Patent Grant
8439608
The invention relates to an assembly comprising a cutting insert, a shim, and a holder body wherein the assembly provides enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface in the chipforming removal of material from a workpiece. Furthermore, the invention relates to an assembly comprising a cutting insert and a shim wherein the assembly facilitates enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface in the chipforming removal of material from a workpiece. In addition, the invention relates to the shim itself, which facilitates enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface in the chipforming removal of material from a workpiece.
In a chipforming material removal operation (e.g., a milling operation, a turning operation, and the like), heat is generated at the interface between the cutting insert and the location where the chip is removed from the workpiece (i.e., the insert-chip interface). It is well-known that excessive heat at the insert-chip interface can negatively impact upon (i.e., reduce or shorten) the useful tool life of the cutting insert. As can be appreciated, a shorter useful tool life increases operating costs and decreases overall production efficiency. Hence, there are readily apparent advantages connected with decreasing the heat at the insert-chip interface.
U.S. Pat. No. 6,053,669 to Lagerberg for CHIP FORMING CUTTING INSERT WITH INTERNAL COOLING discusses the importance of reducing the heat at the insert-chip interface. Lagerberg mentions that when the cutting insert is made from cemented carbide reaches a certain temperature, its resistance to plastic deformation decreases. A decrease in plastic deformation resistance increases the risk for breakage of the cutting insert. U.S. Pat. No. 5,775,854 to Wertheim for METAL CUTTING TOOL points out that a rise in the working temperature leads to a decrease in hardness of the cutting insert. The consequence is an increase in wear of the cutting insert.
Other patent documents disclose various ways to or systems to deliver coolant to the insert-chip interface. For example, U.S. Pat. No. 7,625,157 to Prichard et al. for MILLING CUTTER AND MILLING INSERT WITH COOLANT DELIVERY pertains to a cutting insert that includes a cutting body with a central coolant inlet. The cutting insert further includes a positionable diverter. The diverter has a coolant trough, which diverts coolant to a specific cutting location. U.S. Patent Application Publication No. US 2008-0175678 A1 to Prichard et al. for METAL CUTTING SYSTEM FOR EFFECTIVE COOLANT DELIVERY pertains to a cutting insert that functions in conjunction with a top piece and/or a shim to facilitate delivery of coolant to a cutting location.
U.S. Pat. No. 6,045,300 to Antoun for TOOL HOLDER WITH INTEGRAL COOLANT PASSAGE AND REPLACEABLE NOZZLE discloses using high pressure and high volume delivery of coolant to address heat at the insert-chip interface. U.S. Pat. No. 6,652,200 to Kraemer for a TOOL HOLDER WITH COOLANT SYSTEM discloses grooves between the cutting insert and a top plate. Coolant flows through the grooves to address the heat at the insert-chip interface. U.S. Pat. No. 5,901,623 to Hong for CRYOGENIC MACHINING discloses a coolant delivery system for applying liquid nitrogen to the insert-chip interface.
It is readily apparent that in a chipforming and material removal operation, higher operating temperatures at the insert-chip interface can have a detrimental impact on the useful tool life through premature breakage and/or excessive wear. It would be highly desirable to provide a cutting insert-shim-holder body assembly used for chipforming material removal operations wherein there is an improved delivery of coolant to the interface between the cutting insert and the workpiece (i.e., the insert-chip interface), which is the location on the workpiece where the chip is generated). There would be a number of advantages connected with the improved delivery of coolant to the insert-chip interface.
In a chipforming material removal operation, the chip generated from the workpiece can sometimes stick (e.g., through welding) to the surface of the cutting insert. The build up of chip material on the cutting insert in this fashion is an undesirable occurrence that can negatively impact upon the performance of the cutting insert, and hence, the overall material removal operation. It would be highly desirable to provide a cutting insert-shim-holder body assembly used for chipforming material removal operations wherein there is enhanced delivery of coolant to the insert-chip interface so as to result in enhanced lubrication at the insert-chip interface. The consequence of enhanced lubrication at the insert-chip interface is a decrease in the tendency of the chip to stick to the cutting insert.
In a chipforming material removal operation, there can occur instances in which the chips do not exit the region of the insert-chip interface when the chip sticks to the cutting insert. When a chip does not exit the region of the insert-chip interface, there is the potential that a chip can be re-cut. It is undesirable for the cutting insert to re-cut a chip already removed from the workpiece. A flow of coolant to the insert-chip interface will facilitate the evacuation of chips from the insert-chip interface thereby minimizing the potential that a chip will be re-cut. It would be highly desirable to provide a cutting insert-shim-holder body assembly used for chipforming material removal operations wherein there is enhanced delivery of coolant to the insert-chip interface to reduce the potential that a chip will be re-cut. The consequence of enhanced flow of coolant to the insert-chip interface is better evacuation of chips from the vicinity of the interface with a consequent reduction in the potential to re-cut a chip.
There are a number of different kinds of chipforming material removal operations such as, for example, turning, profiling and facing. Even though they are somewhat different, in some assemblies, each operation uses a cutting insert and a shim along with a holder body. It would be highly desirable to provide a cutting insert-shim assembly (or a cutting insert-shim-holder body assembly) that displays flexibility in addressing different operations without the need for additional components. There would be an advantage to provide a cutting insert-shim assembly (or a cutting insert-shim-holder body assembly) that uses the same components to perform any one of a number of different chipforming material removal operations (e.g., turning, profiling and facing).
A number of factors can impact the extent of the coolant delivered to the insert-chip interface. For example, the size of the structure that conveys the coolant to the cutting insert can be a limiting factor on the extent of coolant supplied to the cutting insert. Thus, it would be highly desirable to provide supply holes that are equal to or larger than the inlets in the cutting insert-shim assembly to maximize the flow of the coolant to the cutting insert. It would be highly desirable to provide a cutting insert-shim assembly in which two or more coolant channels convey coolant to a single discrete cutting location. Further, in order to customize the delivery of coolant, the use of irregular coolant channels and variable areas of the inlet and the discharge in the cutting insert-shim assembly would allow for such customization. One such feature is to provide for a range of diversion angles of the coolant, which can range between about 10 degrees and about 60 degrees
In order to enhance delivery of coolant to the cutting insert-shim assembly, it is advantageous to provide for the coolant to enter the shim through the holder. This can include the use of an external coolant supply or an internal coolant supply
In reference to the manufacturing of a cutting insert, there can be advantages in using multiple pieces, which together form the cutting insert. For example, in some instances a cutting insert formed from a base, which presents the cutting edge, and a core can result in enhanced longevity because only the base need to changed after reaching the end of the useful tool life. In such an arrangement, the core is detachably joins to the base whereby the core is re-used when the base wears out. The base and core can join together via co-sintering, brazing and/or gluing. As an alternative, the base and core can contact one another without joining together as an integral member, but remain separate components even though in close contact. In addition, to enhance performance, the base and the core can be from the same or dissimilar materials depending upon the specific application.
When the preferred embodiment of the cutting insert-shim assembly presents a round geometry, certain advantages can exist. For example, when the cutting insert and shim each has a round geometry, the assembly of multiple components, e.g., a base and a core, does not need indexing. A round cutting insert-shim assembly is not handed so it can be used in left, right and neutral. In profile turning, up to 50% of the round cutting insert-shim assembly can function as the cutting edge. A round cutting insert-assembly is also available to engage an anti-rotation feature.
In one form thereof, the invention is a shim for use with a cutting insert wherein coolant enters the shim and passes into the cutting insert. The shim comprises a shim body, which has a first side surface and a second side surface. The shim body contains a cavity wherein the cavity defines a first opening in the first side surface and a second opening in the second side surface. The first opening provides a first level of coolant communication to the cutting insert. The second opening provides a second level of coolant communication to the cutting insert.
In another form thereof, the invention is a cutting insert-shim assembly. The assembly comprises a cutting insert, which has a bottom surface and a plurality of interior coolant passages wherein each interior coolant passage has an inlet in the bottom surface of the cutting insert. The assembly has a shim, which has a first side surface and a second side surface. The shim contains a cavity communicating with the coolant conduit. The cavity defines a first opening in the first side surface and a second opening in the second side surface. When the shim is in a first condition, the first side surface contacts the bottom surface of the cutting insert and the first opening provides a first level of coolant communication to the interior coolant passages in the cutting insert. When the shim is in a second condition, the second side surface contacts the bottom surface of the cutting insert and the second opening provides a second level of coolant communication to the interior coolant passages in the cutting insert.
In yet another form thereof, the invention is a cutting insert-shim-holder assembly wherein the holder is in communication with a coolant source. The assembly comprises a holder, which has a seat and further contains a coolant conduit having an outlet in the seat. The assembly has a cutting insert with a bottom surface and a plurality of interior coolant passages wherein each interior coolant passage has an inlet in the bottom surface of the cutting insert. The assembly has a shim, which has a first side surface and a second side surface. The shim contains a cavity communicating with the coolant conduit. The cavity defines a first opening in the first side surface and a second opening in the second side surface. When the shim is in a first condition, the first side surface contacts the bottom surface of the cutting insert and the first opening provides a first level of coolant communication to the interior coolant passages in the cutting insert. When the shim is in a second condition, the second side surface contacts the bottom surface of the cutting insert and the second opening provides a second level of coolant communication to the interior coolant passages in the cutting insert.
In still another form thereof, the invention is a cutting insert-shim-holder assembly wherein the holder is in communication with a coolant source. The assembly comprises a holder, which has a longitudinal holder axis and contains a seat and a coolant conduit with an outlet in the seat. The assembly further has a cutting insert that has a bottom surface and contains a plurality of interior coolant passages wherein each interior coolant passage has an inlet in the bottom surface of the cutting insert. There is a shim, which has a first side surface and a second side surface. The shim contains a cavity communicating with the coolant conduit. The cavity defines a first opening in the first side surface and a second opening in the second side surface. The shim is movable between a plurality of positions relative to the outlet of the coolant conduit and the cutting insert. When the shim being in a first condition, the first side surface contacts the bottom surface of the cutting insert and the first opening provides a first level of coolant communication to the interior coolant passages in the cutting insert whereby coolant exits the cutting insert in a first flow pattern. When the shim is in a second condition, the first side surface contacts the bottom surface of the cutting insert, and the first opening provides a first level of coolant communication to the interior coolant passages in the cutting insert whereby coolant exits the cutting insert in a second flow pattern. When the shim is in a third condition, the second side surface contacts the bottom surface of the cutting insert and the second opening provides a second level of coolant communication to the interior coolant passages in the cutting insert whereby coolant exits the cutting insert in a third flow pattern.
The following is a brief description of the drawings that form a part of this patent application:
Referring to the drawings, there should be an appreciation that the cutting insert, as well as the cutting assembly (i.e., cutting insert-shim assembly and cutting insert-shim-holder body assembly), can operate in a number of different applications. The cutting insert, which has internal coolant delivery, is for use in the chipforming removal of material from a workpiece wherein there is enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface. The cutting insert-shim assembly, which has internal coolant delivery, is for use in the chipforming removal of material from a workpiece wherein there is enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface.
The enhanced delivery of coolant to the insert-chip interface leads to certain advantages. For example, enhanced delivery of coolant to the insert-chip interface results in enhanced lubrication at the insert-chip interface which decreases the tendency of the chip to stick to the cutting insert. Further, enhanced flow of coolant to the insert-chip interface leads to better evacuation of chips from the vicinity of the interface with a consequent reduction in the potential to re-cut a chip.
As will be made apparent from the description hereinafter, the nature of the coolant dispersion or spray is such that it is continuous between the adjacent so-called activated interior coolant passages. The coolant actually exits the activated coolant passages in the form of a continuous cone of coolant, By providing such a coolant dispersion, the cutting insert achieves enhanced delivery of coolant to the insert-chip interface.
There should also be an appreciation that the interior coolant passage discharge has an orientation whereby the coolant impinges beneath the chip surface. Such an orientation of the coolant enhances the cooling properties, which enhances the overall performance of the cutting insert.
As will be made apparent from the description hereinafter, the cutting insert-shim assembly can operate in any one of a number of different operations. By orienting the shim relative to the cutting insert and coolant outlet in the seat, the cutting insert-shim assembly effectively carries out any one of a number of different operations (e.g., turning, facing or profiling). It is apparent that advantages (e.g., cost) exist for an assembly of components useful in any one of a number of different chipforming material removal operations without the need to change components.
The description herein of specific applications should not be a limitation on the scope and extent of the use of the cutting insert, the cutting insert-shim assembly or the cutting insert-shim-holder body assembly.
In the chipforming material removal operation, the cutting insert 150 engages a workpiece to remove material from a workpiece typically in the form of chips. A material removal operation that removes material from the workpiece in the form of chips typically is known by those skilled in the art as a chipforming material removal operation. The book Machine Shop Practice [Industrial Press Inc., New York, N.Y. (1981)] by Moltrecht presents at pages 199-204 a description, inter alia, of chip formation, as well as different kinds of chips (i.e., continuous chip, discontinuous chip, segmental chip). Moltrecht reads [in part] at pages 199-200, “When the cutting tool first makes contact with the metal, it compresses the metal ahead of the cutting edge. As the tool advances, the metal ahead of the cutting edge is stressed to the point where it will shear internally, causing the grains of the metal to deform and to flow plastically along a plane called the shear plane . . . . When the type of metal being cut is ductile, such as steel, the chip will come off in a continuous ribbon . . . ”. Moltrecht goes on to describe formation of a discontinuous chip and a segmented chip.
As another example, the text found at pages 302-315 of the ASTE Tool Engineers Handbook, McGraw Hill Book Co., New York, N.Y. (1949) provides a lengthy description of chip formation in the metal cutting process. At page 303, the ASTE Handbook makes the clear connection between chip formation and machining operations such as turning, milling and drilling. The following patent documents discuss the formation of chips in a material removal operation: U.S. Pat. No. 5,709,907 to Battaglia et al. (assigned to Kennametal Inc.), U.S. Pat. No. 5,722,803 to Battaglia et al. (assigned to Kennametal Inc.), and U.S. Pat. No. 6,161,990 to Oles et al. (assigned to Kennametal Inc.).
Referring to the drawings,
The flat surface 56 further contains an arcuate opening (arcuate notch) 60 that extends in a parallel manner for a portion of the circumferential edge 57. There is a coolant discharge port 62 in communication with the arcuate opening 60. The coolant discharge port 62 is in fluid communication with a coolant passage, which has a coolant entrance port. Coolant from a coolant source enters the coolant passage through the coolant entrance port and travels so to exit at the coolant discharge port into the arcuate opening 60. Coolant exiting into the arcuate opening 60 then passes into the cutting insert 150, as will be set forth in more detail hereinafter. The arcuate opening 60 extends about 90 degrees so to communicate with two adjacent interior coolant passages. The specific structure of the coolant source, the coolant passage, and the coolant entrance port is not illustrated, but is substantially the same as corresponding structure illustrated and discussed in conjunction with the screw-on toolholder 114.
Referring to
The cutting insert 150 can be used in conjunction with holders other than the milling cutting 40 described above. For example and referring to
Although not shown in the drawings, the KM® holder 80 further has a coolant passage, which has a coolant entrance port. The coolant entrance port is in communication with a coolant source. As described in more detail hereinafter, the coolant passes from the coolant source through the coolant entrance port into the coolant passage and exits the coolant passage via the coolant discharge port 94 into the arcuate opening 92. Coolant then travels from the arcuate opening 92 into the cutting insert 150. The arcuate opening extends about 180 degrees so to communicate with three adjacent interior coolant passages. The KM® holder 80 further includes an anti-rotation abutment 104 that extends in a radial inward fashion from the upstanding wall 90. The anti-rotation abutment 104 has a peripheral abutment surface 106. As will be the subject of a discussion hereinafter, the peripheral abutment surface 106 presents a geometry that engages the cutting insert 150 to prevent rotation of the cutting insert 150 when in the pocket 86.
As still another example of a holder suitable for use with the cutting insert 150,
The flat surface 124 further contains a threaded aperture 132, which facilitates attachment of the cutting insert 150 to the screw-on toolholder 114, therein.
The flat surface 124 contains an arcuate opening 128, which communicates with a coolant discharge port 130. The screw-on toolholder 114 further has a coolant passage 134, which has a coolant entrance port 135 and a pair of coolant discharge ports 136 and 137. The coolant discharge ports 136, 137 are in communication with a coolant source. As described in more detail hereinafter, the coolant passes from the coolant source 138 through the coolant entrance port 135 into the coolant passage 134 and exits the coolant discharge passage 134 via the coolant discharge ports 136, 137. Coolant then passes into the arcuate opening 128, and, as will be described in more detail, into the cutting insert 150. The arcuate opening extends about 180 degrees so to communicate with three adjacent interior coolant passages.
There should be an appreciation that any one of a number of different kinds of fluid or coolant are suitable for use in the cutting insert. Broadly speaking, there are two basic categories of fluids or coolants; namely, oil-based fluids which include straight oils and soluble oils, and chemical fluids which include synthetic and semisynthetic coolants. Straight oils are composed of a base mineral or petroleum oil and often contain polar lubricants such as fats, vegetable oils, and esters, as well as extreme pressure additives of chlorine, sulfur and phosphorus. Soluble oils (also called emulsion fluid) are composed of a base of petroleum or mineral oil combined with emulsifiers and blending agents Petroleum or mineral oil combined with emulsifiers and blending agents are basic components of soluble oils (also called emulsifiable oils). The concentration of listed components in their water mixture is usually between 30-85%. Usually the soaps, wetting agents, and couplers are used as emulsifiers, and their basic role is to reduce the surface tension. As a result they can cause a fluid tendency to foam. In addition, soluble oils can contain oiliness agents such as ester, extreme pressure additives, alkanolamines to provide Òreserve alkalinityÓ, a biocide such as triazine or oxazolidene, a defoamer such as a long chain organic fatty alcohol or salt, corrosion inhibitors, antioxidants, etc. Synthetic fluids (chemical fluids) can be further categorized into two subgroups: true solutions and surface active fluids. True solution fluids are composed essentially of alkaline inorganic and organic compounds and are formulated to impart corrosion protection to water. Chemical surface-active fluids are composed of alkaline inorganic and organic corrosion inhibitors combined with anionic non-ionic wetting agents to provide lubrication and improve wetting ability. Extreme-pressure lubricants based on chlorine, sulfur, and phosphorus, as well as some of the more recently developed polymer physical extreme-pressure agents can be additionally incorporated in this fluids. Semisynthetics fluids (also called semi-chemical) contains a lower amount of refined base oil (5-30%) in the concentrate. They are additionally mixed with emulsifiers, as well as 30-50% of water. Since they include both constituents of synthetic and soluble oils, characteristics properties common to both synthetics and water soluble oils are presented.
The toolholder body 116 further includes an anti-rotation abutment 140 that extends in a radial inward fashion from the upstanding wall 126. The anti-rotation abutment 140 has a peripheral abutment surface 142. The peripheral abutment surface 142 has a geometry that engages the cutting insert 150 to prevent rotation of the cutting insert 150 when in the pocket 122.
Referring to the remainder of the drawings, the following is a description of a preferred specific embodiment of the cutting insert 150 (see
The components, i.e., the base member 152 and the core member 154, of the cutting insert 150 may be made from one of any number of materials that are suitable for use as a cutting insert. The following materials are exemplary materials useful for a cutting insert: tool steels, cemented carbides, cermets or ceramics. The specific materials and combinations of materials depend upon the specific application for the cutting insert. Applicants contemplate that the base member and the core member may be made from different materials.
In reference to tool steels, the following patent documents disclose tool steels suitable for use as a cutting insert: U.S. Pat. No. 4,276,085 for High speed Steel, U.S. Pat. No. 4,880,461 for Superhard high-speed tool steel, and U.S. Pat. No. 5,252,119 for High Speed Tool Steel Produced by Sintered Powder and Method of Producing the Same. In reference to cemented carbides, the following patent documents disclose cemented carbides suitable for use as a cutting insert: U.S. Patent Application Publication No. US2006/0171837 A1 for a Cemented Carbide Body Containing Zirconium and Niobium and Method of Making the Same, U.S. Reissue Pat. No. 34,180 for Preferentially Binder Enriched Cemented Carbide Bodies and Method of Manufacture, and U.S. Pat. No. 5,955,186 for a Coated Cutting Insert with A C Porosity Substrate Having Non-Stratified Surface Binder Enrichment. In reference to cermets, the following patent documents disclose cermets suitable for use as a cutting insert: U.S. Pat. No. 6,124,040 for Composite and Process for the Production Thereof, and U.S. Pat. No. 6,010,283 for a Cutting Insert of a Cermet Having a Co—Ni—Fe Binder. In reference to ceramics, the following patent documents disclose ceramics suitable for use as a cutting insert: U.S. Pat. No. 5,024,976 for an Alumina-zirconia-silicon carbide-magnesia Ceramic Cutting Tools, U.S. Pat. No. 4,880,755 for a SiAlON Cutting Tool Composition, U.S. Pat. No. 5,525,134 for a silicon Nitride Ceramic and Cutting Tool made Thereof, U.S. Pat. No. 6,905,992 for a Ceramic Body Reinforced with Coarse Silicon Carbide Whiskers and Method for Making the Same, and U.S. Pat. No. 7,094,717 for a SiAlON Containing Ytterbium and Method of Making.
Referring to the base member 152, as especially the illustrations of the base member 152 in
The intersection of the rake surface 156 and the flank surface 158 form a cutting edge 160, which in this embodiment is a generally round cutting edge. As will be described in more detail hereinafter, the cutting edge 160 presents a plurality of discrete cutting locations. In this embodiment, there are six discrete cutting locations 161A through 161F. The discrete cutting locations (161A-161F) are spaced apart about 60 degrees apart. Further, each discrete cutting location (161A-161F) is located mid-way between each pair of adjacent ribs 170.
The rake surface 156 of the base member 152 has a radial outward surface 162, which is radial inward of the cutting edge 160 and extends around the entire circumference of the rake surface 156. Located radial inward of the radial outward surface 162 is a first transition surface 164 and located radial inward of the first transition surface 164 is a second transition surface 166. Each one of the first and second transition surfaces moves toward the bottom of the cutting insert as it moves in a radial inward direction. The second transition surface 166 blends into either a channel 168 or a rib 170.
There should be an appreciation that the surfaces, i.e., radial outward surface 162, the first transition surface 164, and the second transition surface 166, may exhibit any one of a number of different geometries or surface configurations. An objective of these surfaces is to provide a transition between the cutting edge 160 and the interior portion of the base member 152 comprising the channels 168 and the ribs 170. Further, a particular specific geometry may be effective to enhance a chipbreaking feature of the cutting insert. A particular specific geometry may also be effective to enhance coolant delivery to the insert-chip interface as coolant can impinge on this area of the cutting insert.
Referring to
The base member 152 further defines a central core reception aperture 186. The central core reception aperture 186 receives the core member 154. There is a discussion hereinafter of the assembly of the base member 152 and the core member 154.
The base member 152 also has a flank surface 158. The flank surface 158 has a cylindrical flank surface portion 200 adjacent to the rake surface 156. The cylindrical flank surface portion 200 extends toward the bottom surface a selected distance, at which point it transitions into a generally frusto-conically shaped surface portion (see bracket 202).
The generally frusto-conically shaped surface portion 202 presents a sinusoidal-shaped geometry wherein there are a plurality of sinusoidal-shaped valleys or scallops 206. Each one of the sinusoidal-shaped valleys 206 has an opposite side 208, another opposite side 210, and an arcuate mediate portion 212. For each sinusoidal-shaped valley 206, the circumferential width increases from the top to the bottom of the base member 152. Between each one of the sinusoidal-shaped valleys 206, there are sinusoidal-shaped islands 220. Each sinusoidal-shaped island 220 has opposite sides 221, 222 and an arcuate mediate portion 223. For each sinusoidal-shaped island 220, the circumferential width decreases from the top to the bottom of the base member 152.
Each sinusoidal-shaped valley 206 defines a depression that presents an arcuate surface. As will be discussed hereinafter, the sinusoidal-shaped valley 206 can cooperate with an anti-rotation abutment whereby the abutment engages the depression of the sinusoidal-shaped valley 206 to prevent rotation of the cutting insert 150 when in the pocket of the holder. There should be an appreciation that the geometry of the flank surface does not have to present the sinusoidal-shaped scallops. The flank surface can take on other geometries such as, for example, a smooth surface without scallops or depressions.
The base member 152 further has a bottom surface 226. The bottom surface 226 presents a sinusoidal-shaped circumferential edge 228. The sinusoidal-shaped circumferential edge 228 has a plurality of peaks 230A through 230F and a plurality of valleys 232A through 232F.
The bottom surface 226 of the base member 152 further contains notches 238A through 238F and lands 240A through 240F. These notches (238A-238F) and lands (240A-240F) define the profile of the edge at the termination of the central core reception aperture 186.
Referring to the structure of the core member 154, and especially
Referring to the interior surface of the integral generally frusto-conical section 250, moving in a direction toward the bottom end 246, there is an interior transition surface 258 that blends into an interior cylindrical surface 262. Referring to the exterior surface of the integral generally frusto-conical section 250, there is an arcuate exterior surface 264 and a frusto-conical exterior surface 266. There is a bottom cylindrical surface 268, which has a radial outer circumferential edge 270, at the bottom end 246.
As will become apparent from the description below, the cutting insert body 151 contains a plurality of distinct interior coolant passages 300 (see
In order to form the complete cutting insert 150, such as, for example illustrated in
The points of contact between the base member 152 and the core member 154 are very secure. This very secure contact between the base member 152 and the core member 154 is shows in
The contact between the base member and the core member can be through actual joinder of these components together. One can accomplish the joinder of the base member 152 and the core member 154 via any one of a number of ways. For example, techniques such as, co-sintering, brazing and/or gluing are suitable. The specific technique may be particularly applicable to certain materials. For example, co-sintering may be applicable to a situation in which the base member and the core member are of the same material (e.g., tungsten carbide-cobalt material). Gluing may be applicable to a situation in which the materials for the base member and the core member are dissimilar (e.g., a steel core member and a tungsten carbide-cobalt base member). The contact can also be accomplished via compressing the component together while still maintaining theme to be separate and distinct from one another. For example, the cutting insert can be securely threaded to the holder whereby there is a very strong surface-to-surface contact between the base member and the core member due to the very tight connection between the cutting insert and the holder. When the components are compressed together via tightening of the cutting insert to the holder, these components may be separated upon detachment of the cutting insert from the holder.
The choice of specific materials for the components is dependent upon the particular applications for the cutting insert. The use of ceramic-ceramic or carbide-carbide or steel-carbide combinations of the components provides the cutting insert with a variety of material options. By doing so, the cutting insert has an expansive material selection feature that allows for optimum customization of the cutting insert from the materials perspective.
As is apparent, the components, and hence the cutting insert, present a round geometry. By using a round geometry, the assembly of multiple components, e.g., a base and a core, does not need indexing to accomplish. The absence of indexing or special alignment reduces the manufacturing costs and makes the assembly easier in contrast to components that require special alignment. This is especially the case for the core member. The core member has a generally cylindrical/conical geometry. It does not have exterior features that require special alignment or orientation in the assembly to the base. Thus, the assembly of the core to the base is easy and inexpensive as compared to the assembly of components, each of which have complex geometric features.
As mentioned above, the cutting insert 150 has a plurality of distinct interior coolant passage 300. The following description of one interior coolant passage 300 is sufficient for a description of all such interior coolant passages 300.
In reference to each one of the interior coolant passages 300, selected surfaces on the base member 152 and on the core member 154 define the boundaries of the interior coolant passage 300. More specifically, some of the selected surfaces of the base member 152 are those that define the channel 168, i.e., the channel peripheral surfaces 172, 174 and the central trough 176. Other selected surfaces of the base member 152 include the radial inward barrier 178 of one rib 170 and the radial inward barrier 180 of an adjacent rib 170. In reference to the core member 154, the exterior surface helps define the interior coolant passage 300.
The interior coolant passage 300 has an interior coolant passage discharge 302 and an interior coolant passage inlet 304. As is apparent, coolant enters the interior coolant passage 300 through the interior coolant passage inlet 304, travels through the interior coolant passage 300, and then exits via the interior coolant passage discharge 302. Upon exiting the interior coolant passage 300, coolant sprays toward the discrete cutting location in engagement with the workpiece.
In this preferred specific embodiment, it is apparent that the geometry of the coolant flow cross-sectional area of the interior coolant passage 300 changes along the axial length of the interior coolant passage 300, i.e., the axial coolant passage length. Further, there should be an appreciation that the coolant flow cross-sectional area can vary to achieve a specific desired flow configuration or spray pattern at the insert-chip interface. In this particular embodiment, the spray pattern is of a continuous nature to present a continuous cone of coolant in the vicinity of the discrete cutting location. In this regard,
Table I below sets forth the coolant flow areas at the locations shown by the cross-sections 15-15 through 18-18 in
Based on the data from Table I, the coolant passage inlet area is substantially the same as the coolant passage discharge area, the coolant flow area changes along the axial coolant passage length, and the coolant passage inlet being smaller than the coolant port area. In reference to the latter feature, in this preferred specific embodiment of the cutting insert, the coolant port to which it is in communication has a coolant port area equal to 7.06 square millimeters.
Referring to
The coolant flow area increases to a lesser extent from the point of cross-section 16-16 and cross-section 17-17. A comparison between the coolant flow area at the points in the interior coolant passage 300 shown by cross-section 16-16 and 17-17 show a further widening of the interior coolant passage. The coolant flow area as shown in
Referring to
To engage in cutting (i.e., material removal), the cutting insert 150 is in a condition whereby there is a selected one of the plurality of discrete cutting locations engaging the workpiece. The arrow “DCL1” in
Referring to
Referring to
Because of the nature of the geometry of the interior coolant passage, the dispersion of coolant leads to a continuous spray of coolant.
Once the discrete cutting location has worn to a point where change is necessary, the operator can index the cutting insert to the next cutting position.
Test results were conducted to compare a specific embodiment of the inventive (through coolant) cutting insert against a commercial cutting insert (standard cutting insert) made and sold by Kennametal Inc. of Latrobe, Pa. 15650. Both cutting inserts were made from the same grade of cemented (cobalt) tungsten carbide, the same insert style (except for the through coolant feature of the inventive cutting insert) and the same edge preparation wherein the ISO designation for the cutting inserts including the edge preparation was RCGX64SFG. The test results are set forth in Table II below in the number of passes before the cutting insert became worn to the following point wherein the failure criteria was either 0.015 inch of maximum flank wear or a maximum rake face chip of 0.030 inch, whichever occurred first.
Other test parameters are set forth below. Workpiece material: Ti6Al4V. Insert edge style=round with the iC=0.750 inches; the cutter diameter was 3.00 inches; the number of inserts per cutter was one and the length of the pass was 12 inches. The cutting speed was Vc=150 feet/minute; RPM=202; the true chip load=0.006 inch/tooth; prog. chip load=0.010 inch/tooth; axial depth of cut=0.15 inches; radial depth of cut=2.000 inches; feed rate=2.020 inches per minute. The machine was a Mazak FJV; the coolant was wet; the coolant type was Syntilo® [Syntilo is a registered trademark of Castrol Limited, Wiltshire England]; the coolant pressure=1000 psi; the concentration=12.0%; and the MMR (inch2/min)=0.606.
As is apparent from the test results, the inventive cutting insert experienced substantial improvement over the commercial cutting insert. The number of passes before a change was necessary increased from an average of 4.33 to an average of 11.33. This is an increase in the number of passes of about 261 percent, which is greater than 250 percent.
It is readily apparent that the present cutting insert and cutting assembly provides for the improved delivery of coolant to the interface between the milling insert and the workpiece (i.e., the insert-chip interface, which is the location on the workpiece where the chip is generated). By doing so, the present cutting insert and cutting assembly provides for enhanced delivery of coolant to the insert-chip interface so as to result in enhanced lubrication at the insert-chip interface. The consequence of enhanced lubrication at the insert-chip interface is a decrease in the tendency of the chip to stick to the cutting insert, as well as better evacuation of chips from the vicinity of the interface with a consequent reduction in the potential to re-cut a chip.
The present cutting insert and cutting assembly achieve factors that impact the extent of the coolant delivered to the insert-chip interface. For example, the size of the structure that conveys the coolant to the cutting insert can be a limiting factor on the extent of coolant supplied to the cutting insert. The present cutting insert and cutting assembly provide supply holes (coolant ports) that are equal to or larger than the inlets in the cutting insert to maximize the flow of the coolant to the cutting insert. The present cutting insert and cutting assembly provide an arrangement in which two or more coolant channels convey coolant to a single discrete cutting location. The present cutting insert and cutting assembly provide irregular coolant channels and variable areas of the inlet and the discharge in the cutting insert which allow for customization of the coolant delivery. By doing so, one can provide for a range of diversion angles of the coolant, which can range between about 10 degrees and about 60 degrees
The present cutting insert and cutting assembly provides manufacturing and performance advantages. There can be advantages in using multiple pieces, which together form the cutting insert. For example, in some instances a cutting insert formed from a base, which presents the cutting edge, and a core can result in enhanced longevity because only the base need to changed after reaching the end of the useful tool life. In such an arrangement, the core is detachably joins (or functions with) to the base whereby the core is re-used when the base wears out. The base and core can join together via co-sintering, brazing and/or gluing. Furthermore, the base and core can be tightly compressed against one another still maintaining their separate and distinct character. In addition, to enhance performance, the base and the core can be from the same or dissimilar materials depending upon the specific application.
When the preferred specific embodiment of the cutting insert presents a round geometry at one or more locations, certain advantages can exist. For example, when the cutting insert has a round geometry at the location where multiple components are assembled, the assembly of multiple components, e.g., a base and a core, does not need indexing. When the cutting insert is round at the cutting edge, a round cutting insert is not handed so it can be used in left, right and neutral. In profile turning, up to 50% of the cutting insert can function as the cutting edge.
The cutting insert is also available to engage an anti-rotation feature.
Referring to
The holder body 706, which has a longitudinal axis A-A, has an axial forward end 708 and an axial rearward end 710. The holder body 706 has a head portion (bracket 712) adjacent the forward end 708 thereof and a shank portion (bracket 714) adjacent the rearward end 710 thereof. The holder body 706 further comprises a top surface 716 and a bottom surface 718, as well as opposite side surfaces 728, 730. The holder body 706 further contains a seat surface 732 at the axial forward end 708. The seat surface 732 is generally flat and has a generally circular geometry. The holder body 706 further has a semi-circular peripheral upstanding wall 734 that extends in an upward direction (i.e., toward the top surface 716) from the seat surface 732. As will become apparent, the upstanding wall 734 provides support for the cutting insert 150 and the shim 704, when assembled together. The upstanding wall 734 has a protrusion 735 that extends away from the wall 734. See
Holder body 706 is an elongate holder that has a square shank. There should be an appreciation that any one of a number of holders would be suitable for use with the cutting insert-shim assembly. Such holders can have different geometries, except that the seating region including the seat surface and the upstanding wall would be the same as the square shank holder 706.
There should be an appreciation that when the components are in an assembled condition, a scalloped edge surface of the shim 704 (or shim edge surface with an indention) engages the protrusion 735. Such engagement provides an anti-rotation feature for the shim 704, as well as the cutting insert 150. The cutting insert 150 engages the protrusion via the corresponding scallop 206.
The holder body 706 contains an interior coolant passage generally designated as 740. The interior coolant passage 740 has an entrance 742 and an outlet 744. A threaded port section 746 is adjacent the entrance 742. The interior coolant passage 740 also includes an inclined passage section 750, which communicates with the threaded port section 746. The interior coolant passage 740 further has a bowl section 752, which communicates with the inclined passage section 750. Bowl section 752 has a generally circular circumferential edge 754. The bowl section 752 has a diameter “AA” that extends through the center between opposite points on the circumferential edge 754. The holder body 706 further contains a threaded bore 758 wherein the entrance 760 thereto is in the bottom of the bowl section 752. The threaded bore 758 has a termination 762.
The assembly 700 further includes a threaded retainer generally designated as 766, which has a head 768 and a threaded shank 770. A threaded bore 758 threadedly receives the threaded shank 770. As known to those skilled in the art, the threaded retainer 766 securely affixes the cutting insert 150 and the shim 704 to the holder body 706. The threaded shank 770 has a diameter “BB”. The gap 772 between the circumferential edge 754 of the bowl section 752 and the threaded shank 770 has a dimension “CC”. As will be described hereinafter, the coolant travels through the interior coolant passage 740 whereby it exits the interior coolant passage 740 via the opening provided by the gap 772.
Referring to
The shim 704 has a peripheral edge 786, which has a beveled portion 787 on the first side surface 780. The peripheral edge 786 defines a first arcuate notch (or scallop) 788, a second arcuate notch (or scallop) 790, and a third arcuate notch (or scallop) 792. A first arcuate edge section 794 is between to separate the first arcuate notch 788 and the second arcuate notch 790. A second arcuate edge section 796 is between to separate the second arcuate notch 790 and the third arcuate notch 792. A third arcuate edge section 798 is between to separate the third arcuate notch 792 and the first arcuate notch 788. The first arcuate notch 788 and the second arcuate notch 790 are spaced apart angle “DD”, which is approximately ninety degrees about the peripheral edge 786 of the shim 704. The second arcuate notch 790 and the third arcuate notch 792 are spaced apart angle “EE”, which is approximately one hundred-eighty degrees about the peripheral edge 786 of the shim 704. The third arcuate notch 792 and the first arcuate notch 788 are spaced apart angle “FF”, which is approximately ninety degrees about the peripheral edge 786 of the shim 704. The angular measurements are taken from the centers of the arcuate notches.
The shim 704 contains a cavity 800, which passes between the first side surface 780 and the second side surface 782. The cavity 800 defines a first opening 802 in the first side surface 780. The first opening 802 has an arcuate surface 804, which joins to a pair of opposite converging surfaces 806, 808. The converging surfaces 806, 808 then join to a circular surface 812. The arcuate surface 804, the converging surfaces 806, 808 and the circular surface 812 define the first opening 802 in the first side surface 780.
The cavity 800 defines a second opening 818 in the second surface 782. The second opening 818 has a semi-circular surface 820, which joins to opposite diametrical surfaces 822, 824. Diametrical surfaces 822, 824 are disposed apart by an angle “HH”, which is equal to about one hundred-eighty degrees. The diametrical surfaces 822, 824 join to a semi-circular surface 826. The semi-circular surface 820, the opposite diametrical surfaces 822, 824, and the semi-circular surface 826 define the second opening 818.
In essence, the first opening 802 and the second opening 818 are coextensive, except for the barriers 830, 840 (see
As mentioned hereinabove, when in an assembled condition wherein the first side surface 780 contacts the cutting insert 150, there is a first level of coolant flow to the cutting insert 150 through the shim 704. An arrangement wherein the first side surface 780 of the shim 704 contacts the bottom surface of the cutting insert 150 occurs in a turning application, as well as in a facing application. However, as will become apparent hereinafter, the orientation of the shim is different for the two operations.
Referring to
More specifically, in the turning application, the bottom surface of the cutting insert 150 rests securely on and draws tightly against the first side surface 780 of the shim 704.
In operation, coolant exits the interior coolant passage 740 via the gap 772 between the threaded retainer shank 770 and the circumferential edge 754 of the bowl section 752. The coolant then passes into the cavity 800 of the shim 704 through the second opening 818 defined in the second side surface 782. Some coolant travels directly to the first opening 802 and some coolant impinges against the barriers 830, 840 and then passes through the first opening 802. The coolant exiting (see arrows U in
Referring to
More specifically, in the facing application, the bottom surface of the cutting insert 150 rests securely on and draws tightly against the first side surface 780 of the shim 704.
In the facing operation, the general coolant flow is like that in the turning operation. Coolant exits the interior coolant passage 740 via the gap 772 between the threaded retainer shank 770 and the circumferential edge 754 of the bowl section 752. The coolant then passes into the cavity 800 through the second opening 818 defined in the second side surface 782. Some coolant travels directly to the first opening 802 and some coolant impinges against the barriers 830, 840 and then passes through the first opening 802. The coolant exiting (see arrows W in
As also mentioned above, when in an assembled condition wherein the second side surface 782 contacts the cutting insert 150, there is a second level of coolant flow to the cutting insert 150 through the shim 704. An arrangement wherein the second side surface 782 of the shim 704 contacts the bottom surface of the cutting insert 150 occurs in a profiling application.
Referring to
In a profiling application, the bottom surface of the cutting insert 150 rests securely on and draws tightly against the second side surface 782 of the shim 704. More specifically, in the profiling application, the bottom surface of the cutting insert 150 rests securely on and draws tightly against the second side surface 782 of the shim 704.
Coolant exits the interior coolant passage 740 via the gap 772 between the threaded retainer shank 770 and the circumferential edge 754 of the bowl section 752. The coolant then passes into the cavity 800 through the first opening 802. Some coolant travels directly to the second opening 818 and some coolant impinges against the barriers 830, 840 and then passes through the second opening 818. The coolant exiting (see arrows Y in
In the typical chipforming material removal operation, the volume of coolant flowing out of the interior coolant passage 740 is more than sufficient to supply the cutting insert 150 no matter how many interior coolant passages 740 are in communication with the coolant supply. This means that the second level of coolant flow, which is a supply to four distinct interior coolant passages 300, is greater than the first level of coolant flow, which is a supply to two distinct interior coolant passages 300.
It is apparent that the cutting insert-shim-holder body assembly 700 provides a structure that can accommodate different chipforming material removal operations. By merely orienting the shim relative to the cutting insert and the coolant inlet in the seat surface, the coolant flows in a specific pattern to accommodate a specific corresponding chipforming material removal operation.
Referring to
Shim 850 has a first side surface 852 (see
The shim 850 contains a central aperture 878, which is generally cylindrical in geometry. The shim 850 further contains an arcuate opening 880, which is radially outward of the central aperture 878. The arcuate opening 880, which opens to the first side surface 852, has opposite arcuate surfaces 884 and 886 and opposite radial edges 888, 890. The arcuate opening 880 extends about ninety degrees around the peripheral edge of the shim 850.
The arcuate opening 880 passes through to the second side surface 854 of the shim 850. The opening that opens to the second side surface 854 of the shim 850 includes the arcuate opening 880, as well as arcuate cut-outs (894, 896) that extend past the opposite radial ends 888, 890. The combination of the arcuate opening 880 and the arcuate cut-outs (894, 896) extends about one hundred eighty degrees around the peripheral edge of the shim 850.
Referring to
The patents and other documents identified herein are hereby incorporated by reference herein. Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or a practice of the invention disclosed herein. It is intended that the specification and examples are illustrative only and are not intended to be limiting on the scope of the invention. The true scope and spirit of the invention is indicated by the following claims.
This patent application is a continuation-in-part of pending U.S. patent application Ser. No. 12/797,249 filed on Jun. 9, 2010 for CUTTING INSERT WITH INTEGRAL COOLANT DELIVERY AND CUTTING ASSEMBLY USING THE SAME by Joseph V. Nelson, Paul D. Prichard, Linn R. Andras, Thomas O. Muller, and Brad D. Hoffer, which is a continuation-in-part of pending U.S. patent application Ser. No. 11/940,394 filed on Nov. 15, 2007 for MILLING CUTTER AND MILLING INSERT WITH CORE AND COOLANT DELIVERY by Paul D. Prichard and Linn R. Andras, which is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/654,833 filed on Jan. 18, 2007 for MILLING CUTTER AND MILLING INSERT WITH COOLANT DELIVERY by Paul D. Prichard and Linn R. Andras. Applicants hereby claim the benefit of the priority of the above three above-mentioned pending United States patent application, i.e., U.S. patent application Ser. No. 12/797,249 filed Jun. 9, 2010, U.S. patent application Ser. No. 11/940,394 filed on Nov. 15, 2007 and U.S. patent application Ser. No. 11/654,833 filed on Jan. 18, 2007. Applicants hereby incorporate by reference herein the entirety of each of the above-mentioned three pending United States patent application, i.e., U.S. patent application Ser. No. 12/797,249 filed Jun. 9, 2010, U.S. patent application Ser. No. 11/940,394 filed on Nov. 15, 2007 and U.S. patent application Ser. No. 11/654,833 filed on Jan. 18, 2007.
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| Number | Date | Country | |
|---|---|---|---|
| 20110020072 A1 | Jan 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12797249 | Jun 2010 | US |
| Child | 12873516 | US | |
| Parent | 11940394 | Nov 2007 | US |
| Child | 12797249 | US | |
| Parent | 11654833 | Jan 2007 | US |
| Child | 11940394 | US |
