Modular rotary cutting tool, shank of a modular rotary cutting tool, and cutting insert for a modular rotary cutting tool.

Abstract

Rotary cutting tools are disclosed comprising shanks and replaceable cutting inserts are provided. The shank comprises a pocket which receives an interchangeable cutting insert. The pocket includes a floor with a central pin-receiving hole, opposing pocket centering walls, and torque transmitting pocket drive walls. The cutting insert has a relatively long rear pin receivable in the central hole of the shank. A head of the cutting insert includes insert centering surfaces that contact the pocket centering walls of the shank, and insert drive surfaces that contact the torque transmitting pocket drive walls of the shank. The configurations and sizes of the shank and cutting insert features are controlled to provide improved torque transmission, rigidity and stability during operation of the rotary cutting tools.

Description

1 / 24 “MODULAR ROTARY CUTTING TOOL, SHANK OF A MODULAR ROTARY CUTTING TOOL AND CUTTING INSERT FOR A MODULAR ROTARY CUTTING TOOL” FIELD OF THE INVENTION

[001] The present invention relates to modular rotary cutting tools, including replaceable shanks and cutting inserts. FUNDAMENTALS

[002] Drills with replaceable cutting tips are known. Typically, the cutting heads and shanks may have a continuous and complementary configuration, such as fluted drills. Each shank will typically include a structure to retain and rotate an associated cutting head, while the associated cutting head will have a complementary structure to be retained and rotated by the shank. Challenges such as deformation and failure are encountered during the service life of a drill due to the concentration of stresses imposed on the shank retention and drive structure during normal service. This can unduly limit the drill's service life. SUMMARY OF THE INVENTION

[003] Rotary cutting tools comprising shanks and replaceable cutting inserts are provided. The shank consists of a pocket that receives an interchangeable cutting insert. The pocket includes a floor with a central hole for receiving pins, opposing pocket centering walls, and pocket drive walls for torque transmission. The cutting insert has a relatively long back pin that can be fitted into the central hole of the shank. A cutting insert head includes insert centering surfaces that contact the centering walls of the shank pocket, and insert drive surfaces that contact the drive walls of the torque transmission pocket of the shank. Configurations and sizes of features Petition 870250085938, dated 09 / 23 / 2025, page 7 / 71 2 / 24 of the shank and cutting insert are controlled to provide better torque transmission, rigidity, and stability during the operation of rotary cutting tools.

[004] One aspect of the present invention is to provide a modular rotary cutting tool comprising a rod with a central longitudinal axis and a cutting insert installed in a removable manner on the rod. The rod includes a front pocket with a central hole for receiving pins. The cutting insert includes a pin that can be fitted into the pin receiving hole of the rod. The front pocket includes first and second opposing pocket centering walls, first and second torque transmission pocket drive walls, and a pocket floor.The first pocket centering wall defines one plane, the first pocket drive wall defines another plane, the first plane of the pocket centering wall and the first plane of the pocket drive wall intersect at a pocket intersection point P located on the pocket floor at a pocket wall angle A measured at the pocket intersection point P that is greater than 90° and less than 155°, and wherein each of the first and second pocket drive walls are arranged in planes parallel to the longitudinal axis of the rod.

[005] Another aspect of the present invention is to provide a shaft of a modular rotary cutting tool having a central longitudinal axis and including a central hole for receiving a pin and a front pocket. The front pocket includes first and second opposing pocket centering walls, first and second torque transmission pocket drive walls, and a pocket floor. The first compartment centering wall defines one plane, the first compartment drive wall defines another plane, and the first plane of the compartment centering wall and the first plane of the compartment drive wall intersect at a compartment intersection point P located on the compartment floor at a compartment wall angle A measured at Petition 870250085938, dated 09 / 23 / 2025, page 8 / 71 3 / 24 intersection point P which is greater than 95° and less than 155°, and in which each of the first and second drive walls of the compartment are arranged in planes parallel to the longitudinal axis of the rod.

[006] A further aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool having a central longitudinal axis and comprising a head and a pin extending rearward from the head. The head includes first and second insert centering surfaces, first and second torque transmission insert drive surfaces and a rear face.The first centering surface of the insert defines one plane, the first drive surface of the insert defines another plane, and the first plane of the centering surface of the insert and the first plane of the drive surface of the insert intersect at an intersection point of the insert P' located in a plane of the back surface at an angle of the insert surface A' measured at the intersection point of the insert P' that is greater than 90° and less than 155°, wherein each of the first and second drive surfaces of the insert are arranged in planes parallel to the longitudinal axis of the shank.

[007] Another aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool comprising a head with length Lh measured in the axial direction of the cutting insert and a pin extending behind the head in the axial direction with a length Lp, wherein the length ratio of the pin to the head Lp:Lh is greater than 1:1.

[008] A further aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool having a central longitudinal axis including a cutting head comprising first and second insert centering surfaces, first and second torque transmission insert drive surfaces and a rear face. The first insert centering surface defines a plane, the first insert drive surface defines Petition 870250085938, dated 09 / 23 / 2025, page 9 / 71 4 / 24 another plane, the first plane of the insert centering surface and the first plane of the insert drive surface intersect at an intersection point of the insert P' located in a plane of the back surface at an angle of the insert surface A' measured at the intersection point P', and the angle of the insert surface A' is greater than 90° and less than 155°. Each of the first and second drive surfaces of the insert are arranged in planes parallel to the longitudinal axis of the shank.

[009] These and other aspects of the present invention will become more evident from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[010] Figs. 1 and 2 are isometric views, Figs. 3 and 4 are side views, Fig. 5 is a front view and Figs. 6 to 8 are side sectional views taken through various lines of Fig. 5, of a modular rotary cutting tool of the present invention, including a rod and a replaceable cutting insert.

[011] Fig. 9 is an isometric view, Figs. 10-12 are side views and Fig. 13 is a front view of the rotary cutting tool shank shown in Figs. 1-8.

[012] Figs. 14-16 are isometric views, Figs. 17 and 18 are side views, Fig. 19 is a front view and Fig. 20 is a rear view of the cutting insert shown in Figs. 1-8.

[013] Figs. 21-23 are isometric views, Figs. 24 and 25 are side views, Fig. 26 is a front view and Fig. 27 is a rear view of another cutting insert of the present invention.

[014] Figs. 28-30 are isometric views, Figs. 31 and 32 are side views, Fig. 33 is a front view and Fig. 34 is a rear view of another cutting insert of the present invention.

[015] Figs. 35-37 are isometric views, Figs. 38 and 39 are views Petition 870250085938, dated 09 / 23 / 2025, p. 10 / 71 5 / 24 sides, Fig. 40 is a front view and Fig. 41 is a rear view of another cutting insert of the present invention.

[016] Fig. 42 is a side view of a modular rotary cutting tool of the present invention, including a shank and a replaceable cutting insert.

[017] Fig. 43 is a front view of the rotary cutting tool of Fig. 42.

[018] Fig. 44 is a side sectional view of the rotary cutting tool taken from line 44-44 in Fig. 43.

[019] Figs. 45 and 46 are partial side views, and Fig. 47 is a front view of the rotary cutting tool shank shown in Figs. 42-44.

[020] Figs. 48 and 49 are side views, and Fig. 50 is a front view of the cutting insert shown in Figs. 42-44.

[021] Fig. 51 is a side cutaway view taken through line 51-51 in Fig. 50 illustrating a cutting insert and a fixing screw.

[022] Fig. 52 is a rear view of the cutting insert shown in Figs. 42-44 and 50.

[023] Fig. 53 is a partially schematic side view of a portion of the cutting insert shown in Figs. 48-52 illustrating details of a cutting insert pin and the arrangement of the fixing screw.

[024] Fig. 54 is a partially schematic side view, Fig. 55 is a side sectional view taken from line 55-55 in Fig. 54, and Fig. 56 is a side sectional view taken from line 56-56 in Fig. 55, illustrating features of an impact tool that can be used to facilitate the removal of cutting inserts from rotary cutting tool shanks according to the present invention.

[025] Fig. 57 is a partially schematic side view, Fig. 58 is a side sectional view taken from line 58-58 in Fig. 57, and Fig. 59 is a side sectional view taken from line 59-59 in Fig. 58, illustrating the impact tool of Figs. 54-56 in a position inserted in the rotary cutting tool shank. Petition 870250085938, dated 09 / 23 / 2025, p. 11 / 71 6 / 24 DETAILED DESCRIPTION

[026] Figs. 1-20 illustrate a modular rotary cutting tool 5 in the form of a drill with a shank 10 and a replaceable cutting insert 30. A central longitudinal axis is defined through the cutting tool 5, common to the shank 10 and the cutting insert 30. The modular rotary cutting tools of the present invention perform rotary cutting operations on a workpiece and may include drills, countersinking tools, milling tools, reaming tools and the like.

[027] The shank 10 includes a pair of grooves 11 along the sides of the shank 10 and a front pocket 12. The front pocket 12 includes opposing centering walls 14 and torque transmission walls 15. Each pocket drive wall 15 intersects an adjacent pocket centering wall 14. A pocket floor 16 is provided at the bottom of the pocket 12. As described in more detail below, each pocket centering wall 14 and the adjacent pocket drive wall 15 define planes that intersect at the floor 16 at an intersection point P. The location of the intersection point P, as well as an intersection pocket wall angle A of the centering and drive walls 14 and 15, are controlled to provide better torque transmission, rigidity, and stability during the operation of rotary cutting tools, as described in more detail below.

[028] As shown more clearly in the side view of Fig. 12, each pocket centering wall 14 of pocket 12 can be slightly inclined at a seating angle S, which can typically be greater than 0°, for example, greater than 0.1° or greater, or greater than 0.5°, or greater than 1°. The seating angle S can normally be less than 5°, or less than 4°, or less than 3°. The seating angle S can normally vary from 0.5 to 5°, for example, from 1 to 4°, or from 1.5 to 3.5°, or from 2 to 3°. As shown in Fig. 12, the seating angle S for Petition 870250085938, dated 09 / 23 / 2025, p. 12 / 71 7 / 24 each of the centering walls of pocket 14 can be the same. As described in more detail below, the drive walls of pocket 15 can be parallel to each other in planes that are parallel to the central longitudinal axis of rod 10.

[029] As shown in Fig. 9, cooling holes 18 and 19 may be provided on the front surfaces of the rod 10 on opposite sides of the pocket 12. The cooling holes 18 and 19 shown in Fig. 9 are of different sizes. Alternatively, the coolant holes may be the same size. As shown in Figures 4 and 8, a coolant supply hole 28 may be provided through a side wall of the rod 10.

[030] As shown more clearly in Figures 6-13, a central receiving pin hole 20 extends from the bottom of the pocket 16 to the shank 10 along its central longitudinal axis. The receiving pin hole 20 includes a structured and disposed rear tail contact region 21 to engage a rear end 42 of the cutting insert pin 40, as described in more detail below. The receiving pin hole 20 also includes a front contact region 22 that can engage a front end 41 of the pin 40, as described in more detail below. A threaded retaining bolt hole 24 extends at an angle through one side of the shank 10 and intersects the receiving pin hole 20. A retaining bolt 26 can be threaded into the retaining bolt hole 24.

[031] As shown more clearly in Figs. 14-20, the cutting insert 30 has a central longitudinal axis and includes a head 31, a rear face 32, and a front tip 33. Helical channels 34 run along the sides of the head 31. Side edges 35 are provided adjacent to the grooves 34. In addition, front cutting edges 36 are provided on the front part of the head of the cutting insert 31. The front cutting edges 36 can cut a workpiece as the rotary cutting tool 5 is rotated. Once the cutting insert 30 is installed Petition 870250085938, dated 09 / 23 / 2025, p. 13 / 71 8 / 24 on shank 10, the corresponding grooves 11 and 34 on shank 10 and cutting insert 30, respectively, will align to form substantially continuous grooves 11,34. Although two flutes are shown, any other number of flutes may be provided, for example, one flute, three flutes, etc.

[032] The cutting insert 30 includes centering surfaces 37 and torque transmission drive surfaces 38 that are structured and arranged for engagement with the respective pocket centering walls 14 and pocket drive walls 15 of the front pocket 12 of the rod 10. The centering surfaces of the insert 37 may be slightly angled relative to each other to coincide with the seating angles S of the respective pocket centering walls 14. The drive surfaces of the insert 38 may be parallel to each other and parallel to the central longitudinal axis of the insert 30, to correspond to the parallel arrangement of the drive walls of the compartment 15.

[033] Pin 40 extends rearward from the rear face 32 of the cutting insert head 31. In the embodiment shown, pin 40 and head 31 may be provided as a single or integral piece of material; however, they may alternatively be provided as separate components that are joined, threaded, or otherwise mechanically fastened. As shown in Figures 17 and 18, pin 40 includes a front end 41 and a rear end 42. Opposing notches 44 with fastening screw contact surfaces 45 extend radially inward on opposite sides of pin 40. Pin 40 includes a front portion 46 and a tail 48, which are divided by the opposing notches 44. As described in more detail below, the structure and size of the cutting insert head 31 and pin 40, including their relative dimensions, are controlled according to the present invention.

[034] As shown in Fig. 12, rod 10 has a rod diameter Ds. As shown in Fig. 13, each pocket centering wall 14 and the Petition 870250085938, dated 09 / 23 / 2025, page 14 / 71 9 / 24 adjacent pocket drive wall 15 define planes that intersect on a pocket floor plane 16 at a pocket intersection point P. A pocket wall angle A is defined at the pocket intersection point P, where the planes of pocket centering wall 14 and pocket drive wall 15 meet. The pocket offset distance Y is defined as the distance measured on the pocket floor 16 in the plane of pocket centering wall 14 that extends perpendicularly from a plane in which the central longitudinal axis of rod 10 is located to the pocket intersection point P, as shown in Fig. 13. As shown in Figures 12 and 13, pocket 12 has a centering wall width Wc measured on the pocket floor 16 and a drive wall width Wd, measured on the pocket floor 16.As described in more detail below, flat surface areas of each centering wall 14 and adjacent drive wall 15 can be selected relative to each other. By controlling the structure, arrangement, and dimensions of the features described above, the rods of the present invention provide favorable properties such as improved torque transmission, rigidity, and stability during the operation of rotary cutting tools.

[035] As shown in Figures 17 and 20, each centering surface of the insert 37 and the drive surface of the adjacent insert 38 define planes that intersect in a back face plane 32 at an intersection point of the insert P'. An insert surface angle A' is defined at the intersection point of the insert P'. An insert offset distance Y' is defined as the distance measured on the back face 32 in the plane of the centering surface 37 that extends perpendicularly from a plane in which the longitudinal center axis of the cutting insert 30 is located at the intersection point of the insert P', as shown in Fig. 20. As shown in Fig. 20, the insert has an insert centering surface width W'c measured on the back face 32, and Petition 870250085938, dated 09 / 23 / 2025, p. 15 / 71 10 / 24 a drive surface width W'd measured on the rear face 32. As described in more detail below, flat surface areas of each centering surface 37 and adjacent drive surface 38 can be selected relative to each other. According to the present invention, the insert surface angle A', the insert offset distance Y', and other structural features described above are controlled to provide better torque transmission, rigidity, and stability during the operation of rotary cutting tools.

[036] Figs. 21-27 illustrate a cutting insert 130 according to another embodiment of the present invention. The cutting insert 130 includes centering surfaces 137 and torque transmission drive surfaces 138. The cutting insert 130 includes a pin 140 that extends backward and extends backward from a rear face 132 of the cutting insert head 130 with opposing notches 144. As shown in Fig. 27, the cutting insert 130 has an insert intersection point P', insert surface angle A', insert offset distance Y', insert centering surface width Wc, and insert drive surface width Wd.

[037] Figs. 28-34 illustrate another cutting insert 230 according to an embodiment of the present invention. The cutting insert 230 includes centering surfaces 237 and torque transmission drive surfaces 238. A relief channel 239 is provided between the adjacent centering surfaces 237 and the torque transmission surfaces 238. The cutting insert 230 includes a pin 240 extending rearward from a rear face 232 of the cutting insert head 230 having opposing notches 244. As shown in Fig. 34, the cutting insert 230 has an insert intersection point P', insert surface angle A', insert offset distance Y', insert centering surface width Wc, and insert drive surface width Wd. Petition 870250085938, dated 09 / 23 / 2025, p. 16 / 71 11 / 24

[038] Figs. 35-41 illustrate a cutting insert 330 according to another embodiment of the present invention. The cutting insert 330 includes centering surfaces 337 and torque transmission drive surfaces 338. A relief channel 339 is provided between the adjacent centering surfaces 337 and the torque transmission surfaces 338. The cutting insert 330 includes a pin 340 extending rearward from a rear face 332 of the cutting insert head 330 having opposing notches 344. As shown in Fig. 41, the cutting insert 330 has an insert intersection point P', insert surface angle A', insert offset distance Y', insert centering surface width Wc, and insert drive surface width Wd.

[039] Figs. 42-51 illustrate another modular rotary cutting tool 405 of the present invention, including a shank 410 and a cutting insert 430 having features in common with several of the features described in the embodiments above. The shank 410 includes helical channels 411 and a front pocket 412. A floor 416 is provided on the underside of the pocket 412. The pocket 412 includes opposing centering walls 414 and torque transmission walls 415. As shown in Fig. 45, the centering walls 415 of the pocket 416 can be oriented at a seating angle S, which can be selected as described above. Cooling holes 418 are provided on the front surfaces of the shank 410 on opposite sides of the pocket 412 and can be of the same size or different sizes. The rod 410 includes a central receiving pin hole 420 having a tail contact region 421 and a front contact region 422, as described in more detail below.As shown more clearly in Figures 44 and 53, a threaded fastening bolt hole 424 receives a threaded fastening bolt 426 and extends at an angle B relative to the longitudinal axis of the rod 410 from one side of the rod to the receiving hole of the pin 420. An impact hole 428 extends radially through the side of the rod 410 and intersects the receiving hole. Petition 870250085938, dated 09 / 23 / 2025, p. 17 / 71 12 / 24 of pin 420.

[040] The cutting insert 430 includes a head 431, rear face 432 and front tip 433. Helical channels 434 are provided along the side of the cutting insert 430. The side edges 435 are provided adjacent to the grooves 434, and the front cutting edges 436 are provided in front of the head 431.

[041] The cutting insert 430 includes centering surfaces 437 and torque transmission drive surfaces 438. As described in the embodiments above, the centering surfaces of the insert 437 may be slightly angled relative to each other to coincide with the seating of the angles S of the respective centering walls of the fitting 414 of the fitting 412 of the shank 410. The drive surfaces of the insert 438 may be parallel to each other in planes parallel to the central longitudinal axis of the cutting insert 430. A relief channel 439 is provided between the adjacent centering surfaces 437 and the torque transmission surfaces 438.

[042] The cutting insert 430 includes a pin 440 with a front end 441 and a rear end 442. As described above, the pin 440 may be integrally formed with the head 431, or it may be provided as a separate component that is joined or mechanically fastened to the head 431, for example, the head 431 may comprise a carbide material and the pin 440 may comprise a steel material fastened to the head. Opposing notches 444, including contact surfaces of the fastening screw 445, are provided on the side of the pin 440. The pin 440 includes a front portion 446 and a tail 448 divided by the opposing notches 444. In the embodiment shown, the notches 444 are located on opposite sides of the pin 440 spaced circumferentially 180° from each other. Alternatively, a single groove can extend 360° circumferentially around pin 440.

[043] The 410 rod has a diameter Ds and the 412 pocket has a width of Petition 870250085938, dated 09 / 23 / 2025, p. 18 / 71 13 / 24 centering wall Wc measured on pocket floor 416, as shown in Fig. 45. Pocket 412 also has a drive wall width Wd, as shown in Fig. 46. As shown in Fig. 47, each pocket centering wall 414 and the adjacent pocket drive wall 415 define planes that intersect on a pocket floor plane 416 at a pocket intersection point P. A pocket wall angle A is defined at the pocket intersection point P, where the planes of pocket centering wall 414 and pocket drive wall 415 meet. A pocket displacement distance Y is defined as the distance measured on the floor of pocket 416 in the plane of the centering wall of pocket 414 that extends perpendicularly from a plane in which the central longitudinal axis of rod 10 is located to the intersection point of pocket P, as shown in Fig. 47. As shown in Figs.45-47, pocket 412 has a centering wall width Wc measured at the floor of pocket 416 and a drive wall width Wd, measured at the floor of pocket 416. Flat surface areas of each centering wall 414 and adjacent drive wall 415 can be selected relative to each other. The flat surface area of ​​each pocket centering wall 414 can be designated as SAc, while the flat surface area of ​​each pocket drive wall 415 can be designated as SAd. The surface area of ​​the pocket drive unit SAd can be controlled as a percentage of the pocket centering wall surface area SAc, i.e., the percentage SAd / SAc. By controlling the structure, arrangement, and dimensions of the features described above, the rods of the present invention provide favorable properties such as improved torque transmission, stiffness, and stability during the operation of rotary cutting tools.

[044] As shown in Figures 50 and 52, the insert head 430 has an insert head diameter Dh, an insert centering surface width W'c, and an insert drive surface width W'd. As shown Petition 870250085938, dated 09 / 23 / 2025, page 19 / 71 14 / 24 in Fig. 52, each centering surface of the insert 437 and the drive surface of the adjacent insert 438 define planes that intersect in a back face plane 432 at an intersection point of the insert P'. A surface angle of the insert A' is defined at the intersection point of the insert P'. A displacement distance of the insert Y' is defined as the distance measured on the back face 432 in the plane of the centering surface 437 that extends perpendicularly from a plane in which the longitudinal center axis of the cutting insert 430 is located at the intersection point of the insert P', as shown in Fig. 52. As shown in Fig. 52, the insert has a centering surface width of the insert W'c measured on the back face 432, and a drive surface width W'd measured on the back face 432.The flat surface areas of each centering surface 437 and the adjacent drive surface 438 can be selected relative to each other. The flat surface area of ​​each centering surface of the insert 414 can be designated as SA'c, while the flat surface area of ​​each drive surface of the insert 415 can be designated as SA'd. The drive surface area of ​​the insert SA'd can be controlled as a percentage of the centering surface of the insert SA'c, i.e., the SA'd / SA'c percentage. According to the present invention, the insert surface angle A', the insert travel distance Y', and other structural features described above are controlled to provide better torque transmission, stiffness, and stability during the operation of rotary cutting tools.

[045] As shown more clearly in Figures 51 and 53, pin 440 has a total length Lp, and a tail length Lt measured from the rear of notch 444 to the rear end 442 of the pin. Pin 440 has diameter Dp. As shown in Fig. 53, the fastening screw 426 is supplied at a fastening screw angle B measured between a central longitudinal axis of the screw of Petition 870250085938, dated 09 / 23 / 2025, page 20 / 71 15 / 24 fixing 426 and the central longitudinal axis of the pin 440. The angle of the fixing screw B corresponds to a similar angle of the fixing screw hole 424 in the rod 410, as shown in Fig. 44, measured between a central longitudinal axis of the fixing screw hole 424 and the central longitudinal axis of the rod 410. The angle B of the fixing screw and the corresponding angle of the fixing screw hole can normally be from 20 to 40°, for example, from 25 to 35° or from 28 to 32°. As shown schematically in Fig. 53, during the installation and retention of the cutting insert 430 in the rod 410, the fixing screw 426 generates a fixing screw force Fs along the longitudinal axis of the fixing screw 426 at the fixing screw angle B.The fastening screw force Fs has an axial component Fum that acts to force the 440 pin axially into the receiving hole of the 420 pin, and a radial component Fr that acts to radially force portions of the 440 pin against opposing surfaces of the receiving hole of the 420 pin, thus bending or deforming the 440 pin by a controlled amount, as described in more detail above.

[046] A clearance G is provided between pin 440 and the receiving hole of pin 420 of rod 410. The provision of such a clearance G allows the tail 448 of pin 440 to deform by a controlled amount in a radial direction along the radial component Fr of the fastening bolt force Fs. This creates a tail contact region Ct on the tail 448 that engages with an opposite rear inner surface 421 of the receiving hole of pin 420. A direct contact region Cf on the front portion 446 of pin 440 may also contact an opposite front inner surface 442 of the receiving hole of pin 420.

[047] The pocket wall angle A described above may be greater than 90°, or greater than 125°, or greater than 135°, or greater than 140°. The pocket wall angle A may be less than 155°, or less than 150°, or less than 148°, or less than 145°. The pocket wall angle A may vary from 90 to 150°, for example, from Petition 870250085938, dated 09 / 23 / 2025, page 21 / 71 16 / 24 125 to 150°, or from 135 to 148°, or from 140 to 145°.

[048] The surface angle A' of the insert described above may be greater than 90°, or greater than 125°, or greater than 135°, or greater than 140°. The surface angle A' of the insert may be less than 155°, or less than 150°, or less than 148°, or less than 145°. The surface angle A' of the insert may vary from 90 to 150°, for example, from 125 to 150°, or from 135 to 148°, or from 140 to 145°.

[049] The described pocket displacement distance Y can be selected as a percentage of the rod diameter Ds. The Y / Ds percentage can be greater than 0.5%, or greater than 1%, or greater than 2%, or greater than 2.5%, or greater than 3%, or greater than 5%. The Y / Ds percentage can be less than 20%, or less than 17%, or less than 15%. The Y / Ds percentage can range from 1 to 20%, for example, from 2.5 to 17%, or from 3 to 15%, or from 5 to 14%.

[050] The insert displacement distance Y' described above can be selected as a percentage of the insert head diameter Dh. The Y' / Dh percentage can be greater than 0.5%, or greater than 1%, or greater than 2%, or greater than 2.5%, or greater than 3%, or greater than 5%. The Y' / Dh percentage can be less than 20%, or less than 17%, or less than 15%. The Y' / Dh percentage can vary from 1 to 20%, for example, from 2.5 to 17%, or from 3 to 15%, or from 5 to 14%.

[051] The width of the centering pocket wall Wc described above can be selected as a percentage of the rod diameter Ds. The Wc / Ds percentage can be greater than 15%, or greater than 16%, or greater than 18%. The Wc / Ds percentage can be less than 30%, or less than 28%, or less than 25%, or less than 23%. The Wc / Ds percentage can range from 15 to 30%, for example, from 16 to 28%, or from 18 to 25%, or from 18 to 23%.

[052] The width of the insert centering surface W'c described above can be selected as a percentage of the insert head diameter Dh. The W'c / Dh percentage can be greater than 15%, or greater than 16%, or greater than Petition 870250085938, dated 09 / 23 / 2025, page 22 / 71 17 / 24 18%. The W'c / Dh percentage can be less than 30%, or less than 28%, or less than 25%, or less than 23%. The W'c / Dh percentage can vary from 15 to 30%, for example, from 16 to 28%, or from 18 to 25%, or from 18 to 23%.

[053] The drive compartment wall width Wd described above can be selected as a percentage of the pocket centering wall width Wc. The Wd / Cc percentage can be greater than 1%, or greater than 10%, or greater than 15%, or greater than 25%, or greater than 28%. The Wd / Cc percentage can be less than 100%, or less than 90%, or less than 85%, or less than 75%, or less than 60%. The Wd / Cc percentage can range from 1 to 100%, for example, from 10 to 90%, or from 15 to 85%, or from 25 to 75%, or from 28 to 60%.

[054] The width of the insert's drive surface W'd described above can be selected as a percentage of the width of the insert's centering surface W'c. The percentage W'd / C'c can be greater than 1%, or greater than 10%, or greater than 15%, or greater than 25%, or greater than 28%. The percentage W'd / C'c can be less than 100%, or less than 90%, or less than 85%, or less than 75%, or less than 60%. The percentage W'd / C'c can vary from 1 to 100%, for example, from 10 to 90%, or from 15 to 85%, or from 25 to 75%, or from 28 to 60%.

[055] The wall surface area of ​​the pocket unit SAd can be selected as a percentage of the centering wall surface area of ​​the pocket SAc. The SAd / SAc percentage can be greater than 30%, or greater than 34%, or greater than 50%, or greater than 70%, or greater than 75%. The SAd / SAc percentage can be less than 200%, or less than 190%, or less than 145%, or less than 130%, or less than 120%. The SAd / SAc percentage can range from 40 to 170%, for example, from 45 to 165%, or from 50 to 135%, or from 65 to 125%.

[056] The drive surface area of ​​the SA'd insert can be selected as a percentage of the centering surface area of ​​the Petition 870250085938, dated 09 / 23 / 2025, page 23 / 71 18 / 24 SA'c tablet. The SA'd / SA'c percentage can be greater than 30%, or greater than 34%, or greater than 50%, or greater than 70%, or greater than 75%. The SA'd / SA'c percentage can be less than 200%, or less than 190%, or less than 145%, or less than 130%, or less than 120%. The SA'd / SA'c percentage can vary from 40 to 170%, for example, from 45 to 165%, or from 50 to 135%, or from 65 to 125%.

[057] The total length of the insert pin Lp and the length of the insert head Lh can be selected as a ratio. The Lp:Lh ratio can be greater than 1:1, or greater than 1.05:1, or greater than 1.1:1. The Lp:Lh ratio can be less than 2:1, or less than 1.9:1, or less than 1.8:1, or less than 1.5:1. The Lp:Lh ratio can vary from 1:1 to 2:1, for example, from 1.1:1 to 1.8:1, or from 1.1:1 to 1.6:1, or from 1.1:1 to 1.5:1.

[058] The length of the pin tail Lt can be selected as a percentage of the total pin length Lp. The Lt / Lp percentage can be greater than 20%, or greater than 22%, or greater than 24%, or greater than 25%. The Lt / Lp percentage can be less than 40%, or less than 35%, or less than 33%, or less than 32%. The Lt / Lp percentage can range from 20 to 40%, for example, from 22 to 35%, or from 24 to 33%, or from 25 to 32%.

[059] The total length of the pin Lp and the diameter of the pin Dp can be selected as a ratio. The Lp:Dp ratio can be greater than 3:1, or greater than 3.2:1, or greater than 3.4:1, or greater than 3.5:1. The Lp:Dp ratio can be less than 6:1, or less than 5:1, or less than 4:5.1, or less than 4.0:1. The Lp:Dp ratio can vary from 3.0:1 to 6.0:1, for example, from 3.2:1 to 5:1, or from 3.4:1 to 4.5:1, or from 3.5:1 to 4.0:1.

[060] The pin tail length Lt and the pin diameter Dp can be selected as a ratio. The Lt:Dp ratio can be greater than 0.95:1, or greater than 1.0:1, or greater than 1.05:1. The Lt:Dp ratio can be less than 2.0:1, or less than 1.8:1, or less than 1.6:1, or less than 1.5:1. The Lt:Dp ratio can Petition 870250085938, dated 09 / 23 / 2025, p. 24 / 71 19 / 24 ratios range from 0.95:1 to 2.0:1, for example, from 1.0:1 to 1.8:1, or from 1.0:1 to 1.6:1, or from 1.05:1 to 1.5:1.

[061] The pin diameter Dp can be selected as a percentage of the insert head diameter Dh. The Dp / Dh percentage can be greater than 15%, or greater than 17%, or greater than 19%, or greater than 20%. The Dp / Dh percentage can be less than 30%, or less than 27%, or less than 25%, or less than 24%. The Dp / Dh percentage can range from 15 to 30%, for example, from 17 to 27%, or from 19 to 25%, or from 20 to 24%.

[062] The clearance G, for example, between hole 420 and pin 440, can be greater than 0 mm, or greater than 0.002 mm, or greater than 0.003 mm, or greater than 0.004 mm, or greater than 0.005 mm. The clearance G can be less than 0.1 mm, or less than 0.08 mm, or less than 0.05 mm. The clearance G can vary from 0.002 to 0.1 mm, or from 0.003 to 0.08 mm, or from 0.004 to 0.06 mm, or from 0.005 to 0.05 mm.

[063] Current pocket-to-pad designs offer superior torque transmission capability, stiffness, and stability under lateral loads. A good correlation was found between offset distance and performance. When the offset distance falls within the values ​​listed above, pocket stresses remain under controlled limits, providing a robust design. The resulting contact area between the pocket centering walls and the pad centering surfaces was found to be sufficiently large to prevent premature wear under cyclic loads. By providing the offset distances described here, small contact areas can be provided between the pocket centering walls and the pad centering surfaces that help transmit torque, along with torque transmission from the pocket drive walls to the pad drive surfaces.The stresses caused by the additional contact in the centering portions act in different regions than the stresses created by the torque transmitted in the drive regions. However, very high values... Petition 870250085938, dated 09 / 23 / 2025, page 25 / 71 20 / 24 large displacements for the travel distances will cause the cross-section of the pad to be too small, potentially becoming the weakest point in the system.

[064] Due to the clearance G between pin 440 and the receiving hole of pin 420 and the angle B of the longitudinal axis of the adjusting screw to the longitudinal axis of the pin, a force applied by the adjusting screw 426 will create a vertical component necessary for clamping and a lateral component that will attempt to bend the pin and may cause the insert to be clamped slightly inclined or off-center. The deformation of pin 440 and the contact between its tail 448 and the opposite inner wall of the receiving hole of pin 420 add stability and reduce the relative movement between the cutting insert 430 and the pocket 412, especially when oscillating lateral loads are generated in a drilling operation, for example, when drilling on angled surfaces or cross holes.

[065] By using a pin with a high Lp / Dp ratio, contact is achieved between the pin and the hole, and additional clamping force can be applied without generating extra stresses on the pin near the seating surface. A long pin can also store more elastic deformation than a short pin, which keeps the system preloaded and prevents the fastening screw from loosening due to vibration, wear, or thermal expansion of the components. The combination of a long pin with a small angle B, which allows for a longer fastening screw, leads to a greater sum of elastic deformation, i.e., stored energy. By making the pin longer, there is sufficient contact between the pin and the hole, and due to the relatively large diameter of the pin, there can be an increase in the stiffness of the system. The high pressure caused by the contact can be reduced by providing a relatively high Lt:Dp ratio, and the combination of a high Lp:Dp ratio with a high Lt:Dp ratio leads to an improved design.

[066] In addition, the selected Lt:Dp ratio creates sufficient support area to keep the contact pressure with the hole to a minimum. A pressure of Petition 870250085938, dated 09 / 23 / 2025, page 26 / 71 The 21 / 24 contact ratio is found in the tail portion and depends on the pin stiffness (directly affected by Lp / Dp), the clearance G, and the force applied by the clamping screw. Reducing the contact pressure allows a greater force to be applied by the clamping screw, which in turn creates a more stable connection between the insert and the pocket. The relatively high ratio also allows for a reduction in stress in the 444 notch region of the 440 pin.

[067] Figs. 54 to 59 illustrate a removal tool 50 that can be used to remove the cutting inserts of the present invention from the cutting tool shanks, for example, for replacement, inspection, sharpening or repair purposes. The removal tool 50 includes a cam tip 52 at one end thereof. The body of the impact tool 50 may include a generally circular cross-section, while the cam tip comprises a portion having a generally cylindrical outer surface 54 and a cam surface 56. Although not shown in the figures, an opposite end of the removal tool 50 may include a keyed end that can be fitted into a corresponding recess in the retaining screw to tighten and loosen the retaining screw, and the removal tool may generally be L-shaped to facilitate the removal operation as well as the tightening of the retaining screw.

[068] As shown in Figs. 54 to 59, an impact hole 428 extends radially through a side wall of the rod 410 and intersects the receiving hole of the pin 420 in a region of the rear end 442 of the pin 440. For example, the rear end 442 may extend at least 10%, or at least 20%, or at least 30%, or at least 40% into the diameter of the impact hole 428, as shown in Figures 44, 55 and 58. Although the radially extending impact hole is at a slight angle, for example, 5° to 30°, or 15° to 25°, perpendicular to the central longitudinal axis of the rod 410 in the embodiment shown, it may alternatively be provided perpendicularly. In Figs. 55 Petition 870250085938, dated 09 / 23 / 2025, p. 27 / 71 In Figures 22 / 24 and 56, the cam tip 52 is aligned externally with the impact hole 428. In Figures 58 and 59, the cam tip 52 has been inserted into the impact hole 428 in a position where the surface of the cam 56 contacts the rear end 442 of the pin 440. By rotating about the central longitudinal axis of the removal tool 50 from the position shown, the surface of the cam 56 is forced against the rear end 442, thus forcing the pin 440 axially in an extraction direction through the receiving hole of the pin 420. The cam tip 52 exerts sufficient force to remove the cutting insert 430 from the shank 410.

[069] For the purposes of this detailed description, it should be understood that the invention may assume various alternatives and sequences of steps, except where expressly specified otherwise. Furthermore, except in any operational examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims should be understood as being modified in all cases by the term “approximately”. Consequently, unless indicated otherwise, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending on the desired properties to be obtained by the present invention.At a minimum, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be interpreted in light of the reported number of significant digits and by applying common rounding techniques.

[070] Although the ranges and numerical parameters set forth in the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported to the greatest extent possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in its respective test measurements. Petition 870250085938, dated 09 / 23 / 2025, page 28 / 71 23 / 24

[071] Furthermore, it should be understood that any numerical interval cited in this document is intended to include all subintervals subsumed within it. For example, an interval of “from 1 to 10” is intended to include all subintervals between (and including) the minimum recited value of 1 and the maximum recited value of 10, i.e., having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

[072] As used herein, “including,” “containing,” and similar terms are understood in the context of this application as synonyms for “comprising” and are therefore open-ended and do not exclude the presence of additional elements, materials, ingredients, or method steps not described or recited. As used herein, “consisting of” is understood in the context of this application as excluding the presence of any unspecified element, ingredient, or method step. As used herein, “essentially consisting of” is understood in the context of this application as including the specified elements, materials, ingredients, or method steps “and those that do not materially affect the basic and novel feature(s)” of what is being described.

[073] In this application, the use of the singular includes the plural and the plural includes the singular, unless specifically indicated otherwise. For example, although reference is made here to “a” powder composition, “a” cemented carbide body and “a” apparent density, a combination (i.e., a plurality) of these components may be used.

[074] Furthermore, in this application, the use of “or” means “and / or”, unless specifically indicated otherwise, although “and / or” may be used explicitly in certain cases.

[075] Although specific aspects of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to these details could be developed in light of the teachings. Petition 870250085938, dated 09 / 23 / 2025, page 29 / 71 24 / 24 general disclosure. Consequently, the specific arrangements disclosed should be merely illustrative and not limiting as to the scope of the invention, which should be given the full scope of the appended claims and any and all equivalents thereof. Petition 870250085938, dated 09 / 23 / 2025, p. 30 / 71

Claims

1 / 6 CLAIMS 1. Modular rotary cutting tool, CHARACTERIZED in that it comprises: a rod having a central longitudinal axis and comprising a central hole for receiving pins and a front pocket, the front pocket comprising: first and second opposing pocket centering walls; first and second torque transmission pocket drive walls; and a pocket floor;and a removable and installable cutting insert in the front pocket of the rod, comprising a receiveable pin in the rod's receiving pin hole, wherein the first pocket centering wall defines one plane, the first pocket drive wall defines another plane, the first pocket centering wall plane and the first pocket drive wall plane intersect at a pocket intersection point P located on the pocket floor at a pocket wall angle A measured at the intersection point P, and the pocket wall angle A is greater than 90° and less than 155°, and wherein each of the first and second pocket drive walls are arranged in planes parallel to the longitudinal axis of the rod.

2. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the intersection point P is located at a pocket offset distance Y measured on the pocket floor in a direction on the first pocket centering wall plane from a plane in which the longitudinal axis of the rod is located, and the pocket offset distance Y is 1 to 20% of a rod diameter Ds.

3. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the pocket has a pocket centering wall width Wc measured on the pocket floor, a pocket drive wall width Wd measured on the pocket floor, and the pocket drive wall width Wd is greater than 10% of the pocket centering wall width Wc.

4. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that each of the first and second opposing pocket centering walls are arranged at a seat angle S greater than 0.5° measured from the longitudinal axis of the shank.

5. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the first pocket centering wall has a flat surface area SAc, the first pocket drive wall has a flat surface area SAd, and the flat surface area of ​​the first pocket drive wall SAd is 50 to 135% of the flat surface area SAc of the first pocket centering wall.

6. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the shank comprises cooling holes in the front surfaces of the shank on opposite sides of the front pocket.

7. Modular rotary cutting tool, according to claim 6, CHARACTERIZED in that the cooling holes have different sizes, the shank comprises an angled clamping screw hole extending through one side of the shank adjacent to the first opposite pocket centering wall and adjacent to one of the first front surfaces of the shank to the central receiving pin hole, and one of the cooling holes having a smaller size than the other of the cooling holes is located on the first front surface of the shank that is adjacent to the clamping screw hole.

8. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the cutting insert comprises a head with length Lh measured in an axial direction of the cutting insert, a pin extending behind the head in the axial direction having a length Lp, and a length-to-head ratio Lp:Lh is greater than 1:

1.

9. Modular rotary cutting tool, according to claim 8, CHARACTERIZED in that the pin comprises at least one lateral notch located between a front end of the pin and a rear end of the pin and defining a pin tail with a length Lt, and the pin tail length Lt is greater than 20% of a total pin length Lp.

10. Modular rotary cutting tool, according to claim 9, CHARACTERIZED in that the pin tail length Lt is greater than the pin diameter Dp.

11. Modular rotary cutting tool, according to claim 1, CHARACTERIZED in that the pin has a diameter Dp, the pin receiving hole has a diameter Dh greater than the pin diameter Dp, and a clearance G is provided between the pin and the pin receiving hole.

12. A shaft of a modular rotary cutting tool, CHARACTERIZED in that the shaft has a central longitudinal axis and comprises a central hole for receiving a pin and a front pocket, comprising: first and second opposing pocket centering walls; first and second pocket drive walls for torque transmission; and a pocket floor, wherein the first pocket centering wall defines one plane, the first pocket drive wall defines another plane, the first pocket centering wall plane and the first pocket drive wall plane intersect at a pocket intersection point P located on the pocket floor at a pocket wall angle A measured at the pocket intersection point P, and Petition 870250085938, dated 09 / 23 / 2025, page 1.33 / 71 4 / 6 pocket wall angle A is greater than 90° and less than 155°, wherein each of the first and second pocket drive walls are arranged in planes parallel to the longitudinal axis of the rod.

13. Cutting insert for a modular rotary cutting tool having a central longitudinal axis and comprising a head and a pin extending rearward from the head, the head CHARACTERIZED in that it comprises: first and second insert centering surfaces; first and second torque transmission insert drive surfaces;and a rear face, wherein the first insert centering surface defines one plane, the first insert drive surface defines another plane, the first insert centering surface plane and the first insert drive surface plane intersect at an insert intersection point P' located in a rear surface plane at an insert surface angle A' measured at the intersection point P', and the insert surface angle A' is greater than 90° and less than 155°, and wherein each of the first and second insert drive surfaces are arranged in planes parallel to the longitudinal axis of the shank.

14. Cutting insert for a modular rotary cutting tool, according to claim 13, CHARACTERIZED in that the insert intersection point P' is located at an insert offset distance Y' measured in the back surface plane in a direction in the first insert centering surface plane from a plane in which the central longitudinal axis of the insert is located, and the insert offset distance Y' is from 1 to 20% of a head diameter Dh.

15. Cutting insert for a modular rotary cutting tool, of Petition 870250085938, dated 09 / 23 / 2025, page 34 / 71 5 / 6 according to claim 13, CHARACTERIZED in that the first and second insert centering surfaces define an insert centering surface width W'c measured in a plane of the back surface, the first and second insert drive surfaces define an insert drive surface width W'd measured in the plane of the back surface, and the insert drive surface with W'd is at least 10% of the insert centering surface width W'c.

16. Cutting insert for a modular rotary cutting tool, according to claim 13, CHARACTERIZED in that each of the first and second insert centering surfaces are arranged at a seat angle S of at least 0.5° measured from the longitudinal axis of the insert.

17. Cutting insert for a modular rotary cutting tool, according to claim 13, CHARACTERIZED in that the first insert centering surface has a flat surface area SA'c, the first insert drive surface has a flat surface area SA'd, and the flat surface area SA'd of the insert drive surface is 50 to 135% of the flat surface area SA'c of the first centering surface.

18. Cutting insert for a modular rotary cutting tool, CHARACTERIZED in that it comprises: a head with a length Lh measured in an axial direction of the cutting insert; and a pin extending behind the head in the axial direction having a length Lp, wherein the pin-to-head length ratio Lp:Lh is greater than 1:

1.

19. Cutting insert for a modular rotary cutting tool having a Petition 870250085938, dated 09 / 23 / 2025, page.35 / 71 6 / 6 central longitudinal axis including a cutting head, CHARACTERIZED in that it comprises: first and second insert centering surfaces; first and second torque transmission insert drive surfaces; and a rear face, wherein the first insert centering surface defines one plane, the first insert drive surface defines another plane, the first insert centering surface plane and the first insert drive surface plane intersect at an insert intersection point P' located in a plane of the rear surface at an insert surface angle A' measured at the intersection point P', and the insert surface angle A' is greater than 90° and less than 155°, and wherein each of the first and second insert drive surfaces are arranged in planes parallel to the longitudinal axis of the shaft. Petition 870250085938, dated 09 / 23 / 2025, p. 36 / 71.

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