Milling cutting inserts

Abstract

The present invention discloses a milling cutting insert. A cutting tool system including a cutting tool holder and a cutting insert is disclosed. The cutting insert has eight cutting edges and eight wiper edges. A first face and a second face each include at least two cutting edges or two wiper edges located on alternating sides of the cutting insert. The cutting edges and wiper edges are structured and arranged to allow the cutting insert to be used interchangeably in right-handed and left-handed cutting tool holders.

Description

Technical Field

[0001] The present invention relates to a cutting tool, comprising a cutting tool holder and a cutting insert. In particular, the present invention relates to an indexable double-sided tangential milling cutting insert having a cutting edge and a wiper edge. Background Art

[0002] Indexable cutting inserts for cutting tools include, for example, cutting inserts made of carbide, ceramic, coated carbide, coated ceramic, or other hard materials. Such inserts typically have multiple cutting edges located at various corners or around the periphery of the insert. In conventional arrangements, the cutting insert is mechanically secured to a tool holder and is removable relative to the tool holder and can be easily repositioned (i.e., indexed) to present a fresh and new cutting edge to engage the workpiece. Due to the geometric constraints of the cutting insert, many indexable cutting inserts are unidirectional, either right-handed or left-handed.

[0003] In the metalworking industry, the demand for cost reduction and high productivity is increasing. From a geometric perspective, the two common approaches to indexable cutting insert design are either to design a double-sided cutting insert or to design more available cutting edges on a single-sided cutting insert. A double-sided cutting insert can double the number of available cutting edges, which has cost-saving benefits for both the end user and the cutting tool manufacturer. The ideal solution for a cost-effective indexable cutting insert design would be an indexable cutting insert with more available cutting edges and on both sides. However, compared to traditional single-sided cutting inserts, the geometric design of a double-sided cutting insert for milling is a more challenging task because positioning the double-sided cutting insert in the insert recess on the cutting tool holder is complex. The difficulty increases with the number of cutting edges. Furthermore, since the two sides of a single-turn double-sided cutting insert may not be simple mirror images of each other, the design of a single-turn double-sided cutting insert with more indexable cutting edges for milling operations is even more challenging.

[0004] Conventional cutting inserts used for milling 90 degree shoulders may be limited to a total of four cutting edges and four wiper edges. Summary of the Invention

[0005] The present invention provides a cutting insert having eight cutting edges and eight wiper edges. At least two cutting edges or two wiper edges can be disposed on alternating sides of the cutting insert. The cutting edges and wiper edges are structured and arranged to allow the cutting insert to be used in both right-handed and left-handed cutting tool holders. The cutting tool holder is further configured to engage and secure an indexable cutting insert.

[0006] One aspect of the present invention provides an indexable cutting insert including a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; first and second wiper edges formed at intersections between each of the first and second faces and each of the first pair of opposing side surfaces; first and second cutting edges formed at intersections between each of the first and second faces and each of the second pair of opposing side surfaces; and corner edges formed at intersections between each of the first and second faces and each of the corner radii.

[0007] Another aspect of the present invention provides an indexable tangential cutting insert comprising four right-handed cutting regions and four left-handed cutting regions, wherein the cutting insert is interchangeable between a first left-handed cutting tool holder and a second right-handed cutting tool holder.

[0008] Another aspect of the present invention provides a cutting tool system comprising a cutting tool holder having a central longitudinal rotational axis and comprising at least one insert recess in a cutting end, the at least one insert recess comprising a bottom seating surface, a first side wall portion extending substantially perpendicularly from the bottom seating surface, and an indexable cutting insert mounted within the at least one recess, the indexable cutting insert comprising: a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; first and second wiper edges formed at the intersection between each of the first and second faces and each of the first pair of opposing side surfaces; first and second cutting edges formed at the intersection between each of the first and second faces and each of the second pair of opposing side surfaces; and a corner edge portion formed at the intersection between each of the first and second faces and each of the corner radii.

[0009] These and other aspects of the invention will become apparent from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a front isometric view of a cutting insert according to an embodiment of the present invention.

[0011] Figure 2 yes Figure 1 Top isometric view of the cutting insert.

[0012] Figure 3 yes Figure 1 Front view of the cutting insert.

[0013] Figure 4 yes Figure 1 Rear view of the cutting insert.

[0014] Figure 5 yes Figure 1 Top view of the cutting insert.

[0015] Figure 6 yes Figure 1 Left side view of the tangential cutting insert.

[0016] Figure 7 yes Figure 1 Right side view of the tangential cutting insert.

[0017] 8 is a front view of a cutting tool system including a tool holder and a plurality of cutting inserts according to an embodiment of the present invention.

[0018] FIG. 9 is an enlarged view of circular area A of the cutting tool system of FIG. 8 .

[0019] Figure 10 is a bottom view of the cutting tool system shown in FIG. 8 .

[0020] Figure 11 is an isometric view of a tool holder according to an embodiment of the present invention. DETAILED DESCRIPTION

[0021] As used herein, the terms "right-hand" and "right-handed" refer to features of a cutting insert that are oriented so that they can effectively cut a workpiece when the tool holder is rotated in a right-hand or counterclockwise direction as viewed from the cutting end of the tool holder. As used herein, the terms "left-hand" and "left-handed" refer to features of a cutting insert that are oriented so that they can effectively cut a workpiece when the tool holder is rotated in a left-hand or clockwise direction as viewed from the cutting end of the tool holder.

[0022] Figure 1 and 2are front and top isometric views of a double-sided indexable cutting insert 10 according to an embodiment of the present invention. The cutting insert 10 may be an edge-type tangential milling cutting insert. The cutting insert includes a first face 12 and a second face 14 opposite the first face 12, and side surfaces 16, 18, 20, 22. Although a generally rectangular cutting insert 10 is shown in this embodiment, any other suitable shape of cutting insert may be used, for example, square, diamond, etc. The side surfaces 16, 18, 20, 22 serve as seating surfaces when the cutting insert 10 is mounted in a cutting tool holder, such as a milling cutter described below. According to one embodiment of the present invention, the side surfaces 16 and 18 may form a first pair of opposing side surfaces, and the side surfaces 20 and 22 may form a second pair of opposing side surfaces. As Figure 1 、 2 , 3 and 5, the cutting insert 10 includes a central longitudinal axis 11 extending in the Z-axis direction, a second axis 13 extending in the Y-axis direction perpendicular to the central longitudinal axis 11 and parallel to the plane of the side surfaces 16, 18, 20, 22, and a third axis 15 extending in the X-direction perpendicular to both the central longitudinal axis 11 and the second axis 13 and parallel to the plane of the side surfaces 16 and 18. According to one embodiment of the present invention, the cutting insert 10 is a double-sided insert, wherein the first face 12 is substantially identical to the second face 14. The cutting insert 10 is rotationally symmetric about the central longitudinal axis 11 by one hundred and eighty degrees. Therefore, for the sake of brevity, only the first face 12 will be described below. As is known in the art, the first face 12 can become the top surface and the second face can become the bottom surface when mounted in the tool holder, and vice versa.

[0023] like Figure 1-4 As shown in FIG, the cutting insert 10 includes a mounting through-hole 80 extending from the side surface 16 to the side surface 18. The mounting through-hole 80 is adapted to receive a fastener (not shown) for mounting the cutting insert 10 in a cutting tool holder, as shown in FIG. Figure 3 and 4 As shown in FIG, the mounting through hole 80 is centrally located in the side surfaces 16 and 18, the central longitudinal axis 11 passes through the center of the mounting through hole 80, and the second axis 13 and the third axis 15 intersect the central longitudinal axis 11 at the center of the mounting through hole 80, as shown in FIG. Figure 3 Thus, all three X, Y, and Z axes intersect at the center of the mounting through-hole 80. According to an embodiment of the present invention, the second axis 13 may extend through the cutting insert 10 at the midpoint of the side surfaces 20 and 22.

[0024] like Figure 1 、 Figure 2 、 Figure 6 and Figure 7As shown in , the cutting insert 10 includes a first corner radius 32 formed between the side surface 16 and the side surface 20, a second corner radius 34 formed between the side surface 20 and the side surface 18, a third corner radius 36 formed between the side surface 18 and the side surface 22, and a fourth corner radius 38 formed between the side surface 22 and the side surface 16.

[0025] According to an embodiment of the present invention, the features of the first face 12 and the second face 14 of the cutting insert 10 are rotationally symmetric one hundred and eighty degrees about the second axis 13. Figure 1 and 2 As shown in FIG, the cutting insert 10 includes a first wiper edge 24 and a second wiper edge 25 located at the intersection between the side surface 16 and the first face 12. The cutting insert 10 also includes a first wiper edge 26 and a second wiper edge 27 located at the intersection between the side surface 18 and the first face 12. Figure 1 and 2 As shown in FIG, the cutting insert 10 includes a first wiper edge 28 and a second wiper edge 29 at the intersection between the side surface 16 and the second face 14. The cutting insert 10 also includes a first wiper edge 30 and a second wiper edge 31 at the intersection between the side surface 18 and the second face 14. Thus, the double-sided cutting insert 10 includes a total of eight wiper edges.

[0026] like Figure 1 and 2 As shown in FIG, the cutting insert 10 comprises a first cutting edge 40 and a second cutting edge 41 at the intersection between the side surface 20 and the first face 12, and a first cutting edge 42 and a second cutting edge 43 at the intersection between the side surface 22 and the first face 12. Figure 1 and 7 As shown in FIG, the cutting insert 10 includes a first cutting edge 44 and a second cutting edge 45 located at the intersection between the side surface 20 and the second face 14, as well as a first cutting edge 46 and a second cutting edge 47 located at the intersection between the side surface 22 and the second face 14. Thus, the double-sided cutting insert 10 includes a total of eight cutting edges. In the illustrated embodiment, the first and second cutting edges are substantially linear. However, any other suitable cutting edge shape may be used; for example, the cutting edge may be concave, convex, sinusoidal, serrated, or the like.

[0027] like Figure 1 and 2As shown in , the cutting insert 10 includes a corner edge 50 located at the intersection between the first corner radius 32 and the first face 12, a corner edge 52 located at the intersection between the second corner radius 34 and the first face 12, a corner edge 54 located at the intersection between the third corner radius 36 and the first face 12, and a corner edge 56 located at the intersection between the fourth corner radius 38 and the first face 12. Figure 1 、 Figure 6 and Figure 7 , the cutting insert includes a corner edge 58 located at the intersection between the first corner radius 32 and the second face 14, a corner edge 60 located at the intersection between the second corner radius 34 and the second face 14, a corner edge 62 located at the intersection between the third corner radius 36 and the second face 14, and a corner edge 64 located at the intersection between the fourth corner radius 38 and the second face 14. According to an embodiment of the present invention, each corner edge may connect a wiper edge to an adjacent cutting edge, as further described below.

[0028] like Figure 1 、 Figure 2 and Figure 5 As shown, the first face 12 includes a rake face 90 extending inwardly from the first and second wiper edges 24 and 25, a rake face 92 extending inwardly from the first and second wiper edges 26 and 27, a rake face 94 extending inwardly from the first and second cutting edges 40 and 41, a rake face 96 extending inwardly from the first and second cutting edges 42 and 43, and a planar seating surface 98 located between the rake faces 90, 92, 94, and 96. Because the cutting insert 10 is rotationally symmetric about the third axis 15 at one hundred and eighty degrees, it will be understood that the second face 14 of the cutting insert 10 includes a planar seating surface and four rake faces.

[0029] like Figure 5 , the cutting insert 10 has an overall length L measured along the central longitudinal axis 11 and an overall width W measured along the third axis 15. According to embodiments of the present invention, any suitable overall length L and overall width W of the cutting insert 10 may be used. According to embodiments of the present invention, the cutting insert 10 may have any suitable height along the second axis 13.

[0030] like Figure 1 、 2 As shown in FIG3 , the intersection between the side surface 16 and the first face 12 includes a first wiper edge 24, a second wiper edge 25, and a transition edge 66 connecting the first wiper edge 24 to the second wiper edge 25. Figure 1 and 3 As shown in FIG, the first wiper edge 24 extends from the corner edge 56 to the transition edge 66, and the second wiper edge 25 extends from the transition edge 66 to the corner edge 50. Figure 1 and 2 As shown in FIG, the corner edge portion 50 connects the second wiper edge 25 and the first cutting edge 40 at the intersection between the side surface 20 and the first face 12. Figure 1 、 2 As shown in Figures 6 and 7, the intersection between the side surface 20 and the first face 12 includes a first cutting edge 40 and a second cutting edge 41. Figure 1 and 6 As shown in FIG, the first cutting edge 40 extends from the corner edge portion 50 to the second cutting edge 41, and the second cutting edge 41 extends from the first cutting edge 40 to the corner edge portion 52. Figure 1 As shown in FIG, the corner edge portion 52 connects the second cutting edge 41 to the first wiper edge 26 at the intersection between the side surface 18 and the first face 12. Figure 1 and 3 As shown in FIG, the intersection between the side surface 18 and the first face 12 includes a first wiper edge 26, a second wiper edge 27, and a transition edge 68 connecting the first wiper edge 26 to the second wiper edge 27. Figure 1 and 2 As shown in FIG, the first wiper edge 26 extends from the corner edge 54 to the transition edge 68, and the second wiper edge 27 extends from the transition edge 68 to the corner edge 56. Figure 1 and 2 As shown in FIG, the corner edge portion 56 connects the second wiper edge 27 and the first cutting edge 42 at the intersection between the side surface 22 and the first face 12. Figure 1 、 2 As shown in Figures 1 and 2, the intersection between the side surface 22 and the first face 12 includes a first cutting edge 42 and a second cutting edge 43. Figure 1 and 7 As shown in FIG, the first cutting edge 42 extends from the corner edge portion 56 to the second cutting edge 43 , and the second cutting edge 43 extends from the first cutting edge 42 to the corner edge portion 56 .

[0031] According to an embodiment of the present invention, the intersection between the side surface 16 and the first face 12 may be the same as the intersection between the side surface 16 and the second face 14, between the side surface 18 and the first face 12, and between the side surface 18 and the second face 14. Therefore, for the sake of brevity, only the intersection between the side surface 16 and the first face 12 will be described herein, and it should be understood that any description of the intersection between the side surface 16 and the first face 12 herein applies to the intersection between the side surface 16 and the second face 14, between the side surface 18 and the first face 12, and between the side surface 18 and the second face 14. Figure 3As shown, the first wiper edge 24 and the second wiper edge 25 can each include a convex portion along the Y-axis, and the transition edge 66 can include a concave portion along the Y-axis. However, any other suitable shapes and arrangements of wiper and transition edges can be used, such as straight, convex, concave, or complex curved shapes. According to another embodiment of the present invention, the first wiper edge 24 can directly intersect the second wiper edge 25.

[0032] like Figure 3 As shown in FIG, the central portion of the first wiper edge 24 may extend a greater distance in the Y-axis direction than the outer portions of the first wiper edge 24 adjacent to the corner edge 56 and the transition edge 66. Figure 3 As shown in FIG, the center portion of the second wiper edge 25 may extend a greater distance in the Y-axis direction than the outer portion of the second wiper edge 25 adjacent to the transition edge 66 and the corner edge portion 50. The first wiper edge 24 may be formed with a radius R W1 ,like Figure 3 For example, the radius R W1 Typically, the radius R may be in the range of about 3 mm to about 10 mm, about 4 mm to about 7 mm, or about 5 mm to about 6 mm. W1 The second wiper edge 25 may be formed with a radius R W2 ,like Figure 3 For example, the radius R W2 Typically, the radius R may be in the range of about 3 mm to about 10 mm, about 4 mm to about 7 mm, or about 5 mm to about 6 mm. W2 According to an embodiment of the present invention, the first wiper edge radius R W1 Can be equal to the second wiper edge radius R W2 Alternatively, the first wiper edge radius and the second wiper edge radius may be different.

[0033] According to an embodiment of the present invention, the outer portion of the transition edge 66 adjacent to the first and second wiper edges 24 and 25 may extend a greater distance on the Y axis than the central portion of the transition edge 66. The concave transition edge 66 may be formed with a radius R T ,like Figure 3 For example, the transition edge radius R T Typically, the radius R may be in the range of about 0.1 mm to about 4 mm, about 0.5 mm to about 3 mm, or about 1 mm to about 2 mm. T According to an embodiment of the present invention, the first wiper edge radius R is selected to be about 1.5 mm. W1 , Second wiper blade radius R W2 and transition edge radius R TTo allow a desired portion of the wiper edge to contact the workpiece during the cutting operation.

[0034] like Figure 5 As shown, the first wiper edge 24 has a width W W1 The second wiper edge 25 has a width W W2 , the transition edge 66 has a width W T According to an embodiment of the present invention, the first wiper edge width W W1 Typically, it may be in the range of 5% to 60% of the total width W of the cutting insert 10, or 10% to 50% of the total width W, or 25% to 45% of the total width W. According to an embodiment of the present invention, the second wiper edge width W W2 Typically, it may be in the range of 5% to 60% of the total width W of the cutting insert 10, or 10% to 50% of the total width W, or 25% to 45% of the total width W. According to an embodiment of the present invention, the first wiper edge width W W1 Can be equal to the second wiper edge width W W2 Alternatively, the first wiper edge width and the second wiper edge width may be different. According to an embodiment of the present invention, the first wiper edge width W W1 , Second wiper blade width W W2 and transition edge width W T The first wiper edge width W may vary depending on the overall width W of the cutting insert 10. For example, if the overall width W of the cutting insert 10 increases, the first wiper edge width W W1 , Second wiper blade width W W2 and transition edge width W T Alternatively, if the total width W of the cutting insert 10 is reduced, the first wiper edge width W W1 , Second wiper blade width W W2 and transition edge width W T Decrease.

[0035] According to an embodiment of the present invention, the intersection between the first corner radius 32 and the first face 12 may be the same as the intersection between the first corner radius 32 and the second face 14, the intersection between the second corner radius 34 and the first face 12 and the second face 14, the intersection between the third corner radius 36 and the first face 12 and the second face 14, and the intersection between the fourth corner radius 38 and the first face 12 and the second face 14. Therefore, for the sake of brevity, only the intersection between the first corner radius 32 and the first face 12 will be described herein, with it being understood that any description herein of the intersection between the first corner radius 32 and the first face 12 applies to each of the intersections between the corner radii 32, 34, 36, and 38 and the first face 12 and the second face 14. Figure 1 、 2As shown in Figures 3 and 5, the corner edge portion 50 located at the intersection between the first corner radius 32 and the first face 12 connects the second wiper edge 25 to the first cutting edge 40. According to an embodiment of the present invention, the corner edge portion 50 includes a concave curved portion formed with the second wiper edge 25 and a convex curved portion formed with the first cutting edge segment 40. According to an embodiment of the present invention, the portion of the corner edge portion 50 adjacent to the first cutting edge 41 may extend a greater distance in the Y-axis direction than the portion of the corner edge portion 50 adjacent to the second wiper edge 25. Figure 5 As shown, the corner edge portion 50 is formed to have a radius R C For example, the radius R of each corner edge C Typically, the radius R of each corner edge may be in the range of 0.1 mm to 4 mm, or 0.4 mm to 2 mm. C It may be about 0.8 mm.

[0036] According to an embodiment of the present invention, the intersection between the side surface 20 and the first face 12 may be the same as the intersection between the side surface 20 and the second face 14, between the side surface 22 and the first face 12, and between the side surface 22 and the second face 14. Therefore, for the sake of brevity, this document will only describe the intersection between the side surface 20 and the first face 12, and it should be understood that any description of the intersection between the side surface 20 and the first face 12 herein applies to the intersection between the side surface 20 and the second face 14, between the side surface 22 and the first face 12, and between the side surface 22 and the second face 14. According to an embodiment of the present invention, the first cutting edge 40 and the second cutting edge 41 are mirror-symmetrical about the Y axis. As shown in FIG. Figure 6 As shown, the first cutting edge 40 extends between the corner edge 50 and the midpoint of the side surface 20 at the second axis 13, and the second cutting edge 41 extends between the midpoint of the side surface 20 at the second axis 13 and the corner edge 52. Figure 1 and 6 As shown, the first cutting edge 40 and the second cutting edge 41 may intersect at the midpoint of the side surface 20. According to an embodiment of the present invention, the first cutting edge 40 may extend a greater distance along the Y-axis direction at the corner edge portion 50 than at the second axis 13, and the second cutting edge 41 may extend a greater distance along the Y-axis direction at the corner edge portion 52 than at the second axis 13. Figure 6 As shown, the first cutting edge 40 is formed from the second axis 13 at a first cutting edge angle A relative to the central longitudinal axis 11. C1 Extending to the corner edge portion 50, the first cutting edge angle can allow the first cutting edge 40 to be a right-handed cutting edge, as further described below. For example, the first cutting edge angle A C1 It may be at least 0.5 degrees, for example, from 1 degree to 30 degrees, or from 2 degrees to 20 degrees, or from 3 degrees to 10 degrees. Figure 6As shown, the second cutting edge 41 is formed from the second axis 13 at a second cutting edge angle A relative to the central longitudinal axis 11. C2 By extension, the second cutting edge angle can allow the second cutting edge 41 to be a left-handed cutting edge, as further described below. For example, the second cutting edge angle A C2 It may be at least 0.5 degrees, for example, from 1 degree to 30 degrees, or from 2 degrees to 20 degrees, or from 3 degrees to 10 degrees. According to an embodiment of the present invention, the first cutting edge angle A C1 Can be equal to the second cutting edge angle A C2 Alternatively, the first cutting edge angle and the second cutting edge angle may be different.

[0037] like Figure 6 As shown, the first cutting edge 40 has a length L C1 , the second cutting edge 41 has a length L C2 According to an embodiment of the present invention, the first cutting edge length L is selected C1 and the second cutting edge length L C2 To determine the axial depth of cut of the cutting insert 10. Figure 5 As shown, the first cutting edge length L C1 The second cutting edge length L extends between the corner edge portion 50 and the third axis 15. C2 The first cutting edge length L extends between the third axis 15 and the corner edge portion 52. C1 Typically, it may be in the range of 5% to 60% of the total length L of the cutting insert 10, or 10% to 50% of the total length L, or 25% to 45% of the total length L. According to an embodiment of the present invention, the second cutting edge length L C2 Typically, it may be in the range of 5% to 60% of the total length L of the cutting insert 10, or 10% to 50% of the total length L, or 25% to 45% of the total length L. According to an embodiment of the present invention, the first cutting edge length L C1 Can be equal to the second cutting edge length L C2 Alternatively, the first cutting edge length and the second cutting edge length may be different. According to an embodiment of the present invention, the first cutting edge length L C1 and the second cutting edge length L C2 The length L of the first cutting edge may vary depending on the total length L of the cutting insert 10. For example, if the total length L of the cutting insert 10 increases, the first cutting edge length L C1 and the second cutting edge length L C2 Alternatively, if the total length L of the cutting insert 10 is reduced, the first cutting edge length L C1 and the second cutting edge length L C2 Can be reduced.

[0038] According to an embodiment of the present invention, each corner edge portion and its adjacent wiper edge and cutting edge form a cutting area. Figure 1 As shown, the corner edge portion 50, the second wiper edge 25, and the first cutting edge 40 form a cutting zone. In some embodiments, the first face 12 may include four cutting zones, and the second face 14 may include four cutting zones. Therefore, the cutting insert 10 may include a total of eight cutting zones. According to an embodiment of the present invention, the first face 12 may include two right-handed cutting zones and two left-handed cutting zones. Because the cutting insert 10 is rotationally symmetrical one hundred and eighty degrees about the second axis 13, the two right-handed cutting zones are located at diagonally opposite corner edges of the first face 12 and the second face 14. For example, Figure 1 and 2 As shown, the cutting edge segments including corner edges 50 and 54 can be right-handed cutting edge segments, and cutting edge segments 52 and 56 can be left-handed cutting edge segments. As further described below, the cutting insert 10 can be indexed four times in a left-handed tool holder to allow each left-handed cutting edge area to be an active cutting area, and can be indexed four times in a right-handed tool holder to allow each right-handed cutting area to be an active cutting area. Thus, the cutting insert 10 is interchangeable between left-handed and right-handed tool holders. The same cutting insert 10 can be used with both left-handed and right-handed tool holders.

[0039] In the illustrated embodiment, the corner edges 52, 56, 58, and 62, the first wiper edges 24, 26, 28, and 30, and the second cutting edges 41, 43, 45, and 47 of the cutting insert 10 may each form a portion of a left-hand cutting region of the cutting insert 10. The corner edges 50, 54, 56, and 60, the second wiper edges 25, 27, 29, and 31, and the first cutting edges 40, 42, 44, and 46 of the cutting insert 10 may each form a portion of a right-hand cutting region of the cutting insert 10.

[0040] According to embodiments of the present invention, the orientation of the wiper edge, corner edge, and cutting edge allows the cutting insert 10 to achieve tight tolerances during milling of a 90 degree shoulder.

[0041] The cutting insert 10 may be made of any suitable material, such as tool steel, cemented carbide, and superhard materials, such as cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), polycrystalline diamond (PCD), tungsten carbide (WC), cermets, ceramics, etc. The cutting insert 10 of the present invention may be manufactured by any suitable technique, such as cemented carbide powder compacting, grinding, or additive manufacturing, to provide a wiper edge and a cutting edge.

[0042] Figures 8-10 show a cutting tool system 5 according to an embodiment of the present invention. The cutting tool system 5 includes a tool holder 100 and a plurality of cutting inserts 10 tangentially mounted therein. The tool holder 100 includes a tool body 112, which includes a cutting end 114 having a plurality of circumferentially spaced recesses 116 and a mounting end 118 opposite the cutting end 114. The tool body 112 is designed to be rotatably driven around a central longitudinal rotation axis 111. In the illustrated embodiment, the tool holder 100 is commonly known as a right-hand milling cutter and includes a total of five recesses 116. However, it should be understood that the present invention is not limited by the number of recesses 116, and the present invention can be practiced with any desired number of recesses that provide the required cutting capacity. Each of the recesses 116 can accommodate a cutting insert, which is securely retained in the recess 116 by means of an embedded screw (not shown). However, any other suitable method of fastening the cutting insert in the recess can be used, for example, a clamping pin, a clamping wedge, a bolt, a pin, etc. In the illustrated embodiment, each recess 116 of the tool holder 100 accommodates a single cutting insert 10 .

[0043] like Figure 11 As shown, the recesses 116 of the tool holder 100 each include a bottom seating surface 120, a first sidewall portion 122, and a second sidewall portion 124. In the illustrated embodiment, the first sidewall portion 122 can extend generally perpendicularly from the bottom seating surface 120, and the second sidewall portion 124 can extend generally perpendicularly from the bottom seating surface 120 and the first sidewall portion 122. According to embodiments of the present invention, the first sidewall portion 122 can include a threaded mounting hole (not shown) that can be configured to receive a mechanical fastener (not shown) to secure the cutting insert 10 within the insert recess 116. According to embodiments of the present invention, the recess 116 of the tool holder 100 is structured and arranged to mount the cutting insert 10 in a desired orientation for performing a cutting operation. For example, when mounted in the recess 116, the cutting insert 10 can have a negative axial rake angle and a negative radial rake angle. The negative axial rake angle and the negative radial rake angle can provide a positive axial clearance angle and a positive radial clearance angle for the side surfaces of the cutting insert 10, as further described below.

[0044] According to an embodiment of the present invention, a surface of the first sidewall portion 122 can define a plane extending radially outward from the second sidewall portion 124 and circumferentially from the bottom seating surface 120. As shown in FIG8 , the surface of the first sidewall portion 122 can extend circumferentially from the bottom seating surface 120, non-perpendicular to the central longitudinal rotational axis 111 of the tool body 112. When installed in the recess 116, the angle at which the first sidewall portion extends circumferentially from the bottom seating surface 120 can position the wiper edge of the cutting insert 10 at a negative axial rake angle. When the cutting insert 10 is installed in the recess 116, the negative axial rake angle created by the first sidewall portion 122 can provide a positive axial clearance angle between the side surfaces 16 and 18 of the cutting insert 10 and the workpiece. For example, the first sidewall portion 122 can extend circumferentially from the bottom seating surface 120 to provide a positive axial clearance angle of at least 0.25 degrees from the horizontal plane of the tool body 112. The positive axial clearance angle from the horizontal plane of the tool body can generally be in the range of 0.5 degrees to 15 degrees, or 1 degree to 10 degrees, or 2 degrees to 7.5 degrees. When installed in the recess 116 of the tool holder 100, the side surfaces 16 and 18 of the cutting insert 10 can also have the same positive clearance angle with the workpiece. The positive clearance angle created by the recess 116 of the tool holder 100 can allow only the wiper edge of the cutting insert 10 to contact the workpiece, while dragging the side surfaces 16 and 18 away from contact with the workpiece.

[0045] In some embodiments, a surface of the first side wall portion 122 may extend radially outward from the second side wall portion 124 non-perpendicular to the central longitudinal rotational axis 111 of the tool body. For example, the first side wall portion 122 may extend radially outward from the second side wall portion 124 at an angle relative to a horizontal axis of the tool body 112. In some embodiments, the first side wall portion 122 may extend radially outward from the second side wall portion 124 at an angle less than 90 degrees relative to the central longitudinal rotational axis 111 of the tool body 112. When the cutting insert 10 is installed in the recess 116, the angle at which the first side wall portion 122 extends radially outward from the second side wall portion 124 may provide a mounting angle A between the central longitudinal Z-axis 111 of the cutting insert 10 and the central longitudinal rotational axis 111 of the tool body 112. M , as further described below. The second sidewall portion 124 may be perpendicular to the first sidewall portion 122 and, therefore, may also be disposed at an angle relative to the central longitudinal rotational axis 111 of the tool body 112 .

[0046] According to an embodiment of the present invention, the orientation of the bottom seating surface 120 and the second sidewall portion 124 can position the cutting edge of the cutting insert 10 at a negative radial inclination angle when installed in the recess 116. The negative radial inclination angle formed by the bottom seating surface 120 and the second sidewall portion 124 can provide a positive radial clearance angle between the side surfaces 20 and 22 of the cutting insert 10 and the workpiece when the cutting insert 10 is installed in the recess 116. The positive radial clearance angle formed by the recess 116 of the tool holder 100 can allow only the cutting edge of the cutting insert 10 to contact the workpiece, while dragging the side surfaces 20 and 22 away from contact with the workpiece.

[0047] According to embodiments of the present invention, when the cutting insert 10 is installed in the tool body 112 during a cutting operation, the side surfaces 16, 18, 20, and 22 and the planar seating surface of the first and second faces 12, 14 of the cutting insert 10 can engage the recess 116. In certain embodiments, the bottom seating surface 120 can be configured to engage at least one of the planar seating surfaces of the first and second faces 12, 14, and the first and second side wall portions 122, 124 can be configured to engage at least two of the side surfaces 16, 18, 20, and 22 of the cutting insert 10. Thus, the cutting insert 10 is installed in the recess 116 with at least three contact points.

[0048] According to an embodiment of the present invention, the four right-handed cutting zones of the first and second faces 12, 14 allow the cutting insert 10 to be indexed four times in a right-handed tool holder 100, as shown in Figure 8. The four left-handed cutting zones of the first and second faces 12, 14 allow the cutting insert 10 to be subsequently indexed four times in a left-handed tool holder (not shown).

[0049] In certain embodiments, the cutting insert 10 can be mounted in the recess at an angle between the central longitudinal axis 11 of the cutting insert and the central longitudinal rotational axis 111 of the tool body 112. In the embodiment shown in FIG8 , when the cutting insert 10 is mounted in the recess 116 of the tool holder 100, the central longitudinal axis 11 forms a mounting angle A with respect to the central longitudinal rotational axis 111 of the tool body 112. M This allows a single cutting area to become an active cutting area that can contact the workpiece during the cutting operation. For example, mounting angle A M It may be at least 0.01 degrees, for example, 0.1 to 5 degrees, or 0.15 to 2.5 degrees, or 0.2 to 1 degree. M The active cutting area is formed by the corner edge 50, the second wiper edge 25 and the first cutting edge 40. MThe third axis 15 of the cutting insert may additionally be angled with the horizontal axis of the tool body 112. Mounting angle A M The radially outermost portion of each cutting insert 10 from the central longitudinal rotation axis 111 is such that it has a maximum distance from the tool body 112 along the central longitudinal rotation axis 111 .

[0050] According to an embodiment of the present invention, only the active cutting area can contact the workpiece (not shown). In some embodiments, the mounting angle A M A drop between the lowest point of the active wiper edge and the lowest point of the passive wiper edge can be provided along the central longitudinal rotation axis 111. In certain embodiments, the drop between the active wiper edge and the passive wiper edge can be at least 0.005 mm, such as 0.01 mm to 0.2 mm, or 0.02 mm to 0.1 mm. In a particular embodiment, the drop can be 0.03 mm. The drop between the active wiper edge and the passive wiper edge prevents the passive wiper edge from contacting the workpiece. As shown in FIG8 , the mounting angle A M The induced drop between the second wiper edge 25 of the active cutting area and the adjacent passive first wiper edge 24 allows the second wiper edge 25 to contact the workpiece only during the cutting operation.

[0051] The tool holder 100 may be made of any suitable material, such as steel, aluminum, titanium or any other material of sufficient strength.The tool holder 10 of the present invention may be manufactured by any suitable technique, such as machining to provide the insert recess.

[0052] As used herein, the terms "including" and "containing" are to be understood in the context of this application as being synonymous with "comprising" and, therefore, open-ended and do not exclude the presence of additional undescribed or unlisted elements, materials, phases, or method steps. As used herein, "consisting of" is to be understood in the context of this application as excluding the presence of any unspecified elements, materials, phases, or method steps. As used herein, "consisting essentially of" is to be understood in the context of this application as including the specified elements, materials, phases, or method steps, if applicable, and also including any unspecified elements, materials, phases, or method steps that do not materially affect the basic or novel characteristics of the invention.

[0053] For the purposes of the foregoing description, it will be understood that, unless expressly specified to the contrary, the present invention may employ various alternative variations and step sequences. In addition, all numbers expressing, for example, the quantity of ingredients used in the specification and claims should be understood to be modified in all cases by the term "about". Therefore, unless otherwise indicated, the numerical parameters set forth are approximate values that may vary depending on the desired properties sought to be obtained by the present invention. At a minimum, and without attempting to limit the application of the doctrine of equivalents, each numerical parameter should at least be interpreted in light of the number of reported significant figures and by applying ordinary rounding techniques.

[0054] It should be understood that any numerical range recited herein is intended to include all subranges contained therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the recited minimum value of 1 and the recited maximum 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.

[0055] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the plural encompasses the singular. Additionally, in this application, the use of "or" means "and / or" unless explicitly stated otherwise, even though "and / or" could be explicitly used in certain circumstances. In this application, the articles "a," "an," and "the" include plural referents unless explicitly and clearly limited to one referent.

[0056] While specific embodiments of the present invention have been described above for purposes of illustration, it will be apparent to those skilled in the art that numerous changes in the details of the invention may be made without departing from the invention as defined in the appended claims.

Claims

1. A indexable cutting insert comprising: a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; a first wiper edge and a second wiper edge formed at an intersection between each of the first face and the second face and each of the first pair of opposing side surfaces; a first cutting edge and a second cutting edge formed at an intersection between each of the first and second faces and each of the second pair of opposing side surfaces; a corner edge formed at an intersection between each of the first and second faces and each corner radius; as well as a transition edge formed between each of the first and second faces and each of the first pair of opposing side surfaces and connecting the first wiper edge and the second wiper edge, wherein the first wiper edge and the second wiper edge include a convex portion, and The transition edge includes a concave portion extending inwardly in a plane defined by an adjacent one of the first pair of opposing side surfaces. 2 . The indexable cutting insert of claim 1 , further comprising a mounting through-hole extending through the first pair of opposing side surfaces, a center of the mounting through-hole defining a central longitudinal axis.

3. The indexable cutting insert according to claim 2, wherein: The cutting insert defines a second axis perpendicular to the central longitudinal axis and parallel to the first and second pairs of opposing side surfaces, and a third axis perpendicular to the central longitudinal axis and the second axis.

4. The indexable cutting insert according to claim 1, wherein: Each of the convex portions includes a radius within a range from 3 mm to 10 mm.

5. The indexable cutting insert according to claim 1, wherein: The corner edge portion connects the wiper edge and the cutting edge, and forms a concave portion with the wiper edge and a convex portion with the cutting edge.

6. The indexable cutting insert of claim 1 , wherein: The first cutting edge extends from the first corner edge portion to a midpoint of a second pair of opposing side surfaces, and the second cutting edge extends from the midpoint of the second pair of opposing side surfaces to the second corner edge portion.

7. The indexable cutting insert of claim 1 , wherein: The indexable cutting insert is a tangential milling cutting insert.

8. The indexable cutting insert according to claim 3, wherein: The first cutting edge extends at a first cutting edge angle relative to the central longitudinal axis between the midpoint of the second pair of opposing side surfaces and the first corner edge portion, and the second cutting edge extends at a second cutting edge angle relative to the central longitudinal axis between the midpoint of the second pair of opposing side surfaces and the second corner edge portion.

9. The indexable cutting insert according to claim 8, wherein: The first cutting edge angle is 1 to 30 degrees, and the second cutting edge angle is 1 to 30 degrees.

10. The indexable cutting insert of claim 3, wherein: The first surface and the second surface are rotationally symmetric about the second axis by 180 degrees.

11. The indexable cutting insert of claim 1 , wherein: Each corner edge portion and the adjacent wiper edge and the adjacent cutting edge form a cutting area.

12. The indexable cutting insert according to claim 11, wherein: The cutting insert includes four right-handed cutting zones and four left-handed cutting zones.

13. An indexable tangential cutting insert comprising: a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; a first wiper edge and a second wiper edge formed at an intersection between each of the first face and the second face and each of the first pair of opposing side surfaces; a first cutting edge and a second cutting edge formed at an intersection between each of the first and second faces and each of the second pair of opposing side surfaces; wherein the first cutting edge and the second cutting edge intersect each other at a position extending inwardly in a plane defined by an adjacent one of the second pair of opposing side surfaces; as well as a corner edge formed at an intersection between each of the first face and the second face and each corner radius, Each corner edge portion and an adjacent first wiper edge among the first wiper edges and an adjacent second cutting edge among the second cutting edges form a cutting area, The cutting insert includes four right-handed cutting areas and four left-handed cutting areas. Therein, the cutting insert is interchangeable between a first left-handed cutting tool holder and a second right-handed cutting tool holder.

14. A cutting tool system comprising: A cutting tool holder having a central longitudinal axis of rotation and comprising at least one insert recess in a cutting end, the at least one insert recess comprising: bottom seating surface; a first side wall portion extending generally perpendicularly from the bottom seating surface; and An indexable cutting insert mounted in at least one recess, the indexable cutting insert comprising: a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; a first wiper edge and a second wiper edge formed at an intersection between each of the first face and the second face and each of the first pair of opposing side surfaces; first and second cutting edges formed at intersections between each of the first and second faces and each of the second pair of opposing side surfaces; and a corner edge formed at an intersection between each of the first face and the second face and each corner radius, a transition edge formed between each of the first and second faces and each of the first pair of opposing side surfaces and connecting the first wiper edge and the second wiper edge, wherein the first wiper edge and the second wiper edge include convex portions, and The transition edge includes a concave portion extending inwardly in a plane defined by an adjacent one of the first pair of opposing side surfaces.

15. The cutting tool system of claim 14, wherein: Each corner edge and the adjacent wiper edge and the adjacent cutting edge form a cutting zone, and wherein the cutting insert comprises four left-handed cutting zones and four right-handed cutting zones.

16. The cutting tool system of claim 14, the cutting insert further comprising a mounting through-hole extending through the first pair of opposing side surfaces, a center of the mounting through-hole defining a central longitudinal axis, wherein When the cutting insert is mounted in the at least one recess, a central longitudinal axis of the cutting insert forms a mounting angle with the central longitudinal rotational axis of the tool holder.

17. The cutting tool system of claim 16, wherein: The installation angle is 0.1 degrees to 5 degrees.

18. The cutting tool system of claim 14, wherein: The first sidewall portion provides a positive axial clearance angle of 0.5 to 15 degrees from a horizontal plane perpendicular to the central longitudinal rotational axis of the tool holder.

19. A indexable cutting insert comprising: a first face, a second face opposite the first face, a first pair of opposing side surfaces, a second pair of opposing side surfaces, and a corner radius connecting each of the first pair of opposing side surfaces to each of the second pair of opposing side surfaces; a mounting through-hole extending through the first pair of opposing side surfaces, a center of the mounting through-hole defining a central longitudinal axis; a first wiper edge and a second wiper edge formed at an intersection between each of the first face and the second face and each of the first pair of opposing side surfaces, wherein the first wiper edge and the second wiper edge include a convex portion extending away from the central longitudinal axis; a first cutting edge and a second cutting edge formed at an intersection between each of the first and second faces and each of the second pair of opposing side surfaces; a corner edge formed at an intersection between each of the first and second faces and each corner radius; a second axis perpendicular to the central longitudinal axis and parallel to the first pair of opposing side surfaces and the second pair of opposing side surfaces, The first cutting edge and the second cutting edge are mirror-symmetrical about a plane parallel to the central longitudinal axis and parallel to the second axis.

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