Indexable milling cutters with precise coolant flow

Abstract

The present invention discloses an indexable milling cutter with precise coolant flow. The indexable milling cutter includes a milling cutter body having a plurality of chip flutes and a plurality of seat surfaces suitable for mounting cutting blades thereon. The milling cutter body includes a plurality of coolant reservoirs in fluid communication with an adapter. On the one hand, each coolant reservoir is placed along a circular intersection line of a coolant manifold. On the other hand, the longitudinal axis of each coolant reservoir is oriented at a non-zero angle A relative to the central longitudinal axis of the milling cutter. A plurality of coolant conduits in fluid communication with each coolant reservoir provide a plurality of coolant flows aligned with a plurality of specific critical cutting areas of the cutting blade, and a cross-sectional area of ​​each coolant conduit is smaller than a cross-sectional area of ​​the coolant reservoir.

Description

Technical Field

[0001] Generally, embodiments relate to cutting tools, and more particularly, to lightweight cutting tools, such as reamers and the like, made from composite materials including steel, carbon fiber, and the like using additive manufacturing (ie, 3D printing) to optimize the shape and distribution of the material. Background Art

[0002] For example, when trying to use a reamer to machine a large hole, the tool can become very heavy. Heavy tools are problematic for operators who must carry the tool. Additionally, the time to accelerate and decelerate the tool to its required speed decreases as the tool weight and moment of inertia decrease. Furthermore, many machines with automatic tool changers also have weight limits for the tools that the machine can replace. Therefore, there is a need to minimize the weight of large tool holders to allow for easier handling and reduce operating costs.

[0003] refer to Fig.11 and 12 , a specific embodiment of a conventional milling cutter 120 having replaceable cutting inserts 122 is shown. The milling cutter 120 has a plurality of recesses 124 within a milling cutter body 126. The recesses 124 provide clearance for mounting the cutting inserts 122, which are the cutting portions of the milling cutter 120, as the cutting edges 128 of the cutting inserts 122 engage the workpiece at the insert-chip interface, which is where the cutting inserts engage the workpiece.

[0004] Each groove 124 includes a seat surface 132 for receiving its corresponding cutting insert 122. The cutting insert 122 is held against the seat surface 132 by a set screw 134 which is threadedly engaged with an aperture 136 opening at the seat surface 132 of the milling cutter body 126. A shank 138 projects from the milling cutter body 126 which is operatively attached to a rotary drive device (not shown). The milling cutter 120 and the rotary drive device share a common structure. Fig.11 The common axis of rotation is shown by the dashed line AR-AR in FIG. The handle 138 also provides a path for delivering coolant to the milling cutter 120.

[0005] Reference now Fig.12 , Fig.12 It is taken along section line 12-12 Fig.1112 is a cross-sectional view of the milling cutter 120, with section line 12-12 being along the centerline of a coolant conduit 150 contained in the milling cutter body 126. The coolant conduit 150 has a diameter "A". The coolant conduit 150 provides a passage for coolant to travel from a centrally located coolant reservoir 152 within the milling cutter body 126 to the groove 124. The coolant reservoir 152 contains a supply of coolant. A coolant spray nozzle 160 is at an outlet end 154 of the coolant conduit 150, which is adjacent to the groove 124. The coolant conduit 150 further has an inlet end 156 adjacent to or near the reservoir 152.

[0006] With reference to the operation of a particular embodiment of a conventional milling cutter using a coolant spray nozzle 160, coolant is supplied under pressure from a coolant source 112 (shown in schematic form) so that the coolant flows into a coolant reservoir 152, from which the coolant flows and enters the coolant spray nozzle 60 through a coolant conduit 50. The coolant flows through the coolant spray nozzle 60 and the coolant is discharged under pressure in the form of a fan-shaped coolant spray 114 that impacts the intersection between the cutting edge 128 of the cutting insert 122 and the workpiece 116, thereby delivering the coolant to the insert-chip interface.

[0007] Unfortunately, due to geometrical constraints, the coolant channels are usually larger in diameter, and the exiting coolant flow is usually directed over the cutting insert, failing to target all critical cutting areas of the cutting insert. As a result, the cooling effect of the cutting insert is poor, and a relatively large amount of coolant waste is generated. Summary of the invention

[0008] The problems of poor cooling effect and large amount of coolant waste can be solved by forming a coolant reservoir for each cutting insert extending from a coolant manifold to a predetermined distance from the outer surface of the flute. Then, a plurality of coolant holes or conduits extending from the outer surface of the flute to the bottom surface of the coolant reservoir are formed, thereby effectively cooling the critical cutting area of ​​the cutting insert while reducing coolant waste, and each hole or conduit has a relatively small cross-sectional area compared to the coolant reservoir.

[0009] In one aspect, a rotary cutting tool comprises: an adapter including an internal main coolant channel and a secondary coolant channel extending from the internal main coolant channel to a front end surface of the adapter; and a milling cutter attached to the adapter. The milling cutter comprises: a milling cutter body having a plurality of flutes and a plurality of seat surfaces adapted to mount cutting inserts thereon, the milling cutter body further comprising a guide hole adapted to receive a pilot of the adapter; a coolant manifold in fluid communication with the internal main coolant channel of the adapter. At least one coolant reservoir is in fluid communication with the coolant manifold. A plurality of coolant conduits are in fluid communication with the at least one coolant reservoir to provide coolant flow directed to a plurality of specific critical cutting areas of the cutting insert. The at least one coolant reservoir is placed along a circular intersection line of the coolant manifold. In addition, the at least one coolant reservoir has a longitudinal axis, wherein the longitudinal axis of the at least one coolant reservoir is oriented at a non-zero angle A relative to a central longitudinal axis of the milling cutter. In addition, the cross-sectional area of ​​each coolant conduit is smaller than the cross-sectional area of ​​the at least one coolant reservoir.

[0010] On the other hand, a rotary cutting tool includes: an adapter including an internal primary coolant channel and a secondary coolant channel extending from the internal primary coolant channel to the front end surface of the adapter; and a milling cutter attached to the adapter. The milling cutter includes: a milling cutter body having a plurality of flutes and a plurality of seat surfaces suitable for mounting cutting blades thereon, the milling cutter body also including a coolant manifold in fluid communication with the internal primary coolant channel of the adapter. A plurality of coolant reservoirs are in fluid communication with the coolant manifold. A plurality of coolant conduits are in fluid communication with each coolant reservoir to provide a coolant flow directed to a plurality of specific critical cutting areas of the cutting blade. The bottom of each coolant reservoir terminates at a predetermined distance D from each flute of the milling cutter, and wherein the predetermined distance D is in a range between about 0.5 mm and about 2.0 mm.

[0011] On the other hand, a milling cutter includes a milling cutter body having a plurality of chip flutes and a plurality of seat surfaces suitable for mounting cutting blades thereon. The milling cutter body includes a coolant manifold in fluid communication with an internal main coolant channel of an adapter. A plurality of coolant reservoirs are in fluid communication with the coolant manifold, and a plurality of coolant conduits are in fluid communication with each coolant reservoir to provide coolant flow directed to a plurality of specific critical cutting areas of the cutting blades. Each coolant reservoir is placed along a circular intersection line of the coolant manifold. In addition, each coolant reservoir has a longitudinal axis, wherein the longitudinal axis of each coolant reservoir is oriented at a non-zero angle A relative to the central longitudinal axis of the milling cutter. In addition, the cross-sectional area of ​​each coolant conduit is smaller than the cross-sectional area of ​​each coolant reservoir. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Although various embodiments are shown, the specific embodiments shown should not be construed as limiting the claims.It is contemplated that various changes and modifications may be made without departing from the scope of the present disclosure.

[0013] Figure 1 is a side view of a rotary cutting tool according to an embodiment, the rotary cutting tool being, for example, an indexable milling cutter, when attached to a tapered adapter;

[0014] Figure 2 It is along Figure 1 A cross-sectional view of the rotary cutting tool taken along line 2-2;

[0015] Figure 3 is a side view of an indexable milling cutter having precise coolant flow directed to critical areas of a cutting insert according to an embodiment;

[0016] Figure 4 is another side view of a milling cutter according to an embodiment, showing a coolant reservoir, a coolant conduit, and an outlet end in a model;

[0017] Figure 5 is a cross-sectional view of a milling cutter taken along a central longitudinal axis of the milling cutter, showing a pilot hole, a fastener hole, a coolant manifold, and a coolant reservoir in fluid communication with the coolant manifold, according to an embodiment;

[0018] Figure 6 is a partial cross-sectional view of a milling cutter according to an embodiment, showing a guide hole, a coolant manifold, and a coolant reservoir in fluid communication with the coolant manifold;

[0019] Figure 7 is an enlarged cross-sectional view of a coolant flow path according to an embodiment, with coolant flowing through a coolant manifold into a guide of an adapter and into one of the coolant reservoirs of a milling cutter;

[0020] Figure 8 is a front perspective view of a shoulder milling cutter with precise coolant flow directed to critical areas of a cutting insert according to an embodiment;

[0021] Fig. 9 is another front view of a shoulder milling cutter according to an embodiment, showing a coolant reservoir, a coolant conduit, and an outlet port in a model;

[0022] Fig.10 is a rear perspective view of a shoulder milling cutter according to an embodiment showing a guide hole, a coolant reservoir, and a coolant conduit;

[0023] Fig.11 is a perspective view of a conventional indexable milling cutter having a coolant spray nozzle; and

[0024] Fig.12 It is along Fig.11 A cross-sectional view of a conventional indexable milling cutter taken along line 12-12. DETAILED DESCRIPTION

[0025] Reference now Figure 1 and Figure 2 , shows a rotary cutting tool 10 according to an embodiment. Generally speaking, the rotary cutting tool 10 includes a milling cutter 12 and a tapered adapter 14, and at least one cutting blade 13 is mounted on the milling cutter 12. A threaded fastener 15 can be used to attach the milling cutter 12 to the tapered adapter 14. The milling cutter 10 includes a central longitudinal axis (i.e., z-axis) 17. The central longitudinal axis 17 is generally the axis of rotation of the rotary cutting tool 10. The threaded fastener 15 includes a head portion 16 and a threaded portion 18. The milling cutter 12 has threads 20 to allow the fastener 15 to be screwed into the milling cutter 12. The milling cutter 12 can be placed on a guide 22 of the tapered adapter 14, and the threaded fastener 15 can be screwed into the tapered adapter 14 to secure the milling cutter 12 to the tapered adapter 14.

[0026] In the illustrated embodiment, the rotary cutting tool includes a milling cutter 12 and a tapered adapter 14. However, it should be appreciated that the principles encompassed herein can be applied to any type of rotary cutting tool, such as boring bars, drills, etc. Additionally, it should be appreciated that the principles encompassed herein can be applied to any type of adapter, such as non-tapered, cylindrical, etc.

[0027] Directional phrases used herein, such as left, right, front, rear, top, bottom and their derivatives relate to the orientation of elements shown in the drawings and do not limit the claims unless explicitly stated therein. In all drawings, like parts have like reference numerals.

[0028] Approximate language as used herein throughout the specification and claims may be applied to modify any quantitative representation that may vary in a permissible manner without causing a change in its associated basic function. Therefore, values ​​modified by one or more terms such as "about", "approximately" and "substantially" are not limited to the exact values ​​specified. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. Here and throughout the specification and claims, range limitations may be combined and / or interchangeable, unless otherwise indicated by context or language, such ranges are determined and include all subranges contained therein.

[0029] Throughout the text and claims, use of the word "about" with respect to ranges of values ​​(e.g., "about 22 wt % to 35 wt %) is intended to modify both the upper and lower values ​​recited and to reflect the degree of ambiguity associated with measurements, significant figures, and interchangeability, all of which would be understood by one of ordinary skill in the art to which the present disclosure pertains.

[0030] For the purpose of this specification (except in the operating examples), unless otherwise stated, all numerical values ​​representing the quantity and range of components, process conditions, etc. should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters set forth in this specification and the appended claims are approximate values ​​that can vary depending on the desired results attempted to be obtained by the embodiments. At least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be interpreted at least according to the numerical value of the reported significant figures and by adopting general rounding techniques. In addition, as used in this specification and the appended claims, unless clearly and unambiguously limited to a reference, the singular forms "one (a)", "a kind of (an)" and "described" are intended to include plural references.

[0031] Although the numerical ranges and parameters describing a wide range are approximate, the numerical values ​​described in the specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors, which must be caused by the standard deviation found in their respective test measurements (including the standard deviation found in the measuring instrument). Similarly, it should be understood that any numerical range listed herein is intended to include all subranges contained therein. For example, the range "1 to 10" is intended to include all subranges contained between the listed minimum value 1 and the listed maximum value 10, that is, a range with a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless otherwise expressly stated, the various numerical ranges specified in this application are all approximate.

[0032] In the following description and claims, reference is made to a number of terms having the following meanings.

[0033] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0034] "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0035] As used herein, the term "elongated" is defined as something that is longer than it is wide. In other words, the width is less than its length.

[0036] As used herein, the term "circle" is defined as an object having the shape of a circle, that is, an object having a simple closed shape. It is the set of points in a plane at a given distance from a given point, the center; equivalently, it is the curve described by points that move in the plane so that their distance from the given point is constant. The distance between any point and the center is called the radius.

[0037] As used herein, the term "fluid" is defined as a substance, such as a gas or a liquid, that has no fixed shape and readily yields to external pressure.

[0038] As used herein, the term "3D printing" is any of a variety of processes in which materials are joined or solidified under computer control to create a three-dimensional object, with materials being combined together, such as liquid molecules or powder particles being fused together, usually layer by layer. In the 1990s, 3D printing technology was considered suitable only for the production of functional or aesthetic prototypes, and at that time, the broader term for 3D printing was rapid prototyping. Today, the accuracy, repeatability, and range of materials have increased to the point where 3D printing is considered an industrial production technology, with the official term being "additive manufacturing."

[0039] As used herein, the term "hole" is defined as something that is an open slot; a gap; a cavity or an orifice that may have any cross-sectional shape.

[0040] As used herein, the phrase "critical area of ​​the cutting insert" is defined as the area of ​​the chip / insert interface where coolant is delivered.

[0041] As used herein, the term "manifold" is defined as a conduit or chamber that branches into several openings.

[0042] As used herein, the term "reservoir" is defined as a container or chamber for holding a liquid or fluid.

[0043] As used herein, the term "conduit" is defined as any cannula, passage, conduit, or channel through which fluid, air, or other matter is conducted or transported.

[0044] refer to Figure 1 and Figure 2 The tapered adapter 14 is coupled to a mounting system (not shown) of a known machine tool (not shown). The adapter 14 includes a tapered shank 24 adapted to engage the machine tool and a non-tapered shank 26 having a front end surface 28. Figure 2As shown, when the rotary cutting tool 10 is assembled, the guide 22 extends outwardly from the front end surface 28 and is coaxial with the central longitudinal axis 17. The adapter 14 also includes an intermediate flange 30 disposed between the tapered shank 24 and the non-tapered shank 26 for automated handling of the tapered adapter 14.

[0045] A threaded hole 32 may be disposed in a rear end surface 33 of the tapered shank 24 for attaching the adapter 14 to a machine tool. As shown, the tapered adapter 14 is a CV-type adapter manufactured by Kennametal. However, it should be understood that the adapter 14 may be any type known to one of ordinary skill in the art suitable for mounting a rotary tool to a machine tool, such as a DV-type, BT-type, or KM-type adapter manufactured by Kennametal, a CAPTO (Coromant)-type adapter, or an HSK-type adapter.

[0046] In the illustrated embodiment, the tapered adapter 14 includes an internal primary coolant passage 34 extending through the adapter 14 to facilitate the flow of a fluid, such as coolant, from the machine tool to the milling cutter 12. An annular or ring-shaped secondary coolant passage 40 disposed within the guide 22 is in fluid communication with the internal primary coolant passage 34. The secondary coolant passage 40 extends from the internal primary coolant passage 34 to a front end surface 42 of the guide 22. Thus, as shown in FIG. Figure 2 As shown, a fluid such as a coolant can travel completely through the adapter 14 along a coolant flow path F (indicated by arrows) extending from the rear end surface 33 to the front end surface 41. In addition, the tapered adapter 14 includes a pair of circular drive pins 44, 46 disposed on and extending from the front end surface 28.

[0047] exist Figure 1 and Figure 2 In the illustrated embodiment, a total of five (5) cutting blades 13 are mounted on the cutting body 12 of the rotary cutting tool 10. As is known, the cutting blades 13 are indexable. Therefore, the milling cutter 12 is also referred to as an indexable milling cutter. In addition, it should be understood that the embodiments are not limited by the number of cutting blades 13 mounted on the cutter body 12, and the principles broadly covered herein can be applied to a cutter body 12 on which any number of cutting blades 13 can be mounted equidistantly and / or tangentially.

[0048] like Figure 3 and Figure 4As shown, the milling cutter 12 has a cutter body 48, and a plurality of chip flutes 50 are formed in the cutter body 48. The chip flutes 50 provide clearance for the installation of the cutting blade 13 and help to remove the chips generated during the cutting operation. In the illustrated embodiment, the cutting blade 13 is an indexable, replaceable blade made of, for example but not limited to, cemented carbide (e.g., tungsten (cobalt) cemented carbide, which may optionally contain titanium carbide, tantalum carbide and / or niobium carbide), ceramic (e.g., aluminum oxide, silicon aluminum oxynitride (SiAlON), superhard materials (e.g., cubic boron nitride) and metal ceramics (e.g., titanium carbide-based materials). Therefore, the milling cutter 12 is also referred to as an indexable milling cutter. Each cutting blade 13 includes one or more main cutting edges 13a that engage with a workpiece (not shown) at the blade-chip interface. In addition, each cutting blade 13 includes one or more cutting corners 13b and one or more wiping surfaces 13c.

[0049] In the illustrated embodiment, each cutting blade 13 is a polygon having a total of five (5) main cutting edges 13a, a cutting corner 13b and a wiping surface 13c. Therefore, each cutting blade 13 can be indexed by rotating the cutting blade 13 about 72 degrees around its central axis so that different main cutting edges 13a engage with the workpiece during the cutting operation. However, it should be understood that the embodiments are not limited by the number of main cutting edges, wiping surfaces and cutting angles, and the embodiments can be practiced using cutting blades with any desired number of main cutting edges, wiping surfaces and cutting angles. For example, the cutting blade 13 can be a triangle, rectangle, hexagon, octagon, etc. In another example, the cutting blade 13 can be a circle having only a single main cutting edge 13a and an optional wiping surface 13c, and the cutting corner 13b can be removed.

[0050] A seat surface 52 is provided near each flute 50 for placing its corresponding cutting insert 13. As is known, the cutting insert 13 is fixed by a fixing screw 53 ( Fig. 9 ) is held against the seat surface 52, and the fixing screw 53 is engaged with the aperture 55 ( Figure 5 ) threaded engagement. As described above, the shank 54 extends rearwardly and outwardly to allow the milling cutter 12 to be operably attached to the adapter 14. The shank 54 includes one or more drive pin recesses 56 adapted to receive corresponding drive pins 44, 46 of the adapter 14. Figure 5 As shown, a groove 56 is formed in the rear end surface 58 of the milling cutter 12. Figure 2 As shown, when the milling cutter 12 is attached to the adapter 14 , the milling cutter 12 and the adapter 14 share a common axis of rotation (ie, are co-linear) with a central longitudinal axis 17 of the rotary cutting tool 10 .

[0051] Reference now Figure 5The milling cutter 12 includes a guide hole 60 formed in the rear end surface 58 of the milling cutter 12, and the guide hole 60 is suitable for receiving the guide member 22 of the adapter 14. In addition, the milling cutter 12 includes a fastener hole 62 formed in the front end surface 64 of the milling cutter 12, and the fastener hole 62 is suitable for receiving the threaded fastener 15.

[0052] A coolant manifold 66 is formed between the guide hole 60 and the fastener hole 62. Figure 5-7 As shown, the coolant manifold 66 is defined by a cylindrical sidewall 66a having a width W and a substantially planar bottom surface 60b that intersects the sidewall 66a at a circular intersection line 66c.

[0053] In one aspect, Figure 2 and Figure 4-7 As shown, the milling cutter 12 includes a plurality of coolant reservoirs 68 in fluid communication with the coolant manifold 66. Specifically, there is a one-to-one correspondence between the number of cutting blades 13 and the number of reservoirs 68. In other words, the number of coolant reservoirs 68 is equal to the number of cutting blades 13. Thus, in the illustrated embodiment, there are a total of five (5) coolant reservoirs 68 in fluid communication with the coolant manifold 66 (i.e., one coolant reservoir 68 for each cutting blade 13). However, it should be understood that the present invention is not limited by the number of coolant reservoirs 68, and the present invention can be practiced in situations where the number of coolant reservoirs 68 is different from the number of cutting blades 13. For example, it is contemplated that the principles of the present disclosure can be practiced with a single coolant reservoir 68 that can be arranged approximately 360 degrees around the axis of rotation AR of the milling cutter 12, as long as the cutting head 12 maintains sufficient structural integrity.

[0054] like Figure 6 As best shown in FIG. 1 , the coolant reservoirs 68 are equally spaced about the central longitudinal axis 17 of the milling cutter 12. In the illustrated embodiment, each of the five coolant reservoirs 68 is equally spaced about 72 degrees (i.e., 360 / 5) from one another about the central longitudinal axis 17 of the milling cutter 12. Figure 6 As shown, each coolant reservoir 68 is in fluid communication with the coolant manifold 66. Specifically, each coolant reservoir 68 is formed along a circular intersection line 66c between a cylindrical side surface 66a and a bottom surface 66b of the coolant manifold 66.

[0055] In addition, if Figure 5As shown, each coolant reservoir 68 is oriented at a non-zero angle A relative to the central longitudinal axis 17 of the milling cutter 12. In one embodiment, each coolant reservoir 68 is oriented at an angle A between about 15 degrees and about 65 degrees, depending on the size of the milling cutter 12. Each coolant reservoir 68 has a central longitudinal axis CL that intersects at a point P on the central longitudinal axis 17 of the milling cutter 12. In addition, as shown in FIG. Figure 4 As shown, each coolant reservoir 68 has a curved bottom surface 68a.

[0056] refer to Figure 5 , each coolant reservoir 68 can be manufactured by machining a cavity from the guide hole 60 toward the seat surface 52 of the corresponding cutting insert 13 and terminating at a predetermined distance D from the flute 50. In other words, the bottom 68a of each coolant reservoir 68 terminates at a predetermined distance D from the flute 50. In one embodiment, the distance D is between about 0.5 mm and about 2.0 mm. For example, the distance D can be about 1.0 mm. Machining the cavity can use conventional CNC machining methods, which use a ball end mill, a drill, or a combination of the two.

[0057] In addition, if Figure 5 and Figure 6 As shown, each coolant reservoir 68 has a non-circular cross-sectional shape. For example, each coolant reservoir 68 has an elongated or elliptical cross-sectional shape. However, it should be understood that the embodiment is not limited to the cross-sectional shape of each coolant reservoir, and the embodiment can be practiced using one or more coolant reservoirs having a circular cross-sectional shape and one or more coolant reservoirs 68 having a non-circular cross-sectional shape.

[0058] On the other hand, Figure 4 As shown, the milling cutter 12 includes a plurality of coolant conduits 70 disposed within the milling cutter body 48. In the illustrated embodiment, the milling cutter body 48 has three coolant conduits 70a, 70b, 70c in fluid communication with respective coolant reservoirs 68. Each coolant conduit 70a, 70b, 70c extends from its respective coolant reservoir 68 to a respective outlet end 72a, 72b, 72c in the flute 50 adjacent to the respective cutting insert 13.

[0059] Each coolant conduit 70a, 70b, 70c produces a targeted coolant flow 74a, 74b, 74c from its respective outlet end 72a, 72b, 72c. Thus, in the illustrated embodiment, the milling cutter 12 produces a total of three (3) coolant flows directed toward different critical cutting areas of the cutting blade 13. For example, Figure 3 and Figure 4As shown, coolant conduit 70a generates coolant flow 74a aligned with the main cutting edge 13a of the cutting insert 13, coolant conduit 70b generates coolant flow 74b aligned with the cutting corner 13b of the cutting insert 13, and coolant conduit 70c generates coolant flow 74c aligned with the wiping surface 13c of the cutting insert 13.

[0060] Each coolant conduit 70a, 70b, 70c and each outlet port 72a, 72b, 72c can be manufactured by forming a hole extending from the flute 50 to its corresponding coolant reservoir 68. Therefore, the coolant reservoir 68 and the coolant conduits 70a, 70b, 70c can all be manufactured using conventional CNC machining methods that use a ball end mill, a drill, or a combination of both without bottlenecks. In the illustrated embodiment, the coolant conduits 70a, 70b, 70c have a substantially circular cross-sectional shape. However, it should be understood that the embodiments are not limited by the cross-sectional shape of the coolant conduits, and embodiments can be practiced using coolant conduits having non-circular cross-sectional shapes.

[0061] Each coolant conduit 70a, 70b, 70c may have a diameter in a range between about 0.5 mm and about 5.0 mm. The coolant conduits 70a, 70b, 70c may have the same diameter. For example, each coolant conduit 70a, 70b, 70c may have a diameter of about 1.0 mm. Alternatively, one or more coolant conduits may have different diameters. For example, one coolant conduit may have a diameter of about 1.0 mm, while another coolant conduit may have a diameter of about 1.5 mm. In any case, the cross-sectional area of ​​each coolant conduit 70a, 70b, 70c is smaller than the cross-sectional area of ​​the coolant reservoir 68, thereby increasing the coolant pressure.

[0062] In addition, the total cross-sectional area of ​​the coolant conduits 70a, 70b, 70c has a smaller total cross-sectional area than the total cross-sectional area of ​​the coolant reservoir 68. Therefore, the milling cutter 12 uses less coolant than a single coolant conduit having a relatively larger cross-sectional area. For example, if the diameter of the three coolant conduits 70a, 70b, 70c is 1.0 mm, the total cross-sectional area is less than the total cross-sectional area of ​​a single coolant conduit having a diameter of 3.0 mm (i.e., three times the diameter of each of the three coolant conduits 70a, 70b, 70c).

[0063] With three coolant conduits having a diameter of 1.0 mm, the total cross-sectional area is as follows:

[0064] Area (3 × 1.0 mm hole) = (3)π(0.5 2 )=0.75π,

[0065] In the case of a single coolant conduit with a diameter of 3.0 mm, the total cross-sectional area is as follows:

[0066] Area (1×3.0 mm hole) = π(1.5 2 )=2.25π.

[0067] Thus, the total cross-sectional area of ​​three coolant conduits 70a, 70b, 70c having a diameter of 1.0 mm is less than the total cross-sectional area of ​​a single coolant conduit having a diameter of 3.0 mm. Thus, the milling cutter 12 having three coolant conduits uses less coolant than a conventional cutting tool having only a single relatively large coolant conduit.

[0068] When the diameter of the three coolant conduits 70a, 70b, 70c is 1.5 mm, the total cross-sectional area is still smaller than the total cross-sectional area of ​​a single coolant conduit with a diameter of 3.0 mm (ie, twice the diameter of each of the three coolant conduits 70a, 70b, 70c).

[0069] With three coolant conduits having a diameter of 1.5 mm, the total cross-sectional area is as follows:

[0070] Area (3 × 1.5 mm hole) = (3)π(0.75 2 )=1.69π.

[0071] In the case of a single coolant conduit with a diameter of 3.0 mm, the total cross-sectional area is as follows:

[0072] Area (1×3.0 mm hole) = π(1.5 2 )=2.25π.

[0073] Therefore, the total cross-sectional area of ​​three coolant conduits 70a, 70b, 70c, each with a diameter of 1.5 mm, is still less than the total cross-sectional area of ​​a single coolant conduit with a diameter of 3.0 mm. Therefore, the milling cutter 12 with three coolant conduits uses less coolant than a conventional cutting tool with only a single relatively large coolant conduit.

[0074] like Figure 2 As shown, a flow F of a fluid such as coolant flows into the primary coolant passage 34 formed in the rear end surface 33 of the tapered adapter 14. The coolant then travels from the internal primary coolant passage 34 and enters the annular secondary coolant passage 40 disposed in the guide 22, through the corresponding coolant reservoir 68, and into the coolant conduits 70a, 70b, 70c. The coolant then exits the outlet ends 72a, 72b, 72c in coolant streams 74a, 74b, 74c that are precisely directed to critical areas such as the major cutting edge 13a, cutting corner 13b, and wiping surface 13c of the cutting insert 13.

[0075] It should be understood that the embodiments are not limited by the number of coolant conduits, and the embodiments can be practiced with any number of multiple coolant conduits. In other words, depending on the number of critical cutting areas to which the coolant conduits should be directed, the embodiments can be practiced with any number of two or more coolant conduits.

[0076] For example, this principle can be practiced in a rotary cutting tool 10 including a shoulder milling cutter, such as Figure 8 and Fig. 9 As shown, the shoulder milling cutter has four coolant conduits 70a-d and four outlet ports 72a-d that produce a total of four coolant streams 74a-d that are directed to critical areas of the cutting insert 13. Figure 8 and Fig. 9 In the illustrated embodiment, the coolant reservoir 68 and coolant conduits 70a-d are arranged in a manner similar to Figure 1-7 The coolant reservoir 68 and coolant conduits 70a, 70b, 70c of the previous embodiment shown are manufactured in a similar manner.

[0077] exist Figure 8 and Fig. 9 In the illustrated embodiment, the coolant conduit 70a generates a coolant flow 74a from the outlet end 72a directed toward a first portion of the main cutting edge 13a of the cutting blade 13, the coolant conduit 70b generates a coolant flow 74b directed toward a cutting corner 13b of the cutting blade 13, the coolant conduit 70c generates a coolant flow 74c directed toward a wiping surface 13c of the cutting blade 13, and the coolant conduit 70d generates a coolant flow 74d from the outlet end 72d directed toward a second portion of the main cutting edge 13a.

[0078] It should also be noted that the four coolant conduits 70a-d have a smaller cross-sectional area and therefore use less coolant than a conventional cutting tool having a single relatively larger diameter coolant conduit. For example, if one coolant conduit has a diameter of 1.0 mm and the other three coolant conduits have a diameter of 1.5 mm, the cross-sectional area will be less than the cross-sectional area of ​​a single coolant conduit having a diameter of 3.5 mm.

[0079] If one coolant tube has a diameter of 1.0 mm and the other three coolant tubes have a diameter of 1.5 mm, then:

[0080] Area (1×1.0mm hole + 3×1.5mm hole) = π(0.5 2 )+3π(0.75 2 )=1.94π.

[0081] In the case of a single coolant conduit having a diameter of 3.5 mm,

[0082] Area (1×3.5mm hole) = π(1.75 2 )=3.06π.

[0083] Therefore, the total area of ​​the four coolant conduits, one of which has a diameter of 1.0 mm and the other three of which have a diameter of 1.5 mm, is still smaller than a single coolant conduit of 3.5 mm in diameter. Thus, the cutting tool uses less coolant than a conventional cutting tool with a single larger coolant conduit.

[0084] As described above, the rotary cutting tool 10 has a novel cooling technology, which has the following advantages:

[0085] 1) Effective cooling, reducing coolant consumption;

[0086] 2) Coolant pressure increases;

[0087] 3) Multiple, precisely aligned coolant streams per flute; and

[0088] 4) A feasible and economical bottleneck-free manufacturing process.

[0089] Although presently preferred embodiments have been described, the disclosure may be otherwise practiced within the scope of the appended claims.

Claims

1. A rotary cutting tool comprising: an adapter comprising a guide, an internal primary coolant passage, and a secondary coolant passage extending from the internal primary coolant passage to a front end surface of the adapter; as well as A milling cutter, attached to the adapter, the milling cutter comprising: a milling cutter body having a plurality of flutes and a plurality of seat surfaces adapted to mount cutting inserts thereon, the milling cutter body further comprising a guide hole adapted to receive the guide member of the adapter, and a fastener hole formed in the front end surface and adapted to receive a threaded fastener; a coolant manifold formed between the guide hole and the fastener hole and in fluid communication with the secondary coolant passage of the adapter, the coolant manifold being defined by a cylindrical sidewall having a width W and a bottom surface that intersects the sidewall substantially perpendicularly, the coolant manifold extending radially outward relative to the guide hole; at least one coolant reservoir in fluid communication with the coolant manifold; and a plurality of coolant conduits in fluid communication with the at least one coolant reservoir to provide coolant flow directed toward a plurality of specific critical cutting areas of the cutting blade, wherein the at least one coolant reservoir has a longitudinal axis which, when viewed in partial cross-section from the rear of the milling cutter, is located between the cylindrical side surface and the bottom surface of the coolant manifold, wherein the longitudinal axis of the at least one coolant reservoir is oriented at a non-zero angle A relative to a central longitudinal axis of the milling cutter, and The total cross-sectional area of ​​the plurality of coolant conduits is smaller than the cross-sectional area of ​​the at least one coolant reservoir.

2. The rotary cutting tool according to claim 1, wherein the total number of coolant reservoirs is equal to the total number of cutting blades. 3 . The rotary cutting tool of claim 1 , wherein a plurality of coolant reservoirs are equally spaced about the central longitudinal axis of the milling cutter. The rotary cutting tool of claim 1 , wherein the milling cutter comprises a shoulder milling cutter.

5. The rotary cutting tool according to claim 1, wherein the cross-sectional shape of the secondary coolant passage is annular.

6. The rotary cutting tool of claim 1, wherein a bottom of at least one coolant reservoir terminates at a predetermined distance D from each flute of the milling cutter.

7. The rotary cutting tool according to claim 6, wherein the predetermined distance D is within a range between 0.5 mm and 2.0 mm.

8. The rotary cutting tool of claim 1, wherein at least one coolant reservoir has a non-circular cross-sectional shape.

9. The rotary cutting tool according to claim 1, wherein the plurality of specific critical cutting areas include at least two of a major cutting edge, a cutting corner, and a wiping surface of the cutting insert.

10. A rotary cutting tool comprising: an adapter comprising a guide, an internal primary coolant passage, and a secondary coolant passage extending from the internal primary coolant passage to a front end surface of the adapter; as well as A milling cutter, attached to the adapter, the milling cutter comprising: a milling cutter body having a plurality of flutes and a plurality of seat surfaces adapted to mount cutting inserts thereon, the milling cutter body further comprising a guide hole formed in the rear end surface and adapted to receive the guide of the adapter, and a fastener hole formed in the front end surface and adapted to receive a threaded fastener; a coolant manifold formed between the guide hole and the fastener hole and in fluid communication with the secondary coolant passage of the adapter, the coolant manifold being defined by a cylindrical side wall having a width W and a bottom surface that intersects the side wall substantially perpendicularly at a circular intersection line defining an imaginary circle, the coolant manifold extending radially outward relative to the guide hole, wherein the circular intersection line is defined by an intersection between the cylindrical side surface and the bottom surface of the coolant manifold; a plurality of coolant reservoirs in fluid communication with the coolant manifold; and a plurality of coolant conduits in fluid communication with each coolant reservoir to provide coolant flow directed to a plurality of specific critical cutting areas of the cutting insert, wherein at least one of the coolant reservoirs has a longitudinal axis that lies on an imaginary circle defined by the circular intersection lines of the coolant manifolds when viewed in partial cross-section from the rear of the milling cutter, wherein the bottom of each coolant reservoir terminates at a predetermined distance D from each flute of the milling cutter, The predetermined distance D is within a range between 0.5 mm and 2.0 mm.

11. The rotary cutting tool of claim 10, wherein each coolant reservoir is positioned along the circular intersection line.

12. The rotary cutting tool of claim 10, wherein each coolant reservoir has a longitudinal axis, and wherein the longitudinal axis of each coolant reservoir is oriented at a non-zero angle A relative to a central longitudinal axis of the milling cutter.

13. The rotary cutting tool of claim 10, wherein each coolant reservoir has a cross-sectional area, and wherein each coolant conduit has a cross-sectional area that is less than the cross-sectional area of ​​each coolant reservoir.

14. The rotary cutting tool of claim 10, wherein a total number of coolant reservoirs is equal to a total number of cutting blades.

15. The rotary cutting tool of claim 10, wherein the plurality of coolant reservoirs are equally spaced about a central longitudinal axis of the milling cutter.

16. A milling cutter comprising a milling cutter body having a plurality of flutes and a plurality of seat surfaces adapted to mount cutting inserts thereon, the milling cutter body comprising: a coolant manifold formed between the guide bore and the fastener bore and in fluid communication with a secondary coolant passage of an adapter, the coolant manifold being defined by a cylindrical side wall having a width W and a bottom surface, the bottom surface intersecting the side wall substantially perpendicularly at a circular intersection line defining an imaginary circle, the coolant manifold extending radially outwardly relative to the guide bore, wherein the circular intersection line is defined by an intersection between the cylindrical side surface and the bottom surface of the coolant manifold; a plurality of coolant reservoirs in fluid communication with the coolant manifold; and a plurality of coolant conduits in fluid communication with each coolant reservoir to provide coolant flow directed to a plurality of specific critical cutting areas of the cutting blade, wherein each coolant reservoir has a longitudinal axis which, when viewed in partial cross-section from the rear of the milling cutter, lies on an imaginary circle defined by the circular intersection lines of the coolant manifolds, wherein the coolant reservoir has a longitudinal axis, and wherein the longitudinal axis of the coolant reservoir is oriented at a non-zero angle A relative to a central longitudinal axis of the milling cutter, and Wherein the coolant reservoir has a cross-sectional area, and wherein the plurality of coolant conduits have a total cross-sectional area, and wherein the total cross-sectional area of ​​the plurality of coolant conduits is less than the cross-sectional area of ​​the coolant reservoir.

17. The milling cutter of claim 16, further comprising a plurality of coolant reservoirs, wherein the plurality of coolant reservoirs are equally spaced about the central longitudinal axis of the milling cutter.

18. The milling cutter of claim 16, wherein the milling cutter comprises a shoulder milling cutter.

19. The milling cutter according to claim 16, wherein a bottom of the coolant reservoir terminates at a predetermined distance D from each flute of the milling cutter, the predetermined distance D being in a range between 0.5 mm and 2.0 mm.

20. The milling cutter of claim 16, wherein the coolant reservoir has a non-circular cross-sectional shape.

21. The milling cutter according to claim 16, wherein the plurality of specific critical cutting areas include at least two of a major cutting edge, a cutting corner, and a wiping surface of the cutting insert.

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