The present invention relates to a cutting tool and a cutting insert for use in metal cutting processes in general, and for turning and profiling operations in particular.
Within the field of cutting tools used in turning and profiling operations, there are many examples of single-sided or double-sided cutting inserts that have a high degree of circularity in axial cross-sectional views and/or axial end views.
U.S. Pat. No. 7,264,425 discloses a single-sided cutting insert in
U.S. Pat. No. 7,677,145 discloses a double-sided cutting insert which is circular in both axial cross-sectional views and axial end views, and which is suitable for re-profiling railway vehicle wheels.
U.S. Pat. No. 8,371,774 discloses a single-sided cutting insert in
In accordance with one aspect of the present invention, there is provided an indexable cutting insert comprising:
In accordance with another aspect of the disclosed subject matter, there is provided an indexable cutting insert comprising:
For a better understanding, the invention will now be described, by way of example only, with reference to the accompanying drawings in which chain-dash lines represent cut-off boundaries for partial views of a member and in which:
The present invention relates to an indexable cutting insert 20, 120, as shown in
Upper and lower peripheral edges 28, 30 are formed at the intersection of the peripheral side surface 26 and the upper and lower end surfaces 22, 24, respectively.
In some embodiments of the present invention the cutting insert 20, 120 may be indexable about the central axis A1.
In some embodiments of the present invention, the cutting insert 20, 120 may preferably be manufactured by form pressing and sintering a cemented carbide, such as tungsten carbide, and may be coated or uncoated.
In a first aspect of the present invention, the peripheral side surface 26 includes a continuous upper relief surface 32 adjacent the upper peripheral edge 28 and a continuous upper abutment surface 34a spaced apart from the upper peripheral edge 28.
In the first aspect of the present invention, as shown in
It should be appreciated that the non-circularity of the upper relief surface 32 in
Also in the first aspect of the present invention, a number N (N≥2) upper cutting edges 36 are formed on the upper peripheral edge 28, with each upper cutting edge 36 exhibiting mirror symmetry about a bisector plane PB containing the central axis A1.
As shown in
As shown in
It should be appreciated that the non-circularity of the upper peripheral edge 28 in
Although the upper peripheral edge 28 is non-circular in an end view of the cutting insert 20, 120, by tilting the cutting insert 20, 120 in one of the bisector planes PB, as shown in
As shown in
In some embodiments of the present invention, the upper radius of curvature RU may be greater than the radius of the first imaginary circle C1.
Also in some embodiments of the present invention, the upper radius of curvature RU may be no more than 5% greater than the radius of the first imaginary circle C1.
Further in some embodiments of the present invention, each upper cutting edge 36 may extend between two of the N radially outermost points No1, No2, No3, No4.
Yet further in some embodiments of the present invention, any two circumferentially adjacent upper cutting edges 36 may merge at one of the N radially outermost points No1, No2, No3, No4, and the two end points of each upper cutting edge 36 may be coincident with two of the N radially outermost points No1, No2, No3, No4.
When considering the cutting insert 20 in a first embodiment of the present invention, as shown in
By virtue of the N radially outermost points No1, No2, No3, No4 being located closer to the second horizontal plane PH2 than any other point on the upper peripheral edge 28, the height of each upper cutting edge 36 increases as it extends from each of its two end points towards its associated bisector plane PB, such that the operative upper cutting edge 36 advantageously directs cutting chips away from the rotating workpiece.
When considering the cutting insert 120 in a second embodiment of the present invention, as shown in
Also in the second embodiment of the present invention, two of the axially uppermost points Nu1, Nu4 of each upper cutting edge 36 may be coincident with two of the N radially outermost points No1, No2, No3, No4.
As shown in
By virtue of each upper cutting edge 36 having a plurality of discrete axially uppermost points Nu1, Nu2, Nu3, Nu4 and being wave shaped, enables cutting operations to be performed with a relatively low cutting force and improves chip breakage and removal.
It should be appreciated that apart from instances of specific reference to either the first or second embodiments of the invention, the description and claims is applicable to some embodiments of the present invention, which includes both the first and second embodiments of the present invention.
In some embodiments of the present invention, each upper cutting edge 36 may circumferentially extend 360/N° along the upper peripheral edge 28.
Also in some embodiments of the present invention, the upper peripheral edge 28 may have exactly four upper cutting edges 36, and N=4.
As shown in
Also as shown in
In some embodiments of the present invention, any point on the upper peripheral edge 28 may be located further from the central axis A1 than any point on the upper abutment surface 34a.
Also in some embodiments of the present invention, the upper peripheral edge 28 may have N radially innermost points NI1, NI2, NI3, NI4, each contained in at least one of the bisector planes PB.
As shown in
Also as shown in
In some embodiments of the present invention, a through bore 40 coaxial with the central axis A1 may open out to the upper support surface 38.
As shown in
In some embodiments of the present invention, as shown in
Also in some embodiments of the present invention, as shown in
Further in some embodiments of the present invention, each of the protrusions 46 may be partially located on the rake surface 42.
As shown in
In some embodiments of the present invention, the plurality of protrusions 46 may be greater in number than the plurality of N upper cutting edges 36.
Also in some embodiments of the present invention, the plurality of protrusions 46 may be greater in number, by at least a factor of six, than the plurality of N upper cutting edges 36.
As shown in
In some embodiments of the present invention, the lower relief surface 50 may be identical to the upper relief surface 32, and the lower abutment surface 34b may be identical to upper abutment surface 34a.
Also in some embodiments of the present invention, the lower peripheral edge 30 may be identical to the upper peripheral edge 28, having a plurality of N lower cutting edges 52 formed thereon, and the cutting insert 20, 120 may be described as ‘double-sided’ having a total of N*2 upper and lower cutting edges 36, 52.
On reversing the ‘double-sided’ cutting insert 20, 120 and tilting the cutting insert 20, 120 in one of the bisector planes PB, as shown in
By tilting the ‘double-sided’ cutting insert 20, 120 sufficient clearance is provided between the peripheral side surface 26 and the rotating workpiece.
In some embodiments of the present invention, the lower radius of curvature RL may be equal to the upper radius of curvature RU.
As shown in
In some embodiments of the present invention, the median plane M may be located midway between the upper and lower end surfaces 22, 24.
Also in some embodiments of the present invention, the through bore 40 may exhibit mirror symmetry about the median plane M.
Further in some embodiments of the present invention, the peripheral side surface 26 may exhibit mirror symmetry about the median plane M.
Yet further in some embodiments of the present invention, the cutting insert 20, 120 may exhibit mirror symmetry about the median plane M, and the upper relief and upper abutment surfaces 32, 34a may be located between the upper end surface 22 and the median plane M.
In a second aspect of the present invention, the through bore 40 opens out to both the upper and lower end surfaces 22, 24.
Also in the second aspect of the present invention, the through bore 40 and the peripheral side surface 26 have inner and outer undercuts 54, 56, respectively, with respect to an upward-downward direction DUD parallel to the central axis A1.
Further in the second aspect of the present invention, as shown in
It should be appreciated that use of the term “undercut” throughout the description and claims refers to a recess or passage, where a straight line extending in the upward-downward direction DUD from a given sub-surface of the recess or passage intersects another sub-surface of the same recess or passage.
As shown in
In some embodiments of the present invention, the inner and outer undercuts 54, 56 may be visible in a cross-section taken in any plane containing the central axis A1.
As shown in
In some embodiments of the present invention, the inner undercut 54 may be formed by upper and lower bore surfaces 58a, 58b of the through bore 40, and the upper and lower bore surfaces 58a, 58b may be entirely located on opposite sides of the median plane M.
Also in some embodiments of the present invention, the upper and lower bore surfaces 58a, 58b may be spaced apart from one another by a median bore surface 58c.
As shown in
In some embodiments of the present invention, the second and third horizontal planes PH2, PH3 may be coplanar.
In other embodiments of the present invention (not shown), the first and third horizontal planes PH1, PH3 may be coplanar.
As shown in
Also shown in
It should be appreciated that use of the term “external angle” throughout the description and claims refers to an angle between two surface components as measured external to the member on which these components are formed.
In some embodiments of the present invention, the obtuse bore angle α1 may have a value equal to or greater than 160°.
Also as shown in
In some embodiments of the present invention, the outer undercut 56 may be formed by the upper and lower abutment surfaces 34a, 34b, and the upper and lower abutment surfaces 34a, 34b may be entirely located on opposite sides of the median plane M.
Also in some embodiments of the present invention, the upper and lower abutment surfaces 34a, 34b may be spaced apart by a median peripheral surface 34c.
As shown in
In some embodiments of the present invention, in a cross-section taken in any plane containing the central axis A1, the upper and lower abutment surfaces 34a, 34b may form a V-shape.
As shown in
In some embodiments of the present invention, the obtuse abutment angle α2 may have a value equal to or greater than 160°.
Also in some embodiments of the present invention, both the upper and lower end surfaces 22, 24 may include planar upper and lower support surfaces 38, 60, respectively, and the through bore 40 may open out to the upper and lower support surfaces 38, 60.
As shown in
In some embodiments of the present invention, the upper and lower support surfaces 38, 60 may be perpendicular to the central axis A1.
As shown in
In the second aspect of the present invention, the insert receiving pocket 66 has a seat surface 72 and a side wall 74 transverse thereto, and one of the upper and lower end surfaces 22, 24 faces towards the seat surface 72.
In some embodiments of the present invention, as shown in
Also in some embodiments of the present invention, only one of the upper and lower cutting edges 36, 52 may be operative, and the operative upper or lower cutting edge 36, 52 may be associated with the one of the upper and lower end surfaces 22, 24 facing away from the seat surface 72.
In the second aspect of the present invention, as shown in
As shown in
Also as shown in
In some embodiments of the present invention, the clamping member 70 may make contact with one of the upper and lower bore surfaces 58a, 58b at a single inner contact zone ZI, and the third vertical plane Pv3, bisecting the first and second vertical planes Pv1, Pv2, may intersect the single inner contact zone ZI and the side wall 74.
As shown in
By virtue of the upper and lower bore surfaces 58a, 58b forming a V-shape in the cross-section taken in the third vertical plane Pv3, a clamping force FC exerted at the inner contact zone ZI by the clamping member 70 may advantageously have a vertical component directed towards the seat surface 72, thus ensuring firm and stable clamping.
In some embodiments of the present invention, the insert holder 64 may have opposing top and bottom holder surfaces 76, 78, and the insert receiving pocket 66 may be located adjacent to the top holder surface 76.
Also in some embodiments of the present invention, the bottom holder surface 78 may be planar, and the central axis A1 may intersect the bottom holder surface 78 and be non-perpendicular thereto.
As shown in
In some embodiments of the present invention, the first and second inclination angles β1, β2 may have equal values of between 1 and 3 degrees.
Also in some embodiments of the present invention, the first and second inclination angles β1, β2 may correspond to the extent of tilting of the cutting insert 20, 120, required for the operative upper or lower cutting edge 36, 52 to present substantially constant radii of curvature RU, RL to engage the rotating workpiece.
In some embodiments of the present invention, only one of the upper and lower abutment surfaces 34a, 34b may make contact with the side wall 74 of the insert receiving pocket 66 at two spaced apart outer contact zones Zo1, Zo2, and the two outer contact zones Zo1, Zo2 may be entirely located between the median plane M and the seat surface 72.
As shown in
By virtue of the upper and lower abutment surfaces 34a, 34b forming a V-shape in the cross-sections taken in the first and second vertical planes Pv1, Pv2, reaction forces FR at the two outer contact zones Zo1, Zo2, directed away from the side wall 74 of the insert receiving pocket 66, may advantageously have vertical components directed towards the seat surface 72, thus ensuring firm and stable clamping.
As shown in
Also as shown in
Further as shown in
In some embodiments of the present invention, the inner contact plane PI may be located closer to the seat surface 72 than the outer contact plane PO, thus ensuring that any moment of force, resulting from the clamping force FC and the reaction forces FR, urges the cutting insert 20, 120 towards the seat surface 72.
Visual markings adjacent the upper and lower cutting edges 36, 52, and a visual reference marking on the insert holder 64, may be provided to assist an operator when indexing the cutting insert 20, 120.
In some embodiments of the present invention, a shim 80 having opposing top and bottom shim surfaces 82, 84 may be located between the cutting insert 20, 120 and the seat surface 72.
As shown in
In some embodiments of the present invention, the clamping member 70 may be non-threadingly retained in the insert holder 64.
Also in some embodiments of the present invention, the clamping member 70 may be in the form of a clamping lever 86 operatively connected to an actuating member 88.
As shown in
While the present invention has been described with reference to one or more specific embodiments, the description is intended to be illustrative as a whole and is not to be construed as limiting the invention to the embodiments shown. It is appreciated that various modifications may occur to those skilled in the art that, while not specifically shown herein, are nevertheless within the scope of the invention.
The present application claims priority to U.S. Provisional Patent Application No. 62/290,587 filed Feb. 3, 2016. The contents of the aforementioned application are incorporated by reference in their entirety.
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