Fly-cutting system and method, and related tooling and articles

• US 8,443,704 B2
• Filed: 05/11/2010
• Issued: 05/21/2013
• 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: Burke, James P., Campbell, Alan B., Ehnes, Dale L., Wertz, Daniel S.
• Primary Examiner(s): Peterson, Kenneth E.
• Assistant Examiner(s): SWINNEY, JENNIFER B
• Application Number:
  US12/777,611
• Publication Number:
  US 20100218650A1
• Time in Patent Office: 1,106 Days
• Field of Search: 409/25, 409/26, 409/27, 409/28, 409/38, 409/50, 409/51, 409/56, 409/57, 409/75, 409/76, 409/165, 821/31, 821/59, 82/11.1
• US Class Current: 82/1.11
• 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 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 with a fly-cutting head having one or more continuously rotating cutting elements; and

(b) forming subsequent portions of each feature or groove with the fly-cutting head during successive revolutions of the workpiece while the workpiece is rotating, 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,

wherein the initial portion is formed by one pass of a first one of the continuously rotating cutting elements of the fly-cutting head,

wherein the subsequent portion is formed by one pass of the first one of the continuously rotating cutting elements or another one of the continuously rotating cutting elements of the fly-cutting head,

wherein the initial portion and the subsequent portion each has a beginning and an end,

wherein the initial portion and the subsequent portion each has a radius of curvature between the beginning and the end corresponding to a cutting radius of the fly-cutting head used to form the initial portion and the subsequent portion,

wherein the initial portions of the features or grooves formed near the first end of the workpiece are all relatively sharper than all the subsequent portions of the features or grooves formed closer to the second end of the workpiece.

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

rotating the workpiece around a first axis of rotation;

operating the fly-cutting head by rotating the one or more cutting elements around a second axis of rotation;

positioning the fly-cutting head such that the second axis of rotation is non-parallel to the first axis of rotation of the workpiece;

determining a rotational position of the one or more cutting elements as a function of time;

determining a rotational position of the workpiece as a function of time; and

using the fly-cutting head to cut a series of groove segments in the cylindrical workpiece, the series of groove segments including the initial portion and the subsequent portion, wherein for each of the groove segments in the series, the groove segment is cut with a single pass of one of the cutting elements as the fly-cutting head rotates,

wherein using the fly-cutting head to cut a series of groove segments in the cylindrical workpiece comprises locating each groove segment cut in the cylindrical workpiece in a predetermined location relative to the other groove segments on the workpiece using the determined rotational position of the one or more cutting elements and the determined rotational position of the workpiece.

3. The method of claim 2, wherein each of the groove segments has a major axis extending at least approximately parallel to the first axis of rotation.

4. The method of claim 3, wherein the fly-cutting head is angled so that the one or more cutting elements at the end of a cut are farther in a direction of rotation of the workpiece than at the beginning of the cut to offset the rotation of the workpiece.

5. The method of claim 3, wherein each of the series of groove segments has a length parallel to its major axis that extends for less than a length of the workpiece along the first axis of rotation.

6. The method of claim 2, wherein the series of groove segments form a brick pattern in the workpiece.

7. The method of claim 2, wherein the series of groove segments combine to form a succession of grooves approximating longitudinal grooves that extend between a first end and a second end on the workpiece.

8. The method of claim 7, wherein cutting the series of groove segments comprises:

first, cutting each of the groove segments that are adjacent the first end; and

second, cutting progressively closer to the second end to form the remaining groove segments in the series of groove segments.

9. The method of claim 2,

wherein rotating the workpiece around the first axis of rotation consists of rotating the workpiece at a first relatively constant velocity, and

wherein operating the fly-cutting head by rotating the at one or more cutting elements around the second axis of rotation consists of rotating the one or more cutting elements at a second relatively constant velocity.

10. A method of forming features or grooves in a cylindrical workpiece, comprising the steps of:

forming, beginning near a first end of the workpiece, an initial portion of each feature or groove with a fly-cutting head having one or more continuously rotating cutting elements; and

forming subsequent portions of each feature or groove with the fly-cutting head during successive revolutions of the workpiece while the workpiece is rotating, the subsequent portions being formed progressively closer to a second end of the workpiece,

wherein the initial portion is formed by one pass of a first one of the continuously rotating cutting elements of the fly-cutting head,

wherein the subsequent portion is formed by one pass of the first one of the continuously rotating cutting elements or another one of the continuously rotating cutting elements of the fly-cutting head,

wherein the initial portion and the subsequent portion each has a beginning and an end,

wherein the initial portion and the subsequent portion each has a radius of curvature between the beginning and the end corresponding to a cutting radius of the fly-cutting head used to form the initial portion and the subsequent portion,

wherein the initial portions of the features or grooves formed near the first end of the workpiece are all relatively sharper than all the subsequent portions of the features or grooves formed closer to the second end of the workpiece.

11. The method of claim 10, wherein each feature or groove has a major axis extending at a non-zero angle with respect to a central axis of the cylindrical workpiece.

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

rotating the workpiece around a first axis of rotation;

operating the fly-cutting head by rotating the one or more cutting elements around a second axis of rotation;

positioning the fly-cutting head such that the second axis of rotation is non-parallel to the first axis of rotation of the workpiece;

determining a rotational position of the one or more cutting elements as a function of time;

determining a rotational position of the workpiece as a function of time; and

using the fly-cutting head to cut a series of groove segments in the cylindrical workpiece, the series of groove segments including the initial portion and the subsequent portion, wherein for each of the groove segments in the series, the groove segment is cut with a single pass of one of the cutting elements as the fly-cutting head rotates,

wherein using the fly-cutting head to cut a series of groove segments in the cylindrical workpiece comprises locating each groove segment cut in the cylindrical workpiece in a predetermined location relative to the other groove segments on the workpiece using the determined rotational position of the one or more cutting elements and the determined rotational position of the workpiece.

13. The method of claim 12, wherein each of the groove segments has a major axis extending approximately parallel to the first axis of rotation.

14. The method of claim 13, wherein the fly-cutting head is angled so that the one or more cutting elements at the end of a cut are farther in a direction of rotation of the workpiece than at the beginning of the cut to offset the rotation of the workpiece.

15. The method of claim 13, wherein each of the series of groove segments has a length parallel to its major axis that extends for less than a length of the workpiece along the first axis of rotation.

16. The method of claim 12, wherein the series of groove segments combine to form a succession of grooves approximating longitudinal grooves that extend between a first end and a second end on the workpiece.

17. The method of claim 12, wherein cutting the series of groove segments comprises:

first, cutting each of the groove segments that are adjacent the first end; and

second, cutting progressively closer to the second end to form the remaining groove segments in the series of groove segments.

18. The method of claim 12,

wherein rotating the workpiece around the first axis of rotation consists of rotating the workpiece at a first relatively constant velocity, and

wherein operating the fly-cutting head by rotating the at one or more cutting elements around the second axis of rotation consists of rotating the one or more cutting elements at a second relatively constant velocity.

19. The method of claim 10, wherein the features or grooves form a brick pattern in the workpiece.

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

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

removing the material from the workpiece.