The present disclosure relates to a cutting insert and a cutting tool comprising the same.
As an end mill which is one type of cutting tool for milling workpieces, those having a cutting insert that is removably mounted on a mounting seat provided on a body of such end mill are known. As an example of such end mill, the applicant has proposed an end mill that includes a plurality of cutting inserts each having a shape that allows itself to be used as both a center edge and a peripheral edge and that further allows itself to be reused by interchanging the front and back sides thereof (see JP2021-030401 A).
An end mill having the above-described conventional cutting insert is an indexable end mill with a double-sided center edge, intended for multifunctional machining, which has advantageous features wherein it is particularly excellent in terms of economic efficiency and the cutting insert can be stably fixed to a body of a cutting tool in comparison with the conventional configuration.
Here,
In this case, the cutting insert 5A functions as a center edge which has: an inner edge that extends from a peripheral surface of a body to a rotational axis thereof; and a major cutting edge located on the peripheral surface. On the other hand, the cutting insert 5B functions as a peripheral edge having a major cutting edge located at 180 degrees opposite to the major cutting edge of the center edge. In this way, the cutting inserts 5A, 5B are each formed in a substantially rectangular parallelepiped shape and provided with a center edge and a peripheral edge at an edge portion between a front surface (e.g., an upper surface) and a side surface, and are also provided with a similar center edge and peripheral edge on a back surface (e.g., a lower surface); thus, it can be said that cutting edges which can be used four times in total are provided.
As shown in
Under the circumstances set forth above, an object of the present disclosure is to provide a cutting insert whose corner part on the tool center side has an improved machining resistance during hole-forming machining for a workpiece, whereby fracture, etc. of such part can be effectively suppressed, as well as a cutting tool comprising such cutting insert.
In order to achieve the above object, the present disclosure employs the configurations set forth below.
[1] An example of a cutting insert according to the present disclosure includes a first end surface and a second end surface that are each formed in a substantially polygonal plate shape (for example, in general, a rectangular parallelepiped shape) and that each include a first long side and a second long side, and a first short side and a second short side that are located between the first long side and the second long side, the first end surface and the second end surface facing each other. The first end surface and the second end surface each have: a first cutting edge extending from the first long side to a first corner part that is located between the first long side and the first short side; and a second cutting edge extending from the second long side to a second corner part located between the second long side and the first short side. A radius of curvature R3 of a third corner part located on an opposite side of the first corner part with the first long side interposed therebetween is formed larger than a radius of curvature R1 of the first corner part.
As described earlier, the core 6T as shown in
[2] More specifically, the cutting insert may further include short side surfaces that face each other, the short side surfaces each being connected to the first end surface and second end surface, the short side surfaces each including the first short side and the second short side. In such case, these short side surfaces may each be inclined with respect to a plane perpendicular to the first end surface and the second end surface. In addition, it is preferable for a clearance angle in the first short side to be a positive angle, and for a clearance angle in the second short side to be a negative angle. It should be noted that, in the present disclosure, the “clearance angle” being a “positive angle” indicates that the internal angle formed by two intersecting surfaces is an “acute angle,” whereas the “clearance angle” being a “negative angle” indicates that the internal angle formed by two intersecting surfaces is an “obtuse angle.”
[3] In such configuration, it is preferable that the first cutting edge and the second cutting edge of the first end surface and the first cutting edge and the second cutting edge of the second end surface are in a 180-degrees rotationally symmetrical relationship with respect to each other around a predetermined axis virtually extending through the cutting insert.
[4] In such 180-degrees rotationally symmetrical relationship, more specifically, the first corner part in the first end surface and the third corner part in the second end surface may be in a positional relationship of facing each other with the short side surface interposed therebetween, and the third corner part in the first end surface and the first corner part in the second end surface may be in a positional relationship of facing each other with the short side surface interposed therebetween. With such configuration, the cutting insert according to the present disclosure can be used for an end mill intended for multifunctional machining, with the cutting insert being double-sided and indexable. As a result, such cutting insert has the advantage of being excellent in terms of economic efficiency and being able to be stably fixed to a body of a cutting tool.
[5] In the above configuration, the cutting insert may include a chip breaker formed on a rake surface for the first cutting edge, the chip breaker including: a first chip breaker located on the first corner part side with respect to the center of the first long side; and a second chip breaker located on the third corner part side with respect to the center of the first long side. In this case, it is further preferable that the maximum width Wcmax of the second chip breaker is larger than the maximum width Wpmax of the first chip breaker. Here, the “width of the chip breaker” in the present disclosure refers to a width in the direction along the first short side in a plan view showing the cutting insert.
In such configuration, since the distance from the first chip breaker that may be located on the tool periphery side to a “wall” becomes relatively short, it becomes easier to forcibly cause the chips to be curled. On the other hand, since the distance from the second chip breaker that may be located on the tool center side to a “wall” becomes relatively long, it becomes more difficult to forcibly cause the chips to be curled. That is to say, this configuration allows a curling process to be easily adjustable as desired according to the thickness of the chips. As a result, it is possible to improve the machining performance of the cutting insert.
[6] In the above configuration, more specifically, it is even more preferable that the maximum width Wcmax of the second chip breaker is 50% or less of the length of the first short side, in terms of the point of making it easier to control the shape of chips generated during the hole-forming machining.
[7] An example cutting tool according to the present disclosure is effectively configured so as to include a body and a cutting insert according to the present disclosure which is mounted on a body. More specifically, the cutting insert includes a first end surface and a second end surface that are each formed in a substantially polygonal plate shape and that each include a first long side and a second long side, and a first short side and a second short side that are located between the first long side and the second long side, the first end surface and the second end surface facing each other. The first end surface and the second end surface each have: a first cutting edge including a first corner part located between the first long side and the first short side and extending from the first long side to the first short side; and a second cutting edge including a second corner part located between the second long side and the first short side and extending from the second long side to the first short side. A radius of curvature R3 of a third corner part located on an opposite side of the first corner part with the first long side interposed therebetween is formed larger than a radius of curvature R1 of the first corner part.
An embodiment of the present disclosure will be described below with reference to the attached drawings. For the purpose of facilitating the understanding of the description, like components will be denoted with like reference numerals in each of the drawings, wherever possible, and redundant description will be omitted.
As shown in
The cutting inserts 3, 3 are each formed in a substantially rectangular parallelepiped shape and have the same shape so as to be interchangeable with each other (see also
The material of such cutting insert 3 is not particularly limited, and it is preferable for the entire part of the cutting insert 3 to be made of, for example, cemented carbide. In the cutting insert 3, at least a portion containing a first cutting edge 31 and a second cutting edge 32 (described later) may be formed so as to contain any of, for example: hard materials such as cermet, ceramics and a sintered compact containing cubic boron nitride; a material having a coating layer, formed by PVD or CVD, on a surface of such hard materials; and monocrystal diamond or a sintered compact containing diamond, etc.
Next, a more specific configuration of the cutting inserts 3 will be described below. As shown in
In addition, as shown in
The first end surface 10U has a first long side 11U, a second long side 12U, a first short side 13U, and a second short side 14U, that define boundaries between such first end surface 10U and the first long side surface 11, the second long side surface 12, the first short side surface 13 and the second short side surface 14, respectively. Similarly, the second end surface 10L has a first long side 11L, a second long side 12L, a first short side 14L, and a second short side 13L, that define boundaries between such second end surface 10L and the first long side surface 11, the second long side surface 12, the first short side surface 13 and the second short side surface 14, respectively. Due to such characteristics of the configuration, the first cutting edge 31 and the second cutting edge 32 of the first end surface 10U and the first cutting edge 31 and the second cutting edge 32 of the second end surface 10L are 180-degrees rotationally symmetric (i.e., twofold rotational symmetry) with respect to each other around an axis BX that passes through the center of the cutting insert 3 and extends substantially along the first short sides 13U and 14L and the second short sides 14U and 13L. In this way, the axis BX corresponds to an example of “a predetermined axis virtually extending through the cutting insert.”
Here, the first cutting edge 31 on the first end surface 10U side includes a first corner part Cn1 located between the first long side 11U and the first short side 13U, and extends from the first long side 11U to the first short side 13U. In the same way, the first cutting edge 31 on the second end surface 10L side includes a first corner part Cn1 located between the first long side 11L and the first short side 14L, and extends from the first long side 11L to the first short side 14L. Each of such first cutting edges 31 function, in the first state 3C, as a cutting edge that primarily cuts a worked bottom surface of a workpiece 6 during the hole-forming machining of such workpiece 6. In addition, as shown in
In the present embodiment, the radius of curvature R3 of the third corner part Cn3 is formed relatively larger than the radius of curvature R1 of the first corner part Cn1. In addition, in the above-described 180-degrees rotationally symmetrical relationship, the first corner part Cn1 on the first end surface 10U and the third corner part Cn3 on the second end surface 10L are in a positional relationship in which they face each other with the short side surface 13 interposed therebetween. The third corner part Cn3 on the first end surface 10U and the first corner part Cn1 on the second end surface 10L are similarly in a positional relationship in which they face each other with the short side surface 14 interposed therebetween.
Meanwhile, the second cutting edge 32 on the first end surface 10U side includes a second corner part Cn2 located between the second long side 12U and the first short side 13U, and extends from the second long side 12U to the first short side 13U. In the same way, the second cutting edge 32 on the second end surface 10L side includes a second corner part Cn2 located between the second long side 12L and the first short side 14L, and extends from the second long side 12L to the first short side 14L. Such second cutting edges 32 each function, in the second state 3P, as a cutting edge that primarily cuts a worked peripheral surface of the workpiece 6 during milling of such workpiece 6.
As shown in
Regarding the first cutting edge 31 of the cutting insert 3, the first end surface 10U and the second end surface 10L (which are both rake surfaces) are each provided with a chip breaker 3B. Here, such chip breaker 3B is assumed to have: a virtual portion (first chip breaker) located on the first corner Cn1 side (tool periphery side) with respect to the center of the first long side 11U, 11L; and a virtual portion (second chip breaker) located on the third corner part Cn3 side (tool center side) with respect to the center of the first long side 11U, 11L. In the present embodiment, the maximum width (Wcmax) of the second chip breaker is formed so as to be larger than the maximum width (Wpmax) of the first chip breaker. More specifically, the maximum width Wcmax is formed so as to be 50% or less (½ or less) of the first short side 13U, 14L.
According to the cutting inserts 3, 3 configured as described above, as well as the cutting tool 1 on which such cutting inserts 3, 3 are mounted, the cutting inserts 3 functions as an end mill intended for multifunctional machining being double-sided and indexable. Each of the cutting inserts 3, 3 is reusable by inverting the first end surface 10U and the second end surface 10L, and the cutting inserts 3, 3 are also interchangeable; therefore, a single cutting insert 3 can be used four times in total. Accordingly, it is possible to improve the economic efficiency of the tool and facilitate inventory control of products.
In addition, the radius of curvature R3 of the third corner part Cn3 that may be located on the tool center side is formed so as to be relatively larger than the radius of curvature R1 of the first corner part Cn1 that may be located on the tool periphery side. With such configuration, when the core 6T as shown in
Furthermore, the maximum width Wcmax of the second chip breaker that is located on the third corner part Cn3 side with respect to the center of the first long side 11U, 11L is formed so as to be larger than the maximum width Wpmax of the first chip breaker that is located on the first corner part Cn1 side with respect to the center of the first long side 11U, 11L. With such configuration, in the first chip breaker that may be located on the tool periphery side, since the distance to a “wall” is relatively short, it becomes easier to forcibly cause the chips to be curled. On the other hand, in the second chip breaker that may be located on the tool center side, since the distance to the “wall” is relatively large, it becomes more difficult to forcibly cause the chips to be curled. In other words, such configuration is advantageous in that a curling process for chips can be easily adjusted as desired according to the thickness of the chips. As a result, it is possible to further improve the overall machining performance of the cutting insert 3.
Although the present embodiment has been described above with reference to the specific examples, such description has been provided in order to facilitate the understanding of the present disclosure, instead of limiting the interpretation of the present disclosure. More specifically, the present disclosure is not limited to the specific examples, and design modifications that are added as appropriate by a person skilled in the art are also encompassed in the scope of the present disclosure, as long as such design modifications include the characteristics of the present disclosure. In addition, each element, arrangement, material, condition, shape, dimension, scale, etc. included in each of the above-described specific examples is not particularly limited to those described as examples, unless otherwise indicated, and they may be altered as appropriate. Furthermore, regarding each of the elements included in each of the above-described specific examples, different combinations thereof may be employed, as long as no technical contradiction occurs.
More specifically, the cutting insert 3 may not be useable both in the first state 3C and the second state 3P, as long as at least the first cutting edge 31 having the first corner part Cn1 and the third corner part Cn3 is formed and the relationship of the radius of curvature R3>the radius of curvature R1 is satisfied. Further, the leading end part 21 and the trailing end part 22 of the body 2 may be formed as separate parts, and they may be configured as an assembly type or a head-replaceable type, or they may be coupled by welding, etc. In addition, multiple insert pockets D1, D2 may be provided, and multiple cutting inserts 3 may be mounted to the respective insert pockets. Furthermore, as a method of mounting the cutting inserts 3 to the insert pockets D1, D2, a screw-on method or a lever-lock method may be employed; however, the mounting method is not particularly limited thereto and, for example, brazing may be employed. The pitch for arranging the plurality of cutting inserts 3 is not limited to a regular pitch, and the cutting inserts 3 may be arranged at an irregular pitch. Furthermore, when the cutting inserts 3 are used for milling, the chip breaker 3B can be formed mainly in order to provide a positive rake surface and, in such case, the chip breaker 3B does not have to be intended to cause chips to hit against a “wall” to break them into fine pieces.
In addition, it is only necessary that the first cutting edge 31 on the first end surface 10U side extends from the first long side 11U to the first corner part Cn1, and it does not necessarily have to be formed so as to extend to the first short side 13U. In addition, it is only necessary that the first cutting edge 31 on the second end surface 10L side extends from the first long side 11L to the first corner part Cn1, and it does not necessarily have to be formed so as to extend to the first short side 14L. Similarly, it is only necessary that the second cutting edge 32 on the first end surface 10U side extends from the second long side 12U to the second corner part Cn2, and it does not necessarily have to be formed so as to extend to the first short side 13U. In addition, it is only necessary that the first second edge 32 on the second end surface 10L side extends from the second long side 12L to the second corner part Cn2, and it does not necessarily have to be formed so as to extend to the first short side 14L. In other words, the first short sides 13U, 14L may not be used as part of the first cutting edge 31 or the second cutting edge 32.
According to the present disclosure, it is possible to improve the machining resistance of the third corner part of the cutting insert, and as a result, it is possible to effectively suppress fracture, etc. of the third corner part during hole-forming machining for a workpiece.
Number | Date | Country | Kind |
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2023-223128 | Dec 2023 | JP | national |