Cutting insert and cutting tool
Abstract
The present invention provides a cutting insert an indexable cutting insert, for use in a cutting tool for milling operations. The cutting insert is generally rhomboidal in shape having a peripheral side surface extending between and perpendicular to the two opposing end surfaces. A cutting edge section is associated with each end surface and comprises first and second cutting edges merging at a corner cutting edge. The two first cutting edges associated with each end surface, form a non-zero first angle with respect to a median plane of the cutting insert. The peripheral side surface comprises four generally flat major side surfaces, two diametrically opposing radiused corner side surfaces, and two diametrically opposing generally flat minor side surfaces. Each end surface is provided with a flat end region. The flat end regions are parallel and form axially outermost protruding regions of the cutting insert.

Term
Term ended
Expired 3 November 2023, 2.9 years ago.
- Priority
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- Granted
- Expired
- Today
9 claims: 1 independent, 8 dependent
- 1An indexable cutting insert (10), for use in a cutting tool (44) for milling operations, comprising:two identical generally rhomboidal opposing end surfaces (12);a peripheral side surface (14) extending between the two opposing end surfaces (12), the peripheral side surface (14) being perpendicular to a median plane ( M ) of the cutting insert (10) and comprising six component side surfaces, four of the component side surfaces being generally flat major side surfaces (26) and two of the component side surfaces being diametrically opposing radiused corner side surfaces (28), each corner side surface (28) being located between and merging with the two major side surfaces (26);two first cutting edges (32) and two second cutting edges (34) associated with each end surface (12), each first cutting edge (32) forming a non-zero first angle with respect to the median plane ( M ) and each second cutting edge (34) forming a non-zero second angle with respect to the median plane ( M ), the two first cutting edges (32) associated with a given end surface (12) being skew to each other and being located in associated major side surfaces (26) that are parallel to each other, and the two second cutting edges (34) associated with a given end surface (12) being skew to each other and being located in associated major side surfaces (26) that are parallel to each other;two corner cutting edges (36) associated with each end surface (12), each corner cutting edge (36) merging with one first cutting edge (32) and with one second cutting edge (34) and forming therewith a continuous cutting edge section (18);two opposing flat end regions (24), one flat end region associated with each end surface (12), the median plane ( M ) being parallel to each flat end region;a through bore (44) extending between the flat end regions (24), the through bore (44) having an axis defining an axial direction of the cutting insert, the flat end regions (24) forming axially outermost protruding regions of the cutting insert (10).
- 8A cutting tool (44) for milling operations, the cutting tool having an axis of rotation (A) and comprising:a plurality of indexable cutting inserts (10) in accordance with claim 1, each cutting insert (10) being seated in an insert pocket with an operative first cutting edge (32') positioned at a given axial rake angle (γ).
Independent claims2
27 paragraphs in 5 sections, as filed
FIELD OF THE INVENTION
0001This invention relates to a cutting insert and a cutting tool for metal cutting operations in general and for cutting small radius internal corners in particular and also for ramp down cutting operations.
BACKGROUND OF THE INVENTION
0002Such cutting tools, generally in the form of end mills and shell mills, are used in metal working applications in the manufacture of dies and molds and other structures having complex geometrical surfaces and extended shoulders. In these applications it is often required to produce internal corners of small radius, sometimes smaller than 0.5 mm. Generally, complex geometrical surfaces are produced in metal workpieces using ball nose end mills, or end mills with round cutting inserts. There are no ball nose end mills having replaceable cutting inserts that can produce internal corners having a radius as small as 0.5 mm. Also, there are no round cutting inserts having radii as small as 0.5mm.
0003When working a large surface of a workpiece, the most economical approach is to use cutting tools having large radii cutting inserts in order to produce the main large scale features of the surface and then to use tools having small radius cutting capability for producing small scale features and for reducing the radii of internal corners where needed.
0004Cutting inserts having small radius cutting capability are usually rhomboidal in shape, having a cutting nose (or corner) with the required small radius. An example of such a cutting insert and associated cutting tool is disclosed in <patcit id="pcit0001" dnum="EP1157768A1"><text>EP 1 157 768 A1</text></patcit>. The cutting insert has a positive geometry and therefore only two cutting corners.
0005<patcit id="pcit0002" dnum="DE2811086A1"><text>DE 28 11 086 A1</text></patcit> discloses an indexable cutting insert for rotary milling machines, consisting of a parallelepiped-shaped body with a parallelogram-shaped cross-section with two faces lying opposite each other, with two edge faces lying between said faces and two front faces lying opposite each other, whereby the faces and the front faces intersect each other and form principal cutting edges, wherein the faces (11, 12) and the edge faces intersect at an angle of less than 90° and form edges (17, 18), a part whereof forms an ancillary cutting edge, whereas the remaining part is provided in the form of a recess (21, 22), which is designed to hold a clamping element, whereby each recess is made by means of smooth faces (23, 24), the extension whereof is limited by edges running parallel to the ancillary cutting edge.
0006It is an object of the present invention to provide a cutting insert having four cutting corners capable of cutting small radii internal corners in a workpiece. It is also an object of the present invention to provide a cutting tool such as an end mill capable of seating such a cutting insert.
0007It is a further object of the present invention to provide a cutting insert and a cutting tool, of the aforementioned kind, that is also capable of carrying out ramp down cutting operations.
SUMMARY OF THE INVENTION
0008The cutting insert and cutting tool of the present invention are designed for cutting metals and composites. Typically, the cutting insert is manufactured by form-pressing and sintering carbide powders. However, injection-molding techniques can also be used.
0009In accordance with the present invention there is provided an indexable cutting insert, for use in a cutting tool for milling operations, comprising the features of claim 1.
0010If desired, the first angle is different from the second angle.
0011Further if desired, the first angle is equal to the second angle.
0012If desired, the peripheral side surface further comprises two diametrically opposing generally flat minor side surfaces, each minor side surface being located between two major side surfaces.
0013Quite generally, the cutting insert has 180° rotational symmetry about each of first, second and third axes of rotational symmetry, the first axis being perpendicular to the flat end regions and coinciding with the axis of the through bore, the second axis passing through the minor side surfaces and the third axis passing through the corner side surfaces.
0014Preferably, each end surface comprises a rake surface associated with each cutting edge section, the rake surface extending from the cutting edge section inwards towards the median plane.
0015Further preferably, the rake surface merges along a join with a rise that slopes upwardly from the join away from the median plane.
0016Yet further preferably, the rise associated with a given end surface extends from the join to the flat end region of the given end surface.
0017Also in accordance with the present invention there is provided a cutting tool for milling operations, the cutting tool having an axis of rotation A and comprising: <ul id="ul0001" list-style="none" compact="compact"><li>a plurality of indexable cutting inserts in accordance with the present invention, each cutting insert being seated in an insert pocket with an operative first cutting edge positioned at a given axial rake angle (γ).</li></ul>
0018Typically, the axial rake angle (γ) lies in the range of 0° to 5°.
BRIEF DESCRIPTION OF THE DRAWINGS
0019For a better understanding the invention will now be described, by way of example only, with reference to the accompanying drawings in which: <ul id="ul0002" list-style="none" compact="compact"><li><b>Fig. 1</b> is a perspective view of a cutting insert in accordance with the present invention;</li><li><b>Fig. 2</b> is an end view of the cutting insert shown in Fig. 1;</li><li><b>Fig. 3</b> is a side view of the cutting insert shown in Fig. 1;</li><li><b>Fig. 4</b> is another side view of the cutting insert shown in Fig. 1;</li><li><b>Fig. 5A</b> is a partial cross-sectional view of the cutting insert shown in Fig. 2 taken along the line VA-VA;</li><li><b>Fig. 5B</b> is a partial cross-sectional view of the cutting insert shown in Fig. 2 taken along the line VB-VB;</li><li><b>Fig. 5C</b> is a partial cross-sectional view of the cutting insert shown in Fig. 2 taken along the line VC-VC;</li><li><b>Fig. 5D</b> is a partial cross-sectional view of the cutting insert shown in Fig. 2 taken along the line VD-VD; and</li><li><b>Fig. 6</b> is a side view of a cutting tool in accordance with the present invention.</li></ul>
DETAILED DESCRIPTION OF THE INVENTION
0020Attention is first drawn to Figs. 1 to 4 showing an indexable cutting insert <b>10</b> in accordance with the present invention. The cutting insert <b>10</b> has two identical generally rhomboidal opposing end surfaces <b>12</b> with a peripheral side surface <b>14</b> extending therebetween. Each end surface <b>12</b> is bounded by a peripheral edge <b>16</b> at which the end surface <b>12</b> and the peripheral side surface <b>14</b> merge. Each peripheral edge <b>16</b> comprises two continuous cutting edge sections <b>18</b> separated by two non-cutting edge sections <b>20.</b> Adjacent each cutting edge section <b>18</b> is a groove <b>22</b> which borders a generally flat end region <b>24</b> of the end surface <b>12.</b> Therefore, the cutting insert <b>10</b> has two opposing flat end regions <b>24.</b> The two opposing flat end regions <b>24</b> are parallel to each other and to a median plane <b>M</b> of the cutting insert <b>10</b> which is located midway between the flat end regions <b>24.</b>
0021The peripheral side surface <b>14</b> is perpendicular to the median plane <b>M</b> and comprises eight component side surfaces, namely, four generally flat major side surfaces <b>26,</b> two diametrically opposing radiused corner side surfaces <b>28</b> and two diametrically opposing generally flat minor side surfaces <b>30.</b> Each minor side surface <b>30</b> is located between and merges with the two major side surfaces <b>26.</b> Similarly, each corner side surface <b>28</b> is located between and merges with the two major side surfaces <b>26.</b>
0022Each cutting edge section <b>18</b> comprises a first cutting edge <b>32,</b> a second cutting edge <b>34</b> and a corner cutting edge <b>36</b> at which the first and second cutting edges <b>32, 34</b> merge. Each first cutting edge <b>32</b> extends away from the corner cutting edge <b>36</b> with which it merges to an adjacent non-cutting edge section <b>20</b> and towards the median plane <b>M.</b> The first cutting edge <b>32</b> is preferably straight and is inclined at a non-zero first angle <b>θ1</b> with respect to the median plane <b>M.</b> Similarly, each second cutting edge <b>34</b> extends away from the corner cutting edge <b>36</b> with which it merges to an adjacent non-cutting edge section <b>20</b> and towards the median plane <b>M.</b> The second cutting edge <b>34</b> is preferably straight and is inclined at a non-zero second angle <b>θ2</b> with respect to the median plane <b>M.</b> The first and second angles <b>θ1, θ2</b> can be equal or non-equal to each other. The two first cutting edges <b>32</b> associated with a given end surface <b>12</b> being skew to each other and being located in associated major side surfaces <b>26</b> that are parallel to each other, and the two second cutting edges <b>34</b> associated with a given end surface <b>12</b> being skew to each other and being located in associated major side surfaces <b>26</b> that are parallel to each other. The flat minor side surfaces <b>30</b> form a pair of diametrically opposed flat corners of the cutting insert <b>10.</b>
0023Each end surface <b>12</b> comprises a rake surface <b>38</b> adjacent each cutting edge section <b>18.</b> The rake surface <b>38</b> extends from the cutting edge section <b>18</b> inwards towards the median plane <b>M</b> to a join <b>40</b> where it merges with a rise <b>42</b> that slopes from the join <b>40</b> away from the median plane <b>M</b> to the flat end region <b>24.</b> As can be seen in Figs. 2 and 5A to 5D, the rake surface <b>38</b> adjacent the first cutting edge <b>32</b> has a variable length (measured perpendicular to the first cutting edge <b>32)</b> along the cutting edge. It has a first length <b>L1</b> (at cross-section VA-VA) near to an adjacent non-cutting edge <b>20</b> and a second length <b>L2</b> (at cross-section VB-VB) near to an adjacent corner cutting edge <b>36,</b> where the second length <b>L2</b> is greater than the first length <b>L1</b> and continuously varies between these two values along the cutting edge. On the other hand, the rake surface <b>38</b> adjacent with the second cutting edge <b>34</b> has a third length <b>L3</b> which is approximately constant along the length of the second cutting edge <b>34.</b> For the sake of clarity it is pointed out that the line shown as the join <b>40</b> in Figs. 1 and 2 is only illustrative. It will be apparent from Figs. 5A to 5D that the join <b>40</b> is actually a curved region of finite width forming part of the groove <b>22.</b>
0024The cutting insert <b>10</b> has 180° rotational symmetry about first, second and third axes of rotational symmetry <b>R1, R2, R3</b>. The first axis <b>R1</b> is perpendicular to the flat end regions <b>24,</b> the second axis <b>R2</b> passes through the minor side surfaces <b>30</b> and the third axis <b>R3</b> passes through the corner side surfaces <b>28.</b> The second and third axes <b>R2, R3</b> lie in the median plane <b>M</b> and the first axis <b>R1</b> is perpendicular to the second and third axes <b>R2, R3.</b> The cutting insert <b>10</b> is provided with a through bore <b>44</b> having as axis the first axis of rotational symmetry <b>R1.</b> The through bore <b>44</b> extends between the flat end regions <b>24</b> and defines an axial direction of the cutting insert. It should be noted from the side views of the cutting insert <b>10</b> in Figs. 3 and 4 that the cutting insert <b>10</b> is widest in the axial direction of the cutting insert <b>10</b> at regions where the flat end regions <b>24</b> are directly opposite each other. In other words, the flat end regions <b>24</b> form axially outermost protruding regions of the cutting insert <b>10.</b> Typically, the radius <b>R</b> of the corner cutting edges <b>36</b> is in the range 0.2 to 6.35 mm.
0025Attention is now drawn to Fig. 6 showing a cutting tool <b>46</b> in accordance with the present invention. The cutting tool <b>46</b> is an end mill capable of cutting small radii internal corners in a workpiece <b>48</b> in accordance with the value of the radius <b>R</b> of the corner cutting edges <b>36.</b> The cutting tool <b>46</b> is also capable performing ramp down cutting operations by means of the second cutting edge <b>34.</b> The cutting tool <b>46</b> has an axis of rotation <b>A</b> and comprises a cutter body <b>50</b> with the indexable cutting inserts <b>10</b> in accordance with the present invention seated in insert pockets <b>52</b> of the cutter body <b>50.</b> Each cutting insert <b>10</b> has two effective operative cutting edges, one operative first cutting edge <b>32'</b> and one operative second cutting edge <b>34',</b> and one operative corner cutting edge <b>36'.</b> The insert pockets <b>52</b> are so designed that the operative first cutting edge <b>32'</b> is positioned with and an axial rake angle γ of typically close to 0° but generally no larger than 5°. Since the operative first cutting edge <b>32'</b> makes a first angle <b>θ1</b> with respect to the median plane <b>M</b> of the cutting insert <b>10</b> an inherent back clearance a typically close to <b>θ1</b> but generally no less than <b>θ1</b>-5° is obtained between the cutting insert <b>10</b> and portions of the surface of the workpiece <b>48</b> adjacent the operative second cutting edge <b>34'.</b>
0026The operative first cutting edge <b>32'</b> can be divided into a leading portion adjacent the operative cutting corner <b>36',</b> a trailing portion distal the operative cutting corner <b>36'</b> and an intermediate portion therebetween. In cutting operations involving the production of internal small radius corners in a workpiece, such as in the manufacture of dies and molds, it is mainly the operative cutting corner <b>36'</b> that is involved in the cutting operation. It will be appreciated that even if the leading portion of the operative first cutting edge <b>32'</b> also participates in such cutting operations, the groove <b>22</b> should extend adjacent the whole length of the operative first cutting edge <b>32'</b> from the leading portion to trailing portion, in order to provide clearance between the end surface <b>12</b> adjacent the trailing portion of the operative first cutting edge <b>32'</b> and the workpiece <b>48.</b> It will also be appreciated that if instead of the flat minor side surfaces <b>30</b> the cutting insert were to have corners protruding beyond the flat minor side surfaces <b>30,</b> then that part of the cutting insert protruding beyond the flat minor side surfaces <b>30</b> associated with the operative first cutting edge <b>32'</b> would disadvantageously enter the cutting circle defined by the operative first cutting edge <b>32'.</b> This is especially important when working in the region of extended shoulders and also in ramp up cutting operations.
0027Although the present invention has been described to a certain degree of particularity, it should be understood that various alterations and modifications can be made within the scope of the appended claims.
Contents5
5 sheets
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Every citation, both ways
| Document | Relation | Office | Cited during |
|---|---|---|---|
| US12502716B2 | Cited by | United States of America | Applicant |
| EP4151344A4 | Cited by | European Patent Office (EPO) | Search report |
| WO2017129423A1 | Cited by | World Intellectual Property Organization (WIPO) | International search |
| EP1002608A | Cites | European Patent Office (EPO) | – |
| DE2015059A | Cites | Germany | – |
| DE2811086A | Cites | Germany | – |
| GB1084975A | Cites | United Kingdom | – |
| US5839858A | Cites | United States of America | – |
28 members in 17 offices
Priority claims3
| Document | Office | Kind | Date |
|---|---|---|---|
| 15309302 | Israel | – | |
| 15309302 | Israel | A | |
| 0300909 | Israel | W |
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| KR20050086531A | Republic of Korea | A | |
| EP1575728A1 | European Patent Office (EPO) | A1 | |
| US2005214080A1 | United States of America | A1 | |
| BR0316527A | Brazil | A | |
| PL375482A1 | Poland | A1 | |
| CN1717291A | China | A | |
| RU2005116022A | Russian Federation | A | |
| JP2006507138A | Japan | A | |
| ZA200504155B | South Africa | B | |
| US7147407B2 | United States of America | B2 | |
| EP1575728B1This record | European Patent Office (EPO) | B1 | |
| AT381404T | Austria | T | |
| ATE381404T1 | Austria | T1 | |
| KR100796914B1 | Republic of Korea | B1 | |
| DE60318245D1 | Germany | D1 | |
| PT1575728E | Portugal | E | |
| ES2295655T3 | Spain | T3 | |
| DE60318245T2 | Germany | T2 | |
| AU2003278583B2 | Australia | B2 | |
| RU2348491C2 | Russian Federation | C2 | |
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Numbers
- Publication
- 1575728
- Application
- 37698792
Titles3
- German
- WERKZEUGEINSATZ UND WERKZEUG
- English
- CUTTING INSERT AND CUTTING TOOL
- French
- PLAQUETTE DE COUPE ET OUTIL DE COUPE
Classification
- CPC, 17
- B23C5/109
- B23C5/202
- B23C2200/0416
- B23C2200/0438
- B23C2200/085
- B23C2200/086
- B23C2200/125
- B23C2200/201
- B23C2200/246
- B23C2200/361
- B23C2200/366
- B23C2210/402
- Y10T407/23
- Y10T407/1924
- Y10T407/1936
- Y10T407/1962
- B23C2200/326
- IPC, 3
- B23C5 20
- B23C
- B23C5 10
Designated states27
- Contracting states, 27
- Austria
- Belgium
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