1. Field of the Invention
The invention pertains to the field of cutting tools. More particularly, the invention pertains to a cutting tool with a wedge clamping system that resists centrifugal forces to securely hold a cutting insert in the pocket of the cutting tool during a cutting operation.
2. Description of Related Art
Conventional cutting tools with insert cartridges use various means for mounting the insert cartridges to the tool body. One known method of clamping an insert cartridge in a pocket of a cutting tool is by means of a clamp wedge. Unfortunately, the insert cartridge has a tendency to fly out of the pocket at higher cutting speeds due to centrifugal forces, thereby increasing cycle times and associated costs.
The problem of securely clamping an insert cartridge in a pocket of a cutting tool is solved by providing a cutting tool with a wedge clamping system that resists centrifugal forces to securely hold a cutting insert in the pocket of the cutting tool during a cutting operation.
In one aspect of the invention, a cutting tool comprises a cutting tool comprises a pocket including a top wall, a bottom wall, a side wall and a rear wall; and a wedge clamping system comprising an insert cartridge and a clamp wedge. The insert cartridge includes a recess for interacting with a protrusion on the clamp wedge in such a way that the clamp wedge exerts a force vector in an axial direction when the clamp wedge is threaded into the pocket, thereby reducing deflection of an adjacent pocket of the cutting tool when the cutting tool is placed in a locked condition.
In another aspect of the invention, a cutting tool comprises a pocket including a top wall, a bottom wall, a side wall and a rear wall (24); an insert cartridge comprising a top wall, a bottom wall opposite the top wall, a pair of opposing side walls extending between the top and bottom walls, and an insert pocket formed in the top wall of the insert cartridge at an intersection between the front wall of the insert cartridge and one of the side walls of the insert cartridge (14) for receiving a cutting insert; and a clamp wedge comprising a top wall, a bottom wall opposite the top wall, a front wall, a rear wall opposite the front wall, and a pair of opposing side walls extending between the top and bottom walls, wherein the insert cartridge includes a recess for interacting with a protrusion on the clamp wedge in such a way that the clamp wedge exerts a force vector in an axial direction when the clamp wedge is threaded into the pocket, thereby reducing deflection of an adjacent pocket of the cutting tool when the cutting tool is placed in a locked condition.
While various embodiments of the invention are illustrated, the particular embodiments shown should not be construed to limit the claims. It is anticipated that various changes and modifications may be made without departing from the scope of this invention.
Referring now to
In general, the pocket 12 includes a top wall 18, a bottom wall 20, a side wall 22 (
Referring now to
In general, the top wall 30, the bottom wall 32, the front wall 34 and the rear wall 36 are substantially perpendicular to the side walls 38, 40. In one aspect of the invention, a recess, shown generally at 46, is formed in the top wall 30 for accommodating a protrusion 82 (
In the illustrated embodiment, the recess 46 extends from the front wall 34 toward the rear wall 36, but does not extend entirely to the rear wall 36. Also, the recess 46 does not extend entirely to the side walls 38, 40, but is located inward therefrom. The recess 46 includes a bottom wall 48, a pair of opposing side walls 50, 52, a first rear wall 54 and a second rear wall 56. The bottom wall 48 includes a first portion 48a that is formed substantially perpendicular to the front wall 34, and a second portion 48b formed at an angle 58 greater than zero (0) degrees with respect to the first portion 48a. In other words, the second portion 48b of the bottom wall 48 is not formed perpendicular to the front wall 34. In one embodiment, for example, the angle 58 can be between about one (1) degree and about ten (10) degrees. In addition, the first rear wall 54 is formed at an angle 59 greater than zero (0) degrees and less than ninety (90) degrees with respect to the first portion 48a and the second portion 48b of the bottom wall 48 of the recess 46. Similarly, the second rear wall 54 is formed at an angle 60 greater than zero (0) degrees and less than ninety (90) degrees with respect to the first portion 48a and the second portion 48b of the bottom wall 48 of the recess 46. The angles 59, 60 can be equal to each other, or the angles 59, 60 can be different from each other.
Referring now to
In general, the top wall 64, the bottom wall 66, the front wall 68 and the rear wall 70 are substantially perpendicular to the side walls 72, 74. In another aspect of the invention, the second portion 64b is formed at an angle 62 greater than zero (0) degrees and less than ninety (90) degrees with respect to with respect to the first portion 64a. In other words, the second portion 64b of the top wall 64 is not perpendicular with respect to the front and rear walls 68, 70 such that a thickness of the clamp wedge 16 is largest proximate the front wall 68 and smallest proximate the rear wall 70. When the insert cartridge 14 and the clamp wedge 16 are in the locked condition, the top wall 64 of the clamp wedge 16 engages the top wall 18 of the pocket 12. Specifically, the first portion 64a of the top wall 64 of the clamp wedge 16 is designed to not make contact with the first portion 18a of the top wall 18 of the pocket 12, and the second portion 64b of the top wall 64 of the clamp wedge 16 engages the second portion 18b of the top wall 18 of the pocket 12. The clamp wedge 16 also includes a threaded bore 80 extending from the front wall 68 through the rear wall 70 to allow a wedge screw (not shown) to be threaded into the threaded bore 80 to draw the clamp wedge 16 into the pocket 12.
In another aspect of the invention, the bottom wall 66 of the clamp wedge 16 includes a protrusion 82 that is accommodated in the recess 46 of the insert cartridge 14. In general, the protrusion 82 is generally the same shape as the recess 46. In the illustrated embodiment, the protrusion 82 extends from the front wall 68 toward the rear wall 70, but does not extend entirely to the rear wall 70. Also, the protrusion 82 does not extend entirely to the side walls 72, 74, but is located inward therefrom. The protrusion 82 includes a front wall 84, a top wall 86, a pair of opposing side walls 88, 90, a first rear wall 92 and a second rear wall 94. The top wall 86 includes a first portion 86a that is formed substantially perpendicular to the front wall 84, and a second portion 86b formed at an angle 96 greater than zero (0) degrees with respect to the first portion 86a. In other words, the second portion 86b of the top wall 86 is not formed perpendicular to the front wall 84. In one embodiment, for example, the angle 96 can be between about one (1) degree and about ten (10) degrees. In one embodiment, the angle 96 is approximately equal to the angle 58 between the first portion 48a and the second portion 48b of the bottom wall 48 of the recess 46. In another embodiment, the angle 96 is different than the angle 58.
It should be noted that the first rear wall 92 is formed substantially perpendicular (i.e. at an angle of about ninety (90) degrees) with respect to the first portion 86a, unlike the first rear wall 54 of the recess 46. Similarly, the second rear wall 94 is formed substantially perpendicular (i.e. at an angle of about ninety (90) degrees) with respect to the first portion 86a, unlike the second rear wall 56 of the recess 46.
As described above, the cutting tool 10 of the invention with the wedge clamping system 13 causes the clamp wedge 16 to press against the top wall 18 and the insert cartridge 14 to press against the bottom wall 20 of the pocket 12 to securely hold the insert cartridge 14 in place when in the locked condition during a cutting operation.
The patents and publications referred to herein are hereby incorporated by reference.
Having described presently preferred embodiments the invention may be otherwise embodied within the scope of the appended claims.