CUTTING TOOL INSERT WITH MOLDED INSERT BODY

Abstract

A cutting tool comprising may include at least one abrasive tip that includes an abrasive cutting edge, and an insert body. The insert body includes a moldable material, and the moldable material is adhered to a portion of the abrasive tip.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A depicts a cutting tool insert of the prior art.

FIGS. 1B-1C include a top and side view of a cutting tooling setup of the prior

FIGS. 2A-2C are a selection of top-view illustrations of various insert-molded cutting tool insert according to various embodiments of the present disclosure.

FIG. 3 is an embodiment of a cutting tool insert with a cutting blank containing a protrusion.

FIG. 4 is an embodiment of a cutting tool insert with a cutting blank containing a depression.

FIG. 5 is an embodiment of a cutting tool that includes a tribochemical body.

FIG. 6 is a diagram illustrating an exemplary cutting tool insert manufacturing process.

Claims

1. A cutting tool comprising: at least one abrasive tip comprising an abrasive cutting edge; andan insert body, wherein the insert body comprises a moldable material, wherein the moldable material is adhered to a portion of the abrasive tip.

2. The cutting tool insert according to claim 1, wherein the moldable material comprises a polymeric material.

3. The cutting tool insert according to claim 1, wherein the moldable material comprises a ceramic material.

4. The cutting tool insert according to claim 1, wherein the moldable material comprises a carbide material.

5. The cutting tool insert according to claim 1, wherein the moldable material comprises a metallic material.

6. The cutting tool insert according to claim 1, wherein the insert body further comprises structural enhancing components, thermal components, physicochemical components, or mixtures thereof.

7. The cutting tool insert according to claim 1, further comprising a tribochemical body positioned to extend the useful life of the cutting tool insert.

8. The cutting tool insert according to claim 1, wherein the at least one abrasive tip comprises a superabrasive material.

9. The cutting tool according to claim 1, wherein the at least one abrasive tip comprises a ceramic material.

10. The cutting tool according to claim 1, wherein the at least one abrasive tip comprises a carbide material.

11. The cutting tool according to claim 1, wherein the at least one abrasive tip further comprises a protrusion, a depression, or a mixture thereof.

12. The cutting tool according to claim 1, wherein the at least one abrasive tip or the cutting tool insert further comprises a coating, the coating comprising a metal, ceramic, oxide, organic resin, laminate, composite, or mixtures thereof.

13. A method, comprising: providing at least one abrasive tip comprising an abrasive cutting edge;providing a moldable material to form an insert body; and,insert-molding the at least one abrasive tip and moldable material to form a cutting tool insert.

14. The method according to claim 13, wherein the moldable material is selected from the group consisting of polymeric material, ceramic material, carbide material, metal material or blends thereof.

15. The method according to claim 13, wherein the moldable material further comprises a structural enhancing component, a thermal component, a physicochemical component, or a mixture thereof.

16. The method according to claim 13, wherein the step of insert-molding the insert comprises simultaneously forming the insert body and securing the insert body to the abrasive tip.

17. The method according to claim 13, wherein the step of insert-molding the material further comprises at least one of injection molding, transfer molding, casting, cold pressing, heating, sintering, or binder removal.

18. The method according to claim 13, further comprising the step of heating the cutting tool insert after insert-molding.

19. The method according to claim 13, further comprising the step of coating the cutting tool insert.

20. The method according to claim 13, further comprising the step of coating the at least one abrasive tip prior to insert-molding.

21. The method according to claim 13, further comprising the step of grinding the cutting tool insert.

22. A cutting tool insert comprising: at least one abrasive tip comprising an abrasive cutting edge; andan insert body, comprising: a moldable material comprising polymeric materials, ceramic materials, carbide materials, metallic materials, composite materials, or mixtures thereof,wherein the moldable material is adhered to a portion of the abrasive tip; andan additive comprising a structural enhancing component, a thermal component, a physicochemical component, or a mixture thereof.