Profiling is used to machine complex grooves. Access to the grooves can often be a challenge. Surface finish and surface integrity are important factors. For example, many aerospace engine components contain complex grooves with difficult access and the need for outstanding surface finish. The shape and material (often difficult materials to work with) of these components makes profile grooving the best solution.
Components with complex grooves in difficult to machine materials are often very expensive to manufacture. Ensuring process security can be a challenge due to the combination of accessing the grooves and working with complex-shaped materials. When machining components with complex shapes, look for inserts that make profile grooving more efficient. Replace right- and left-hand conventional tools with a single tool to minimize number of tools needed. This results in fewer tool changes and more room in the turret. Using profiling inserts is often a good way to remove a lot of material in a short time.
Wrap around occurs when round inserts are used for plunging or profiling into corners. A large insert radius creates high cutting pressures, which means feed needs to be reduced. However, if the feed is reduced too much, vibration may occur. To reduce the vibration problem, the insert diameter should be as small as possible compared to the radius that is generated. If the same insert radius must be used on several different grooves, use dwelling (micro stops) to form short chips and avoid vibration.