feature in the surface of the workpiece while the workpiece is rotated around a central axis of rotation, the initial feature having a major axis extending at an angle with respect to the axis of rotation;

(d) rotating the workpiece around the central axis of rotation; and

(e) using the fly-cutting head to form a subsequent feature in the surface of the workpiece, the subsequent feature having a major axis extending at an angle with respect to the axis of rotation, wherein the subsequent feature is in predetermined location relative to the initial feature.

8. The method of claim 7, wherein the subsequent feature is aligned with and adjoins the initial feature such that the two features approximate a single continuous feature.

9. The method of claim 7, wherein the method further comprises, after forming the initial feature and before forming the subsequent feature, the step of forming additional features in the surface of the workpiece and around the perimeter of the workpiece, wherein at least some of the additional features have a major axis extending at an angle with respect to the axis of rotation.

10. The method of claim 7, further comprising the steps of:

(f) applying a viscous polymeric material to the workpiece such that the material substantially conforms to the surface of the workpiece; and

(g) removing the material from the workpiece.