Cutting insert with internal coolant delivery and cutting assembly using the same

This patent application is pending US Patent Application No. 11 / by Paul D. Prichard and Linn R. Andras, filed November 15, 2007, entitled Milling and Milling Inserts with Core and Coolant Delivery. This is a partial continuation application of the specification of No. 940,394. U.S. Patent Application No. 11 / 940,394 is filed on January 18, 2007 by Paul D. Prichard and Linn R. A partial continuation of Andras' US Patent Application No. 11 / 654,833, which is co-pending the name Milling and Milling Inserts with Coolant Service. Applicants filed the above two pending U.S. patent applications, namely U.S. Patent Application No. 11 / 940,394 filed on November 15, 2007 and U.S. Patent Application No. 11 filed on January 18, 2007. 11 / 654, 833 claims the priority of the specification here. Applicants further filed the above two mentioned pending US patent applications, namely US Patent Application No. 11 / 940,394, filed November 15, 2007, and January 18, 2007. The entire US Patent Application No. 11 / 654,833 is incorporated herein by reference in its entirety.

The present invention relates to a cutting insert having internal coolant delivery and an assembly that uses the cutting insert for use in removing chip formation of material from a workpiece. In particular, the present invention provides coolant at the interface between an adjacent cutting insert and the workpiece (ie, the interface between the insert and the chip) in order to reduce excessive heat at the interface between the insert and the chip. With respect to cutting inserts for use in chip forming material removal operations and assemblies that use cutting inserts with improved delivery.

In chip forming material removal operations (eg milling operations, turning operations, etc.), the interface between the cutting insert and the location where the chips are removed from the workpiece (ie, the interface between the insert and the chips). Heat is generated in. It is well known that excess heat at the interface between the insert and the chips can adversely affect (ie reduce or shorten) the effective tool life of the cutting insert. As can be understood, shortening the effective tool life increases operating costs and reduces overall production efficiency. Therefore, there is a very obvious advantage in reducing heat at the interface between the insert and the chips.

US Pat. No. 6,053,669, entitled Chip Forming Cutting Insert with Internal Cooling by Lagerberg, describes the importance of reducing heat at the interface between the insert and the chip. Lagerberg notes that cutting inserts made of cemented carbide reduce their resistance to plastic deformation when they reach a certain temperature. Decreased resistance to plastic deformation increases the risk of cutting insert breakage. U.S. Pat. No. 5,775,854, named Wertheim's Metal Cutting Tool, points out that increasing machining temperatures reduce the hardness of cutting inserts. As a result, the wear of the cutting insert increases.

Other patent documents disclose various methods or systems for delivering coolant to the interface between the insert and the chips. For example, US Pat. No. 7,625,157, entitled Milling and Milling Inserts with Coolant Delivery by Prichard et al., relates to cutting inserts that include a cutting body with a central coolant inlet. The cutting insert also includes a displaceable diversion controller. The diversion regulator has a coolant trough that diverts the coolant to a specific cutting position. US Patent Application Publication No. 2008-0175678A1 entitled Metal Cutting System for Effective Coolant Delivery by Prichard et al. Works with superstructures and / or shims to facilitate delivery of coolant to the cutting position. Regarding cutting inserts.

U.S. Pat. No. 6,045,300, named Tool Holder with Antoun's integrated coolant flow path and replaceable nozzle, provides high pressure and mass delivery of coolant to handle heat at the interface between inserts and chips. It discloses its use. U.S. Pat. No. 6,652,200, named Tool Holder with Kraemer's Coolant System, discloses the groove between the cutting insert and the top plate. The coolant flows through the groove and copes with the heat at the interface between the insert and the chips. U.S. Pat. No. 5,901,623, named Hong's cryogenic cutting, discloses a coolant delivery system for applying liquid nitrogen to the interface between inserts and chips.

In chip forming and material removal operations, it is very clear that high operating temperatures at the interface between inserts and chips can have an unfavorable effect on effective tool life due to premature breakage and / or excessive wear. is there. A chip-forming material that improves the delivery of coolant to the interface between the cutting insert and the workpiece (ie, the interface between the insert and the chip) (where the chip is generated on the workpiece). It would be highly desirable to provide cutting inserts for use in removal operations. There will be many benefits associated with improving the delivery of coolant to the interface between the insert and the chips.

In the chip forming material removal operation, chips generated from the workpiece may adhere to the surface of the cutting insert (for example, by welding). Accumulation of chips on such cutting inserts is an undesired event that can adversely affect the performance of the cutting inserts and thus the overall material removal operation. To provide a cutting insert for use in chip forming material removal operations with improved coolant delivery to the insert-chip interface to improve lubrication at the insert-chip interface. Would be very desirable. As a result of improved lubrication at the interface between the insert and the chips, the tendency of chips to adhere to the cutting insert is reduced.

In the chip forming material removing work, when chips adhere to the cutting insert, there may be a case where the chips do not come out from the region of the boundary surface between the insert and the chips. If the chips do not exit the area of the interface between the insert and the chips, the chips may be recut. Recutting chips that have already been removed from the workpiece is not desirable for milling inserts. The flow of coolant to the interface between the insert and the chips facilitates the discharge of chips from the interface between the insert and the chips, thereby minimizing the possibility of the chips being recut. It is very much possible to provide cutting inserts used in chip forming material removal operations that improve the delivery of coolant to the interface between the insert and the chips and reduce the likelihood that the chips will be recut. Would be desirable. As a result of improving the flow of coolant to the interface between the insert and the chips, the chips are better discharged from the vicinity of the interface, and as a result the possibility of recutting the chips is reduced.

There are several factors that can affect the degree of coolant delivered to the interface between the insert and the chips. For example, the dimensions of the structure that feeds the coolant to the cutting insert can be a limiting factor on the degree of coolant supplied to the cutting insert. Therefore, in order to maximize the flow of coolant to the cutting insert, it would be highly desirable to provide a supply hole equal to or greater than the inlet in the cutting insert. It would be highly desirable to provide a cutting insert that delivers coolant to a single discontinuous cutting position through two or more coolant passages. In addition, to customize the delivery of coolant, the use of irregular coolant passages and variable areas of inlets and outlets within the cutting insert to allow such customization. One such feature is to provide various diversion angles for the coolant, which can range from about 10 degrees to about 60 degrees.

It is advantageous for the coolant to enter the cutting insert through the holder in order to improve the delivery of the coolant. This can include the use of an external coolant supply or an internal coolant supply.

When it comes to manufacturing cutting inserts, it may be advantageous to use multiple parts that form the cutting insert together. For example, in some cases, a cutting insert formed from a cutting edge base and core may extend life because only the base needs to be replaced after reaching the end of effective tool life. .. In such an arrangement, the core is detachably joined to the base so that the core is reused when the base is worn. The base and core can be joined to each other by co-sintering, brazing and / or gluing. As an alternative, the base and core can be brought into contact with each other, even if they are in close contact, with separate components, without joining them together as an integral member. In addition, to improve performance, the base and core can be from the same or different materials depending on the particular application.

Certain advantages may exist if a preferred embodiment of the cutting insert exhibits a round geometry. For example, if the cutting insert has a round geometry, there is no need to index the assembly of multiple components, eg the base and core. Since the round cutting insert has no hand, it can be used with left hand, right hand and without hand. In contour turning, up to 50% of the round cutting insert can function as a cutting edge. Also, the round cutting insert is available to engage the anti-rotation feature.

<p> In one of its forms, the present invention is a metal cutting insert useful in chip formation and material removal from workpieces. The metal cutting insert includes a metal cutting insert body, and the metal cutting insert body includes a cutting edge having at least one discontinuous cutting position. The cutting insert body further includes a separate internal coolant flow path that communicates with the discontinuous cutting position. A separate internal coolant flow path has a coolant flow path inlet that defines the coolant flow path inlet cross-sectional area, a coolant flow path discharge port that defines the coolant flow path discharge port cross-sectional area, and an axial coolant flow path length. .. A separate internal coolant flow path defines the coolant flow cross-sectional area along its axial coolant flow path length. The cross-sectional area of the coolant flow path inlet is almost the same as the cross-sectional area of the coolant flow path discharge port. The geometry of the coolant flow cross-sectional area varies along the length of the coolant flow path in the axial direction.</p><p> In its alternative form, the invention is a metal cutting assembly useful in chip formation and material removal from workpieces, where the coolant source supplies the coolant to the metal cutting assembly. The metal cutting assembly includes a holder with pockets. The pocket presents a flat surface containing the coolant port. The coolant port has a coolant port cross-sectional area and communicates with the coolant source. The pocket accepts metal cutting inserts. The metal cutting insert includes a metal cutting insert body, and the metal cutting insert body includes a cutting edge having at least one discontinuous cutting position. The metal cutting insert body further includes a separate internal coolant flow path that communicates with the discontinuous cutting position. A separate internal coolant flow path has a coolant flow path inlet that defines the coolant flow path inlet cross-sectional area, a coolant flow path discharge port that defines the coolant flow path discharge port cross-sectional area, and an axial coolant flow path length. .. A separate internal coolant flow path defines the coolant flow cross-sectional area along its axial coolant flow path length. The cross-sectional area of the coolant flow path inlet is almost the same as the cross-sectional area of the coolant flow path discharge port. Geometric shape The coolant flow cross-sectional area varies along the axial coolant flow path length.</p><p> The following is a brief description of the drawings that form part of this patent application.</p>

<figref num="1">Of one particular embodiment of a milling assembly in which the milling assembly has a milling body carrying multiple cutting inserts, which is five cutting inserts in this particular embodiment, and the pockets carry one cutting insert. It is an isometric view.</figref><figref num="1A">It is a front view of one of the pockets of the milling assembly of FIG. 1 in which the pocket does not have a cutting insert in it.</figref><figref num="2">FIG. 3 is an isometric view of a particular embodiment of a KM® holder body carrying a cutting insert in a pocket but not in the pocket. KM is a registered trademark of Kennametal Inc., Latrobe, Pennsylvania 15650.</figref><figref num="2A">It is a top view of the pocket of the KM (registered trademark) holder body of FIG. 2 which does not have a cutting insert inside.</figref><figref num="3">An isometric view of a particular embodiment of a threaded toolholder body carrying a cutting insert in the pocket but not in the pocket, connecting between the coolant source and the coolant drain port in the plane of the pocket. Is shown in a schematic form.</figref><figref num="3A">It is the top view of the pocket which does not include a cutting insert in the screw type tool holder body of FIG.</figref><figref num="4">It is an isometric view of the base member of a cutting insert which shows the rake face and the flank surface of a base member.</figref><figref num="4A">It is an enlarged view of a part of the base member of FIG. 4 which shows the flow path defined between two ribs in detail.</figref><figref num="5">It is an isometric view of the base member of a cutting insert which shows the bottom surface and the flank surface of a cutting insert.</figref><figref num="6">It is an isometric view of the core member of a cutting insert which shows the top surface and the side surface of a core member.</figref><figref num="7">It is an isometric view of the core member of cutting which shows the bottom surface and the side surface of a core member.</figref><figref num="7A">It is an isometric view of a base member and a core member. The core member is disassembled from the base member.</figref><figref num="8">FIG. 5 is an isometric view of an assembly of a cutting insert base member and a core member showing a rake face and a flank surface of the cutting insert.</figref><figref num="9">It is an isometric view of the bottom surface of a cutting insert.</figref><figref num="10">It is an enlarged view of a part of the bottom surface which shows the position of the joint between a base member and a core member.</figref><figref num="11">FIG. 5 is a bottom view of a particular embodiment of the cutting insert of FIG.</figref><figref num="12">FIG. 5 is a side view of a particular embodiment of the cutting insert of FIG.</figref><figref num="13">It is an isometric view with a part of the cutting insert and holder removed to show the delivery of coolant to discontinuous cutting positions.</figref><figref num="14">FIG. 5 is a top view of a particular embodiment of a cutting insert.</figref><figref num="14A">FIG. 6 is an enlarged view of a portion of sectional view 14B showing a separate internal coolant passage.</figref><figref num="14B">It is sectional drawing of the cutting insert of FIG. 14 cut along the sectional line 14B-14B.</figref><figref num="15">FIG. 4 is a cross-sectional view of a cutting insert showing a separate internal coolant passage cut along section lines 15-15 of FIG. 14B.</figref><figref num="15A">It is an enlarged view of a part of the cross section of FIG. 15 in the circle shown by 15A showing the geometry of the internal coolant flow path.</figref><figref num="16">FIG. 4 is a cross-sectional view of a cutting insert showing a separate internal coolant passage cut along section line 16-16 of FIG. 14B.</figref><figref num="16A">16 is an enlarged view of a part of the cross section of FIG. 16 showing the geometric shape of the internal coolant flow path in the circle shown by 16A.</figref><figref num="17">FIG. 4 is a cross-sectional view of a cutting insert showing a separate internal coolant passage cut along section line 17-17 of FIG. 14B. Section lines 17-17 are cut at an angle "M" equal to 30.18 degrees.</figref><figref num="18">FIG. 4 is a cross-sectional view of a cutting insert showing a separate internal coolant passage cut along section line 18-18 of FIG. 14B. Section lines 18-18 are cut at an angle "N" equal to 50.10 degrees.</figref><figref num="19A">FIG. 5 is a top view showing a cutting insert in a pocket at one cutting position where the coolant inlet communicates with the coolant source and the platform member engages the flank.</figref><figref num="19B">FIG. 5 is a top view showing a cutting insert in a pocket at an indexed cutting position where the coolant inlet communicates with the coolant source and the platform member engages the flank.</figref><figref num="20">It is a top view of the cutting insert which shows the coolant flow.</figref><figref num="21">It is sectional drawing of the cutting insert which shows the flow of coolant passing through an internal coolant flow path.</figref>

With reference to the drawings, it will be appreciated that the cutting inserts of the present invention as well as the cutting assemblies of the present invention can operate in many different applications. Cutting inserts with internal coolant delivery are used in the removal of chip formation of material from workpieces. In this regard, the cutting insert is located near the interface between the cutting insert and the workpiece (ie, the interface between the insert and the chips) to reduce excess heat at the interface between the insert and the chips. It is intended for use in chip forming material removal operations with improved coolant delivery.

Improved delivery of coolant to the interface between the insert and the chips leads to certain benefits. For example, improved delivery of coolant to the interface between the insert and the chips improves lubrication at the interface between the insert and the chips and reduces the tendency of chips to adhere to the cutting insert. In addition, improving the flow of coolant to the interface between the insert and the chips will result in better drainage of the chips from the vicinity of the interface, thus reducing the likelihood of recutting the chips.

As will be apparent from the following description, the nature of coolant application or injection is such that it is continuous between adjacent, so-called activated internal coolant channels. The coolant actually exits the working coolant flow path in the form of a continuous cone of coolant. By providing such a coolant application, improved delivery of coolant to the interface between the insert and the chips is achieved in the cutting insert.

It will also be appreciated that the internal coolant flow path outlet has a direction in which the coolant hits below the chip surface. Such orientation of the coolant improves the cooling properties, which improves the overall performance of the cutting insert.

The description of a particular application herein does not impose any restrictions on the scope and extent of use of the cutting insert.

In the chip forming material removal operation, the cutting insert 150 engages with the workpiece to remove the material from the workpiece, generally in the form of chips. A material removing operation for removing a material from a workpiece in the form of chips is generally known to those skilled in the art as a chip forming material removing operation. Book by Moltrecht, Machine Shop Practice [Industrial Press Inc., New York, New York (1981)], pages 199-204, discusses chip formation and various types of chips (ie, continuous chips, discontinuous chips, piecewise chips), among others. is there. Moltrecht wrote on pages 199-200, "When the cutting tool first comes into contact with the metal, it pressurizes the metal before the cutting edge. When the tool advances, the metal at the tip of the cutting edge cuts the inside. Stress is applied to the metal particles, causing them to deform and plastically flow along a surface called the shear plane ... If the metal to be cut is of a diffusive type, such as steel, the chips are continuous. It can be peeled off with a typical ribbon ... "[partly]. Moltrecht goes on to describe the formation of discontinuous chips and segmented chips.

As another example, the text on pages 302-315 of ASTE Tool Engineers Handbook, McGraw Hill Book Co., New York, New York (1949) provides a long description of chip formation in the metal cutting process. Page 303 of the ASTE Handbook makes a clear link between chip formation and cutting operations such as turning, milling and drilling. The following patent documents, Battaglia et al., US Pat. No. 5,709,907 (assigned to Kennametal Inc.), Battaglia et al., US Pat. No. 5,722,803 (assigned to Kennametal Inc.), and Oles et al., US Pat. No. 6,161,990. The book (transferred to Kennametal Inc.) describes the formation of chips during material removal operations.

With reference to the drawings, FIG. 1 is an isometric view showing the milling assembly represented by 40 as a whole. The milling assembly 40 has a milling body 42 with a central milling body 44. A plurality of lobes 46 extend radially outward from the central milling body 44. Each lobe 46 has a radial inner edge 46 and a radial outer edge 48. Each lobe 46 further has a distal end 47.

At the distal end 47, each of the lobes 46 includes a pocket 54 having a plane 56. The plane 56 is substantially circular and has a peripheral edge 57. The upright wall 58 is at one end of the plane 56, and the upright wall 58 extends around a portion of the peripheral edge 57.

The plane 56 further includes an arc-shaped opening (arc-shaped notch) 60 extending parallel to a portion of the peripheral edge 57. There is a coolant discharge port 62 that communicates with the arcuate opening 60. The coolant discharge port 62 communicates fluidly with a coolant flow path having a coolant inlet port. Coolant from the coolant source travels from the coolant inlet port into the coolant flow path, exits the coolant discharge port and enters the arcuate opening 60. As described in more detail below, the coolant exiting the arcuate opening 60 is then delivered to the cutting insert 150. The arcuate opening 60 extends approximately 90 degrees and communicates with two adjacent internal coolant channels. The specific structures of the coolant source, coolant flow path and coolant inlet port are not shown, but are similar to the corresponding structures shown and described with the threaded tool holder 114.

Referring to FIG. 1A, as described herein above, the milling body 42 has a pocket 54 and an adjacent upright wall 58. The upright wall 58 includes an anti-rotation platform 70 extending radially inward from the upright wall 58. The anti-rotation platform 70 further has a peripheral edge 72. As described in more detail below, the peripheral pedestal edge 72 exhibits a geometric shape that engages the cutting insert 150, so that the anti-rotation pedestal 70 prevents rotation when the cutting insert 150 is in the pocket 54. To do. Collaboration with the anti-rotation platform 70 and its cutting inserts is in line with the structural lines set forth and described in U.S. Pat. No. 6,238,133 B1 entitled Anti-Rotation Mounting Mechanism for Round Cutting Inserts by DeRoche et al. It is a thing.

The cutting insert 150 can also be used with a holder other than the milling cutter 40 described above. For example, with reference to FIGS. 2 and 2A, the cutting insert 150 can be used with the KM® holder 80. The KM® holder 80 has a distal end 82 and a proximal end 84. The KM® holder 80 further has a pocket 86 having a plane 88 at its distal end 82. Plane 88 has a circular geometry and a peripheral edge 89.

The upright wall 90 is adjacent to the plane 88. The upright wall 90 extends to a portion of the peripheral edge 89 of the plane 88. Plane 88 further includes an arcuate opening 92 that communicates with coolant discharge port 94. Plane 88 further comprises a threaded aperture 96 that facilitates installation of the cutting insert 150 into the KM® holder 80.

Although not shown in the drawings, the KM® holder 80 further has a coolant flow path with a coolant inlet port. The coolant inlet port communicates with the coolant source. As described in more detail below, coolant is delivered from the coolant source, passes through the coolant inlet port, enters the coolant flow path, exits the coolant flow path from the coolant discharge port 94, and enters the arcuate opening 92. .. The coolant then moves from the arcuate opening 92 into the cutting insert 150. The arcuate opening extends approximately 180 degrees and communicates with three adjacent internal coolant channels.

The KM® holder 80 further includes an anti-rotation platform 104 extending radially inward from the upright wall 90. The anti-rotation abutment 104 has a peripheral abutment surface 106. The peripheral platform surface 106 exhibits a geometric shape that engages the cutting insert 150 to prevent rotation when it is in the pocket 86, as described below.

As yet another example of a holder suitable for use with the cutting insert 150, FIGS. 3 and 3A show a threaded tool holder 114 having a tool holder body 116. The tool holder body 116 has a distal end 118 and a proximal end 120. The tool holder body 116 has a pocket 122 at its distal end 118. The pocket 122 exhibits a plane 124 having a substantially cylindrical shape with a peripheral edge 125. There is an upright wall 126 along a portion of the peripheral edge 125 of the plane 124.

The flat surface 124 further includes a threaded aperture 132 that facilitates installation of the cutting insert 150 into the threaded tool holder 114.

Plane 124 includes an arcuate opening 128 communicating with coolant discharge port 130. The threaded tool holder 114 further has a coolant flow path 134. The coolant flow path 134 has a coolant inlet port 135 and a pair of coolant discharge ports 136 and 137. Coolant discharge ports 136 and 137 communicate with the coolant source. As described in more detail below, the coolant is fed from the coolant source 138, passes through the coolant inlet port 135, enters the coolant flow path 134, and exits the coolant discharge flow path 134 through the coolant discharge ports 136, 137. The coolant is then fed into the arcuate opening 128 and into the cutting insert 150, as described in more detail. The arcuate opening extends approximately 180 degrees and communicates with three adjacent internal coolant channels.

It will be appreciated that any one of many different types of fluids or coolants is suitable for use in cutting inserts. Broadly speaking, there are two basic categories of fluids or coolants: oil-based fluids, including straight oils and soluble oils, and chemical fluids, including synthetic and semi-synthetic coolants. Straight oils consist of mineral oils or petroleum base oils and may contain polar lubricants such as fats, vegetable oils and esters, as well as extreme pressure additives of chlorine, sulfur and phosphorus. Soluble oil (also called emulsion fluid) consists of a base oil of petroleum or mineral oil mixed with an emulsifier and a mixture. Petroleum or mineral oil, which is a mixture of emulsifier and mixture, is the basic component of soluble oil (also called emulsified oil). The concentration of the described components in their water mixture is usually 30-85%. Soaps, surfactants, wetting agents and couplers are commonly used as emulsifiers and their basic function is to reduce surface tension. As a result, they tend to foam the fluid. In addition, soluble oils include oily agents such as esters, extreme pressure additives, biocides such as alkanolamines for providing oryzave alkaline nitio, triazines or oxazolidene, and defoamers such as long-chain organic fatty alcohols or salts. It may contain foaming agents, corrosion inhibitors, antioxidants and the like. Synthetic fluids (chemical fluids) can be further divided into two subgroups: true solutions and surface active fluids. True solution fluids consist primarily of alkaline inorganic and organic compounds and are configured to provide corrosion protection to water. Chemical surface active fluids consist of a mixture of alkaline inorganic and organic corrosion inhibitors with anionic and nonionic wetting agents to provide lubrication and improve wettability. Chlorine, sulfur and phosphorus based extreme pressure lubricants and some of the more recently developed polymer physical extreme pressure agents can be additionally incorporated into this fluid. Semi-synthetic fluids (also called semi-chemicals) contain a small amount of refined base oil (5-30%) in the concentrate. They additionally have emulsifiers as well as 30-50% water Be mixed. Since they contain both synthetic and soluble oil components, they exhibit properties common to both synthetic and water-soluble oils.

The tool holder body 116 further includes an anti-rotation platform 140 extending radially inward from the upright wall 126. The anti-rotation abutment 140 has a peripheral abutment surface 142. The peripheral surface 142 has a geometric shape that engages the cutting insert 150 to prevent rotation when the cutting insert 150 is in the pocket 122.

For the rest of the drawings, the following is a cutting insert 150 (FIGS. 8 and 9) suitable for use with any of the holders: milling cutter body 42, KM® holder 80 and threaded tool holder 114. (See) is a description of a preferred specific embodiment. The cutting insert 150 is useful in removing chip-forming material from the workpiece, where the coolant source supplies the coolant to the cutting insert. The cutting insert 150 includes a cutting insert body 151 (see FIG. 8) that includes a base member 152 and a core member 154. As will be described in more detail below, the base member 152 and the core member 154 work together to form the cutting insert body 151. As will be apparent from the following description, the base and core members can be joined together to form an integral part, or they can be compressed together while maintaining their individual independent and distinct properties.

The components, i.e. the base member 152 and core member 154 of the cutting insert 150, may be made from any number of materials suitable for use as cutting inserts. The following materials, tool steels, cemented carbide, cermets or ceramics are exemplary materials useful for cutting inserts. The particular material and combination of materials depends on the particular application of the cutting insert. The Applicant believes that the base member and the core member may be made of different materials.

Regarding tool steel, the following patent documents disclose tool steel suitable for use as a cutting insert. US Pat. No. 4,276,085 named High Speed Steel, US Pat. No. 4,880,461 named Carbide High Speed Steel, and high speed steel made from sintered powder and methods for its manufacture. US Pat. No. 5,252,119. Regarding cemented carbide, the following patent documents disclose cemented carbide suitable for use as a cutting insert. US Patent Application Publication No. 2006/0171837A1 entitled Carbide Body Containing Zyrosine and Niob and Method for Producing It, US Reissue Named Selective Binder-Enriched Carbide Alloy Body and Method of Manufacture US Pat. No. 34,180, and US Pat. No. 5,955,186, entitled Coated Cutting Insert with AC Porous Substrate with Non-Layered Surface Binder Rich. With respect to cermets, the following patent documents disclose US Pat. No. 6,124,040, entitled Composites and Methods of Manufacturing, and Co-Ni-Fe Binders, which disclose cermets suitable for use as cutting inserts. US Pat. No. 6,010,283, entitled Cermet Cutting Insert. Regarding ceramics, the following patent documents disclose ceramics suitable for use as cutting inserts. Alumina-Zirconia-Silicon Carbide-Magnesia Ceramic US Pat. No. 5,024,976, US Pat. No. 5,024,976, US Pat. US Pat. No. 5,525,134, US Pat. No. 6,905,992, a ceramic body reinforced with coarse silicon carbide whiskers and a method for producing the same, and a US patent, Sialon containing itterbium, and a manufacturing method. 7th, 094,

With reference to the drawings of the base member 152, particularly the base member 152 of FIGS. 4, 4A and 5, the base member 152 includes a rake face 156 and a flank surface 158. Since the core member 154 fits into the base member 52 to form the cutting insert 150, the flank surface 158 of the base member 152 is the flank surface of the cutting insert 150. Similarly, the rake face 156 of the base member 152 provides the working rake face of the cutting insert 150 for sizing and positioning the core member 154 with respect to the base member 152.

The intersection of the rake face 156 and the flank surface 158 forms the cutting edge 160. The cutting edge 160 is a substantially round cutting edge in this embodiment. As will be described in more detail below, the cutting edge 160 exhibits a plurality of discontinuous cutting positions. In this embodiment, there are six discontinuous cutting positions 161A-161F. The discontinuous cutting positions (161A to 161F) are separated by about 60 degrees. Further, each discontinuous cutting position (161A-161F) is located in the middle between each pair of adjacent ribs 170.

The rake face 156 of the base member 152 has a radial outer surface 162. The radial outer surface 162 is the radial inner side of the cutting edge 160 and extends around the entire perimeter of the rake face 156. The first transition surface 164 is located inside the radial outer surface 162 in the radial direction, and the second transition surface 166 is located inside the first transition surface 164 in the radial direction. Each of the first and second transition planes moves towards the bottom of the cutting insert as it moves inward in radius. The second transition surface 166 fuses with either the groove 168 or the rib 170.

Surface, i.e., radially outer surface 162, a first transition surface 164 and second transition surface 166, a plurality of different geometrical shapes or surface shape will be appreciated that may exhibit any shape. The purpose of these surfaces is to provide a transition between the cutting edge 160 and the internal portion of the base member 152 including the grooves 168 and ribs 170. In addition, certain special geometries may be effective to improve the tip break function of the cutting insert. Also, certain special geometries may be effective to improve coolant delivery to the interface between the insert and the chips, as the coolant can hit this region of the cutting insert.

Referring to FIG. 4A, which is a partial enlarged view of FIG. 4, each of the grooves 168 has a pair of opposing groove peripheral surfaces, namely a groove peripheral surface 172 and a groove peripheral surface 174. Each groove 168 further has a central trough 176. Each adjacent rib 170 has a radial inner barrier 180 and an opposing radial inner barrier 181 which defines a lateral boundary of the groove 168. Each of the ribs 170 also has a peripheral contact surface 182.

The base member 152 further defines the central core receiving aperture 186. The central core accepting aperture 186 receives the core member 154. Hereinafter, the assembly of the base member 152 and the core member 154 will be described.

The base member 152 also has a flank 158. The flank 158 has a cylindrical flank 200 adjacent to the rake face 156. The cylindrical flank 200 extends towards the bottom of the selected distance, where it transitions to a substantially truncated cone-shaped surface (see bracket 202).

The substantially truncated cone-shaped surface portion 202 exhibits a sinusoidal geometry with a plurality of sinusoidal valleys or scalloped portions 206. Each of the sinusoidal valleys 206 has an opposing side 208, another opposing side 210, and an arcuate intermediate portion 212. In each sinusoidal valley 206, the circumferential width increases from the top to the bottom of the base member 152. There is a sinusoidal island portion 220 between each of the sinusoidal valley portions 206. Each sinusoidal island portion 220 has an opposing side 221,222 and an arc-shaped intermediate portion 223. In each sinusoidal island portion 220, the circumferential width decreases from the top to the bottom of the base member 152.

Each sinusoidal valley 206 defines a recess that exhibits an arcuate surface. As described below, the sinusoidal valley 206 can work with the anti-rotation platform so that the platform engages the recess of the sinusoidal valley 206 and the cutting insert 150 Prevents rotation when in the holder pocket. It will be appreciated that the geometry of the flank does not have to exhibit a sinusoidal scalloped portion. The flanks can also take other geometric shapes, such as scalloped or smooth surfaces without dents.

The base member 152 further has a bottom surface 226. The bottom surface 226 exhibits a sinusoidal peripheral edge 228. The sinusoidal peripheral edge 228 has a plurality of peaks 230A to 230F and a plurality of valleys 232A to 232F.

The bottom surface 226 of the base member 152 further includes notches 238A to 238F and land portions 240A to 240F. These notches (238A to 238F) and lands (240A to 240F) define the outer shape of the edge at the end of the central core receiving aperture 186.

With reference to the structure of the core member 154, and especially with reference to FIGS. 6 and 7, the core member 154 includes an upper end 244 and a bottom end 246. Adjacent to the upper end 244 is a substantially circular portion 248, adjacent to the bottom end 246 is an integrated substantially headed conical portion 250, and the integrated substantially mounted conical portion 250 is substantially circular. It extends from portion 248 through the arcuate transition section 251. The upper end 244 has a radial outer top surface 252 having a circumferential outer edge 254. Radially inside the outer top surface 252 in the radial direction is the inner edge 256 in the radial direction.

With reference to the inner surface of the one-piece, substantially headed conical portion 250, moving in the direction towards the bottom end 246, there is an internal transition surface 258 that fuses with the inner cylindrical surface 262. Reference to the outer surface of the one-piece substantially headed conical portion 250, there is an arcuate outer surface 264 and a heading conical outer surface 266. At the bottom end 246 is a bottom cylindrical surface 268 with a radial outer rim 270.

As will be apparent from the following description, the cutting insert body 151 includes a plurality of separate internal coolant channels 300 (see FIG. 14) formed between the base member 152 and the core member 154. As described in more detail, when attached to the pocket of the holder, adjacent pairs of separate internal coolant channels 300 correspond to each of the discontinuous cutting positions.

For example, the base member 152 and the core member 154 are joined to each other to form a complete cutting insert 150 as shown in FIG. FIG. 8A shows a core member 154 disassembled from the base member 152 and aligned with the base member 152. Since the central core receiving aperture 186 of the base member 152 receives the core member 154, the outer surface of the core member 154 contacts the selected region of the base member 152. More specifically, the arcuate outer surface 264 portion and the heading cone outer surface 266 portion come into contact with the respective arcuate contact surfaces 182 of the ribs 168. In the drawings, the contact surface 182 is shaded.

The contact point between the base member 152 and the core member 154 is very strong. This very strong contact between the base member 152 and the core member 154 is shown in FIGS. 10 and 15. The degree of contact is strong enough and fluid tight at the contact position. The degree of contact is strong enough that the components do not separate during use.

The contact between the base member and the core member can be due to the actual joining of these components. The joining of the base member 152 and the core member 154 can be achieved by any of a plurality of methods. For example, techniques such as co-sintering, brazing and / or gluing are suitable. Specific techniques may be applied specifically to specific materials. For example, co-sintering may be applied when the base member and the core member are made of the same material (for example, tungsten carbide-cobalt material). Adhesion may be applied if the material of the base member and the material of the core member are different (eg, steel core member and tungsten carbide-cobalt base member). Contact can also be achieved by compressing the components together while maintaining the themes to be independent and distinct from each other. For example, the cutting insert can be screwed tightly to the holder, resulting in a very strong surface-to-surface contact between the base and core members due to the very tight connection between the cutting insert and the holder. is there. If the components are compressed together by tightening the cutting insert into the holder, these components may be separated when the cutting insert is engaged and disengaged from the holder.

The choice of the particular material of the component depends on the particular application of the cutting insert. The use of component ceramic-ceramic or carbide-carbide or steel-carbide combinations provides a variety of material choices for cutting inserts. In doing so, the cutting insert has the features of extended material selection that allows the cutting insert to be optimally customized in terms of material.

As is clear, the components, and thus the cutting inserts, exhibit a round geometry. By using round geometry, there is no need to perform indexing on multiple components, such as base and core assemblies. Without indexing or special alignment, unlike components that require special alignment, manufacturing costs are low and assembly is easy. This is especially true for core members. The core member has a substantially cylindrical / conical geometry. It has no external function that requires special alignment or orientation in assembly to the base. Therefore, assembling the core to the base is easier and cheaper than assembling components, each with complex geometric features.

As mentioned above, the cutting insert 150 has a plurality of separate internal coolant channels 300. The following description of one internal coolant flow path 300 is sufficient to describe all such internal coolant flow paths 300.

For each of the internal coolant flow paths 300, the selected surface of the base member 152 and the selected surface of the core member 154 define the boundary of the internal coolant flow path 300. More specifically, some of the selected surfaces of the base member 152 are the surfaces that define the grooves 168, i.e. the groove peripheral surfaces 172, 174 and the central trough 176. Other selected surfaces of the base member 152 include a radial inner barrier 178 of one rib 170 and a radial inner barrier 180 of adjacent ribs 170. For the core member 154, the outer surface defines the internal coolant flow path 300.

The internal coolant flow path 300 has an internal coolant flow path discharge port 302 and an internal coolant flow path inlet 304. As is apparent, the coolant enters the internal coolant flow path 300 through the internal coolant flow path inlet 304, travels within the internal coolant flow path 300, and then exits through the internal coolant flow path outlet 302. Upon exiting the internal coolant flow path 300, coolant is injected into the discontinuous cutting position that is engaged with the workpiece.

FIG. 14 provides a reference point for explaining the geometry of the internal coolant flow path 300, particularly the internal coolant flow path 300, in a preferred particular embodiment of the cutting insert 150, the top surface of the cutting insert 150. It is a figure. FIG. 14B is a cross-sectional view of the cutting insert 150 of FIG. 14 cut along the cross-sectional line 14B-14B of FIG. FIG. 14A is an enlarged view of the portion inside the circle 14A of FIG. 14B showing the internal coolant flow path 300. As shown in FIG. 14B, sectional views of FIG. 15, FIG. 15A, FIG. 16, FIG. 16A, FIG. 17 and FIG. 18 are cut in a direction substantially perpendicular to the general direction of the coolant flow. The cross-sectional area can be regarded as the coolant flow area at a specific position along the internal coolant flow path.

In this preferred particular embodiment, the geometry of the internal coolant flow path 300 in the coolant flow cross-sectional area varies along the axial length of the internal coolant flow path 300, i.e. the axial coolant flow path length. It is clear to do. Further, it will be appreciated that the coolant flow cross-sectional area can be varied to obtain a particular desired flow shape or injection pattern at the interface between the insert and the chips. In this particular embodiment, the injection pattern is of a continuous nature, exhibiting a continuous cone of coolant in the vicinity of the discontinuous cutting position. In this regard, FIG. 20 shows the coolant injection pattern (arrows indicated by "CF") when two adjacent internal coolant channels are operating, i.e. communicating with the coolant source during material removal operations. ) Is shown in a schematic form.

Table I below describes the coolant flow area at the positions shown in sections 15-15 to 18-18 of FIG. 14B in a particular embodiment of the cutting insert. The specific numbers in this table are solely for the preferred particular embodiment and are not intended to limit the scope of the invention as defined by the appended claims. Table I also shows the distance of each cross section from the internal coolant flow path inlet 304. The reference letters "W", "X", "Y" and "Z" correspond to the positions of the cross sections shown in Table I. More specifically, the distances "W", "X", "Y" and "Z" are at positions where the cross section passes through the radial inner surface of the internal coolant flow path 300.<tables num="1"><img file="JP2013528126A_D0001.tif" /></tables>

Based on the data in Table I, the coolant flow path inlet area is about the same as the coolant flow path discharge area, the coolant flow area varies along the axial coolant flow path length, and the coolant flow path inlet is the coolant port. Smaller than the area. With respect to the coolant port area characteristics, in this preferred particular embodiment of the cutting insert, the coolant port with which the cutting insert communicates has a coolant port area equal to 7.06 mm2.

With reference to FIGS. 15A and 16A, the internal coolant flow paths combine in cross section with an arcuate radial inner surface 600 and a pair of sides 602, 604 that generally move radially outward and at apex 610. Can be defined by a pair of merging radial outer surfaces 606, 608. From the comparison between the coolant flow area of FIG. 15A and the coolant flow area of FIG. 16A, it is clear that the coolant flow area of the internal coolant flow path 300 increases from the internal coolant flow path inlet 304 to the position reaching the cross section 16-16. Is. The arcuate radial inner surface 600 extends to some extent so that the length of the pair of confluent radial outer surfaces 606, 608 that join each other at the apex 610 is increased. A pair of side portions 602, 604 that generally move outward in radius remain somewhat constant in this region of the internal coolant flow path 300. The increase in coolant flow area results from an increase in the width of the arcuate radial inner surface 600 and, as a result, an increase in the dimensions of the pair of confluent radial outer surfaces 606, 608 that join together at the apex 610.

The coolant flow area increases to a lesser extent from cross sections 16-16 and 17-17. Comparing the coolant flow area at the position shown in cross section 16-16 and the coolant flow area at the position shown in cross section 17-17 in the internal coolant flow path 300, it can be seen that the internal coolant flow path is further expanded. The coolant flow area shown in FIG. 18 indicates the coolant flow area of the internal coolant flow path discharge port 302. It is clear that there is an overall lateral expansion and radial contraction of the internal coolant flow path as it moves from the inlet to the outlet.

FIG. 15A shows the geometry of the internal coolant flow path inlet 304. FIG. 18 shows the geometry of the internal coolant flow path discharge 302. Comparing these geometric shapes, it can be seen that the geometric shape of the internal coolant flow path inlet 304 is different from the geometric shape of the internal coolant flow path discharge 302. This is true even if the coolant flow path inlet area is approximately the same as the coolant flow path discharge area.

With reference to FIGS. 19 and 19A, during operation the cutting insert is held in the pocket of a holder, such as a milling cutter 40. In holders such as the milling 40, the cutting insert 150 is held in the pocket by a screw that penetrates the cutting insert and enters the threaded aperture in the pocket. To secure the cutting insert in the pocket, the cutting insert is oriented such that the anti-rotation platform 70 engages the flank of the cutting insert. In this regard, the peripheral edge 72 exhibits a geometry that matches the geometry of the sinusoidal valley 206. This engagement creates a platform that limits rotational movement when the cutting insert is in the pocket.

To engage in cutting (ie, material removal), the cutting insert 150 is in a state where there is a selected one of multiple discontinuous cutting positions that engage the workpiece. The arrow DCL1 in Figure 19A generally indicates the selected discontinuous cutting position. When in this state, the corresponding pairs of separate internal coolant channels 300A and 300B communicate with the arcuate aperture through the coolant channel inlets 304A and 304B, and even with the coolant source through the coolant port. There is.

With reference to FIG. 19A, it can be seen that the relative position between the cutting insert and the pocket allows the arcuate aperture to fluidly communicate with a pair of adjacent internal coolant flow path inlets 304A and 304B. It is understood that coolant from the coolant source flows simultaneously into both the internal coolant flow path 300A and the internal coolant flow path 300B, whereby the internal coolant flow paths 300A and 300B can be considered to be operating. It will be appreciated that the pocket may contain an arcuate aperture (or similar feature) that allows three internal coolant channels to communicate with the coolant source at the same time.

With reference to FIG. 21, the coolant travels on the surface defining the internal coolant flow path 300, as can be understood. As the coolant travels on the arcuate surface of the core, the coolant moves radially outward toward the internal coolant flow path outlet 302. Therefore, the coolant flows through the cutting edge when exiting the internal coolant flow path discharge port 302. By flowing outward in radius, the coolant works better to overflow the cutting edge that is engaged with the workpiece. The coolant injection pattern indicates the spray angle DA1. This angle is the angle with respect to the axis parallel to the rake face of the cutting insert. It will be understood that the spraying angle can range from about 10 degrees to about 60 degrees. Referencing FIG. 13 again shows a similar feature that the coolant disperses as it exits the internal coolant flow path outlet.

Due to the geometric nature of the internal coolant flow path, the application of coolant leads to a continuous injection of coolant. FIG. 20 is a schematic view showing this continuous coolant injection. The continuous injection of coolant ensures that sufficient coolant is used to flood the interface between the insert and the chips at discontinuous cutting positions. As mentioned herein, delivery of sufficient coolant to the interface between the insert and the chips provides several benefits.

When the discontinuous cutting position wears to a position that requires replacement, the operator can index the cutting insert to the next cutting position. FIG. 19B shows the following cutting positions. The arrow DCL2 in Figure 19B generally indicates the next selected discontinuous cutting position. When in the new position, the corresponding pair of separate internal coolant channels (300B and 300C) communicate with the coolant source through the coolant channel inlets 304B and 304C and the cutting insert 150 is in the selected discontinuous cutting position. Deliver coolant to. Therefore, coolant is supplied to the interface between the insert and the chip corresponding to the new discontinuous cutting position.

Test results are performed to compare certain embodiments of the invention (through coolant) cutting inserts with commercial cutting inserts (standard cutting inserts) manufactured and sold by Kennametal Inc. of Latrobe, Pennsylvania 15650. It was. Both cutting inserts were made with the same grade of carbide (cobalt) tungsten carbide, the same insert type and the same cutting edge treatment (except for the through coolant function of the invention cutting insert). The ISO symbol for cutting inserts, including cutting edge treatment, was RCGX64SFG. The test results for the number of passes until the cutting insert wears to the following positions are shown in Table II below. The failure criterion was either maximum flank wear of 0.015 inches or maximum rake face chips of 0.030 inches, whichever occurred first.<tables num="2"><img file="JP2013528126A_D0002.tif" /></tables>

Other test parameters are listed below. Work material Ti6Al4V. Insert blade type = round, iC = 0.750 inch, cutter diameter 3.00 inch, number of inserts per cutter 1 and path length 12 inch. Cutting speed is Vc = 150 ft / min, rpm = 202, actual chip load = 0.006 inch / tooth, program chip load = 0.010 inch / tooth, axial depth of cut = 0.15 inch, radial depth of cut = 2.000 inch, Feed rate = 2.020 inches per minute. Machine is Mazak FJV, coolant is wet, coolant type is Syntilo® [Syntilo is a registered trademark of Castrol Limited in Wiltshire England], coolant pressure = 1000psi, concentration = 12.0%, MMR (inch)²/ Minutes) = 0.606.

As is clear from the test results, the invention cutting insert showed a significant improvement over the commercial cutting insert. The number of passes required to be exchanged 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, over 250 percent.

Delivery of coolant to the interface between the milling insert and the workpiece by this cutting insert and assembly (ie, the interface between the insert and the chip, which is the position on the workpiece where the chips are generated). The improvement is very clear. In doing so, the cutting inserts and assemblies improve the delivery of coolant to the insert-chip interface to improve lubrication at the insert-chip interface. As a result of improved lubrication at the interface between the insert and the chips, the tendency of chips to adhere to the cutting insert is reduced, as well as better discharge of chips from the vicinity of the interface, resulting in better discharge. The possibility of recutting chips is reduced.

In this cutting insert and assembly, factors that affect the degree of coolant delivered to the interface between the insert and the chips are achieved. For example, the dimensions of the structure that feeds the coolant to the cutting insert can be a limiting factor on the degree of coolant supplied to the cutting insert. The cutting insert and assembly are provided with supply holes (coolant ports) equal to or greater than the inlet in the cutting insert to maximize the flow of coolant into the cutting insert. In this cutting insert and assembly, two or more coolant passages provide an arrangement that feeds the coolant to a single discontinuous cutting position. The cutting inserts and assemblies provide irregular coolant passages and variable inflow and outlet areas within the cutting inserts that allow customization of coolant delivery. By doing so, various diversion angles of the coolant can be provided. This angle can range from about 10 degrees to about 60 degrees.

The cutting inserts and assemblies offer manufacturing advantages and performance advantages. There may be advantages in using multiple parts that form a cutting insert together. For example, in some cases, cutting inserts formed from a cutting edge base and core can lead to extended life, as only the base needs to be replaced after reaching the end of effective tool life. .. In such an arrangement, the core is detachably coupled (or works together) to the base so that the core is reused as the base wears. The base and core can be bonded together by co-sintering, brazing and / or gluing. Moreover, the base and core are tightly compressed against each other but still retain their distinct and individual characteristics. In addition, to improve performance, the base and core can be from the same or different materials depending on the particular application.

Certain advantages may exist if a suitable particular embodiment of the cutting insert exhibits a round geometry in one or more positions. For example, if the cutting insert has a round geometry at the position where the multiple components are assembled, then the multiple components, such as the base and core assembly, do not need to be indexed. When the cutting edge of the cutting insert is round, the round cutting insert has no hand, so it can be used with left hand, right hand, and no hand. In contour turning, up to 50% of the cutting insert can function as a cutting edge.

Cutting inserts are also available to engage anti-rotation features.

The patents and other documents presented herein are incorporated herein by reference. Other embodiments of the invention will become apparent to those skilled in the art by considering the specifications or practices of the invention disclosed herein. The specifications and examples are merely exemplary and are not intended to limit the scope of the invention. The true scope and spirit of the present invention is indicated by the following claims.