Tool carrier with notch, cutting insert and method for making same
a tool carrier and cutting insert technology, applied in the field of cutting inserts, can solve the problems of another problem, and affecting the performance of the tool carrier, and achieve the effects of reducing the manufacturing cost of the cutting insert, reducing the stress, and eliminating the formation of cracks in the tool carrier
Active Publication Date: 2019-04-04
KENNAMETAL INC
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- Summary
- Abstract
- Description
- Claims
- Application Information
AI Technical Summary
Benefits of technology
[0008]The problem of the formation of cracks in a tool carrier during the manufacturing process is solved by providing a notch at the intersection between the vertical back wall and the horizontal support surface of the pocket of the carrier formed with a non-planar first portion having a radius and a planar second portion having an inclination angle with respect to the horizontal support surface. The planar second portion allows the mold to move relative to the tool carrier during shrinkage of the tool carrier to reduce stress in the vicinity of the notch, thereby eliminating the formation of cracks in the tool carrier. In addition, the notch eliminates the need to produce a chamfer in the cutting tip, thereby decreasing manufacturing cost of the cutting insert.
[0011]In yet another aspect of the invention, a method for manufacturing a tool carrier for a cutting insert by using an injection molding process, the tool carrier comprising a body and a pocket formed in the body for accommodating a cutting tip of a cutting insert, the method comprising affixing the cutting tip to the pocket of a tool carrier by brazing, wherein the pocket includes a vertical back wall, a horizontal support surface, and a notch formed at an intersection between the vertical back wall and the horizontal support surface of the pocket for accommodating brazing material, and wherein the notch has a non-planar first portion proximate the vertical back wall and formed with a radius, R1, and a planar second portion extending between the first portion and the horizontal support surface and formed at an inclination angle, A, with respect to a plane parallel to the horizontal support surface of the pocket, and wherein the notch eliminates formation of cracks in the tool carrier during the injection molding process.
Problems solved by technology
A problem has been observed when the tool carrier 100 is manufactured using an injection molding process.
Because the tool carrier 100 shrinks differently in the horizontal and vertical direction, the mold will “drag” the notch portion of the tool carrier 100, thus creating cracks, which is detrimental to the performance of the tool carrier 100.
Another problem has been observed when the cutting tip is affixed to the tool carrier.
Unfortunately, producing the chamfer in the cutting tip increases the manufacturing cost of the cutting insert.
Method used
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Embodiment Construction
[0023]Referring now to FIGS. 1-6, a cutting insert 10 is shown according to an embodiment of the invention. In general, the cutting insert 10 includes a tool carrier 12 having a body 13 with at least one pocket 14. The cutting insert 10 also includes at least one cutting tip 16 affixed to the tool carrier 12. In the illustrated embodiment, the tool carrier 12 has a total of four pockets 14 and four cutting tips 16 affixed thereto. However, it will be appreciated that the invention is not limited by the number of pockets and cutting tips, and that the invention can be practiced with any desirable number of pockets and cutting tips.
[0024]As used herein, the term “super-hard material” is taken to mean materials with Vickers hardness greater than about 25 GPa. Such materials include, but is not limited to, diamond, cubic boron nitride, boron sub-oxide, boron carbide, polycrystalline diamond (PCD), polycrystalline cubic boron nitride (PCBN), and silicon carbide-bonded diamond (ScD).
[0025...
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A cutting insert includes a tool carrier having a body with a pocket, and a cutting tip affixed to the pocket by brazing. The pocket is defined by a vertical back wall and a horizontal support surface. A notch is formed at the intersection between the vertical back wall and the horizontal support surface. The notch has a non-planar first portion proximate the vertical back wall and formed with a radius, R1, and a planar second portion extending between the first portion and the horizontal support surface and formed at an inclination angle with respect to a plane parallel to the horizontal support surface of the pocket. The design of the notch significantly reduces thermal stress and eliminates the formation of cracks in the pocket of the tool carrier when using an injection molding process to form the tool carrier.
Description
FIELD OF THE INVENTION[0001]The present invention relates to cutting inserts and, more particularly, to cutting inserts comprising a cutting tip made of a super-hard material, such as PCBN, and the like, affixed onto a tool carrier made of a suitable material, such as cemented carbide, and the like.BACKGROUND OF THE INVENTION[0002]A super-hard cutting edge is provided to a cutting insert by affixing a hard-metal body, such as a PCBN tip, to what is commonly known as a tool carrier or carrier by means of a brazing material, such as a liquid brazing solder.[0003]Polycrystalline diamond (PCD) or polycrystalline cubic boron nitride (PCBN), diamond and diamond composite materials are commonly used to provide the super-hard cutting edge for cutting tools, such as cutting inserts used in metal machining.[0004]Referring now to FIGS. 8 and 9, a conventional tool carrier 100 (also known as a blank) includes a pocket 102 defined by a vertical back wall 102a and a horizontal seating surface 102...
Claims
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IPC IPC(8): B23B27/18
CPCB23B27/18B23B2200/0495B23B2205/12B23B2226/125B23B2240/08B23B29/00B23B29/24B23B29/244B23B29/246B23B27/145B23B2200/0447B23B2226/315
Inventor WANG, QIMYERS, NEALCHEN, SHIKAUFMANN, IGOR
Owner KENNAMETAL INC