Cutting blade with a control chamber

Abstract

The present invention discloses a cutting blade having a control cavity. A cutting tool system including a cutting tool and the cutting blade is disclosed. The cutting blade has an indexable cutting edge and a seating surface feature that enables a uniform faceting along a portion of each cutting edge of the indexable blade. A first seating surface and a second seating surface of the cutting blade each include a control cavity adjacent to a cutting edge facet. Each control cavity allows its corresponding cutting edge to have a facet width defined by the cavity to provide a uniform surface. The control cavities reduce and limit the amount of the first seating surface and the second seating surface that needs to be ground. A method of manufacturing such a cutting blade is disclosed.

Description

Field of the Invention

[0001] The present invention relates to indexable cutting inserts and cutting tool systems, and more particularly, to indexable double-sided cutting inserts having features that ensure uniform facet widths. Background of the Invention

[0002] Modern high-performance cutting tools use replaceable and generally indexable inserts due to the high-quality insert materials that support high cutting speeds and feeds. Common materials for inserts include tungsten carbide, polycrystalline diamond, and cubic boron nitride.

[0003] Indexable inserts use symmetric polygon shapes such that when a first cutting edge becomes dull, the indexable insert can be rotated or flipped to present a newly formed cutting edge that is accurately located at the same geometric position. Geometric repeatability saves manufacturing time by allowing for regular updates of the cutting edge without tool grinding, setup changes, or entering new values into the CNC program.

[0004] Common shapes for indexable inserts include squares, triangles, and rhomboids (diamonds), which provide multiple cutting edges on each side of the insert. For example, a double-sided or reversible square insert can be flipped to provide eight cutting edges.

[0005] Conventional indexable inserts include features on the seating surface that are ground to provide the desired clearance surface and toolholder contact surface. The ground surfaces can result in inconsistent and non-uniform widths of the facets along the cutting edge. Failure to provide uniform facets can result in reduced cutting edge efficiency and can prevent visual inspection of the indexable insert for uniformity. Summary of the Invention

[0006] There is provided a cutting insert that includes seating surface features that achieve uniform faceting along a portion of each cutting edge of the indexable insert. The first seating surface and the second seating surface of the cutting insert each include a control cavity that abuts a cutting edge margin facet. Each control cavity allows its corresponding cutting edge to have an edge facet width defined by the cavity to provide a first face and a second face with a uniform surface. Additionally, the control cavities reduce and limit the amount of the first seating surface and the second seating surface that need to be ground.

[0007] Aspects of the present invention provide a cutting blade, comprising: a first face; a second face opposite the first face; a plurality of side surfaces adjoining the first face and the second face; a plurality of cutting edges formed at intersections between the plurality of side surfaces and the first face; a plurality of edge facets formed on the first face, wherein each of the plurality of edge facets is formed adjacent to each of the plurality of cutting edges; and a plurality of control cavities recessed in the first face, wherein each of the plurality of control cavities adjoins each of the first facets.

[0008] Another aspect of the present invention provides a cutting tool, which includes a tool body, and the tool body includes a cutting blade mounted in a blade groove of the tool body.

[0009] Another aspect of the present invention provides a method of manufacturing a cutting blade. The method includes: pressing and sintering a metal carbide powder to form a blade blank, the blade blank including a first face, a second face opposite the first face, and a plurality of side surfaces adjoining the first face and the second face, the first face including a plurality of control cavities recessed in the first face; surface grinding a plurality of edge facets located on the first face, between each of the control cavities and one of the plurality of side surfaces, to form cutting edges at intersections between each of the plurality of edge facets and adjacent side surfaces of the plurality of side surfaces.

[0010] These and other aspects of the present invention will become more apparent from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a top isometric view of a cutting blade according to an embodiment of the present invention.

[0012] Figure 2 is Figure 1 a top view of the cutting blade of

[0013] Figure 3 is Figure 2 an enlarged view of a circular region of the cutting blade of

[0014] Figure 4 is Figure 1 a side view of the cutting blade of

[0015] Figure 5 is Figure 1 a top view of the cutting blade of

[0016] Figure 6 is a side cross-sectional view of the cutting blade taken along line 6-6 through Figure 5 of

[0017] Figure 7 is throughFigure 5 Side view cross-sectional view of a cutting blade taken along line 7-7.

[0018] Figure 8 Is a front view of a cutting tool such as a milling cutter, where Figure 1 The cutting blade is mounted in a groove of the cutting tool.

[0019] Figure 9 Is Figure 8 An enlarged view of the circular region of the cutting tool. Detailed Description of the Invention

[0020] Figure 1 And 2 Show a cutting blade 10 according to an embodiment of the present invention. The cutting blade 10 may include a double-sided, polygonal, tangential cutting blade. In the illustrated embodiment, the cutting blade 10 is generally square-shaped and includes a first face 12, a second face 14 on the opposite side relative to the first face 12, and a plurality of side surfaces 16 extending between the first face 12 and the second face 14. However, it should be understood that the double-sided cutting blade 10 may also be triangular, rectangular, pentagonal, etc. As Figure 1 And 2 Shown, the cutting blade 10 includes a central axis 11 and a mounting through-hole 80 extending from the first face 12 to the second face 14. The central axis 11 of the mounting through-hole 80 is perpendicular to the top surface 12 and the bottom surface 14. The central axis 11 defines the rotational axis of the cutting blade 10. The mounting through-hole 80 may be configured and arranged to receive a clamping stud 90. As Figure 2 Shown, the first face 12 and the second face 14 may be twisted relative to each other about the central axis 11. The twist angle α between the first face 12 and the second face 14 may be in the range of 0 degrees to 30 degrees. As Figure 2 Shown, the twist angle α may be measured between the cutting edge of the first face 12 and the cutting edge of the second face 14, and the twist angle is formed by the intersection of the side surface 16 with the first face 12 and the second face 14.

[0021] In the illustrated embodiment, the first face 12 and the second face 14 may be the same. For simplicity, the first face 12 will be described in detail herein. However, it should be understood that any discussion of the first face 12 may apply to the second face 14. As is known in the art, when mounted within a tool holder (not shown), the first face 12 may become the top surface and the second face may become the bottom surface, and vice versa. As Figure 1 And 2 Shown, the first face 12 of the cutting blade 10 may have 90-degree rotational symmetry with respect to the central axis 11 of the mounting through-hole 80.

[0022] As Figure 1 And 2As shown, for a total of four cutting edges 18, the cutting edges 18 are formed at the intersection between the first face 12 and the respective side surfaces 16. In some embodiments, for a total of four additional cutting edges 18 (i.e., a total of eight cutting edges 18 of the cutting blade 10), the cutting edges 18 may be formed at the intersection between the second face 14 and the respective side surfaces 16. Each cutting edge 18 is identical to each other. Therefore, for the sake of brevity, only one cutting edge 18 will be described herein, and it should be understood that any description of one cutting edge 18 herein applies to all cutting edges 18.

[0023] As Figure 1 and 2 shown, each cutting edge 18 may extend from the first corner portion 20 towards the second corner portion 20. According to an embodiment of the present invention, each main cutting edge 18 may extend only above a part of the intersection between the first face 12 and the respective side surface 16. For example, the length of each cutting edge 18 may generally be in the range of 20% to 80% of the length of the side surface 16, or in the range of 40% to 60% of the length of the side surface 16.

[0024] According to an embodiment of the present invention, for a total of four edge facets 22, the edge facets 22 are formed on the first face 12 adjacent to each cutting edge 18. In some embodiments, for a total of four additional edge facets 22 (i.e., a total of eight edge facets 22 of the cutting blade 10), the edge facets 22 may be formed adjacent to each cutting edge 18 of the second side surface 14.

[0025] As Figure 1 and 2 shown, the edge facets 22 may extend along the entire length of each cutting edge 18. According to an embodiment of the present invention, the edge facets may provide clearance for the cutting edge 18. In some embodiments, the edge facet 22 may include a first blade 24 forming the cutting edge 18 and a second blade 26 spaced apart from the first blade 24. In the illustrated embodiment, each edge facet 22 may be generally planar between the first blade 24 and the second blade 26. However, any other suitable arrangement may be used, for example, the edge facet 22 may be concave, convex, etc. The width of the edge facet 22 may vary based on the position of the cavity 40, as further described below.

[0026] As Figure 4As shown, for a total of four corner wiper facet surfaces 30, the corner wiper facet 30 can be formed at the intersection between the first face 12 and the corresponding side surface 16. In some embodiments, for a total of four additional corner wiper facets 30 (i.e., a total of eight corner wiper facets 30 of the cutting blade 10), the corner wiper facet 30 can be formed at the intersection between the second face 14 and the corresponding side surface 16. Each corner wiper facet 30 is identical to each other. Therefore, for the sake of brevity, only one corner wiper facet 30 will be described herein, and it should be understood that any description of one corner wiper facet 30 herein applies to all corner wiper facets 30.

[0027] As Figure 2 and 4 shown, the corner wiper facet 30 extends from the edge facet 22 to the second corner portion 20 along the intersection of the side surface 16 and the first face 12. According to an embodiment of the present invention, the corner wiper facet 30 can include a first blade 32 that intersects with the side surface 16 and a second blade 34 that is spaced apart from the first blade 32. In the illustrated embodiment, each corner wiper facet 30 can be generally planar between the first blade 32 and the second blade 34. However, any other suitable arrangement can be used. For example, the corner wiper facet 30 can be concave, convex, etc. In the illustrated embodiment, the length of the corner wiper facet 30 is less than the length of the edge facet 20. However, any other suitable arrangement can be used. For example, the length of the corner wiper facet 30 can be greater than or equal to the length of the edge facet 20.

[0028] According to an embodiment of the present invention, the first blade 32 can form a wiper cutting edge. As Figure 1 and 2 shown, each first blade 32 can extend from the cutting edge 18 to the second corner portion 20. According to an embodiment of the present invention, each first blade 32 can extend only above a part of the intersection between the first face 12 and the corresponding side surface 16. For example, the length of each first blade 18 can generally be in the range of 10% to 60% of the length of the side surface 16, or in the range of 15% to 40% of the length of the side surface 16. In the illustrated embodiment, the length of the first blade 32 is less than the length of the cutting edge 18. However, any other suitable arrangement can be used. For example, the length of the first blade 32 can be greater than or equal to the length of the cutting edge 18.

[0029] As Figure 1 、 2As shown in FIGS. 3 and 4, each of the side surfaces 16 is arranged at a right angle to each other, and the four corner portions 20 connect the side surfaces to each other. The corner portions 20 connect each side surface 16 and extend between the first face 12 and the second face 14. Since each corner portion 20 is substantially the same as each other, for the sake of brevity, only one corner portion 20 will be discussed herein, and it should be understood that any description of one corner portion 20 herein applies to all corner portions 20. According to an embodiment of the present invention, a plurality of corner portions 20 extend between each of the plurality of primary cutting edges 18 and each of the plurality of corner finishing edge facets 30.

[0030] According to an embodiment of the present invention, for a total of four contact surfaces 36, the contact surfaces 36 are formed on the first face 12 and extend radially inward from the second edge 34 of each corner finishing edge facet 30. In some embodiments, for a total of four additional contact surfaces 36 (i.e., a total of eight contact surfaces 36 of the cutting blade 10), the contact surfaces 36 may be formed on the second face 14 and extend from the second edge 34 of each corner finishing edge facet 30. Each contact surface 36 is the same as each other. Therefore, for the sake of brevity, only one contact surface 36 will be described herein, and it should be understood that any description of one contact surface 36 herein applies to all contact surfaces 36.

[0031] As Figure 1 , 2 and 7 show, the contact surface 36 extends from the second edge 34 of the corner finishing edge facet to the mouth portion 60 of the mounting hole 80. The plurality of contact surfaces 36 provide an area on the first face 12 that will be engaged by the groove 116 of the cutting tool 100. In the illustrated embodiment, the contact surface 36 is generally planar, however, any other suitable arrangement may be used. According to an embodiment of the present invention, the plurality of contact surfaces 36 may be the highest surface height on the first face 12 and the second face 14.

[0032] According to an embodiment of the present invention, for a total of four control cavities 40, the control cavities 40 are formed on the first face 12 and extend radially inward from the second edge 26 of the adjacent contact surface 36 between the edge facets 22. The control cavity may be recessed in the first face 12. In some embodiments, for a total of four additional control cavities (i.e., a total of eight control cavities of the cutting blade 10), the control cavities 40 may be formed on the second face 14 and extend from the second edge 26 of each edge facet 22. Each control cavity 40 is the same as each other. Therefore, for the sake of brevity, only one control cavity 40 will be described herein, and it should be understood that any description of one control cavity 40 herein applies to all control cavities 40. As described more fully below, the control cavity 40 may define the width of the edge facet 22 during the manufacture of the cutting blade 10 to provide a uniform cutting edge.

[0033] As Figure 2 and3 As shown in 3 , the control cavity 40 includes a bottom surface 48, a first sidewall portion 42, a radially inward cutting edge 44, a second sidewall portion 46, and a third sidewall portion 47. The first sidewall portion 42 extends from the bottom surface 48 adjacent to the second cutting edge 26 of the margin facet 22. The radially inward cutting edge 44 is provided along the mouth 60 of the mounting hole 80. The second sidewall portion 46 extends from the bottom surface 48 between the margin facet 22 and the corner chamfer facet 30 from the radially inward cutting edge 44 toward the first sidewall portion 42. The third sidewall portion 47 extends from the bottom surface 48 from the radially inward cutting edge 44 toward the first sidewall portion 42 opposite the second sidewall portion 46.

[0034] As Figure 3 and 6 As shown in 6 , the control cavity 40 may include a first transition fillet 52 between the bottom surface 48 and the first sidewall portion 42, a radially inward transition fillet 54 between the bottom surface 48 and the radially inward cutting edge 44, a second transition fillet 56 between the bottom surface 48 and the second sidewall portion 46, and a third transition fillet 57 between the bottom surface 48 and the third sidewall portion 47. According to an embodiment of the present invention, the transition fillets may include a generally semi-circular cross-section. However, transition fillets of any other suitable cross-sectional shape may be used, such as rectangular, square, trapezoidal, hexagonal, oval, triangular, etc. Alternatively, the transition fillets may be provided as walls angled with respect to the bottom surface 48. According to an embodiment of the present invention, the transition fillets may help to define the shape of the control cavity 40 on the first face 12.

[0035] According to an embodiment of the present invention, during the manufacture of the cutting blade 10, the control cavity 40 may be provided on the first face 12 and subsequently on the margin facet 22, the corner chamfer facet 30, and the contact surface 36. In certain embodiments, the control cavity 40 may be pressed into the first face 12 and the second face 14 during the manufacturing process. In certain embodiments, the control cavity 40 may be formed by a blade die during the pressing manufacturing step of the cutting blade 10.

[0036] According to an embodiment of the present invention, during the manufacture of the cutting blade 10, the blade blank can be conventionally powder pressed and sintered by any means known in the art to form an initial blade blank, the initial blade blank including a first face, a second face opposite the first face, and a plurality of side surfaces. According to an embodiment of the present invention, the first face and / or the second face of the initial blade blank may include a control cavity 40. Then, the plurality of side surfaces of the blade blank can be ground to provide the desired shape known to those skilled in the art. Then, the first face and the second face can be initially ground to achieve the desired thickness of the cutting blade and to dress the plurality of contact surfaces 36. The edge facet 22 can be a surface dressed by grinding to form a cutting edge 18 at the intersection between the plurality of side surfaces of the first face and / or the second face and the control cavity 40. Then, the corner chamfer facet 30 can be a surface dressed by grinding to form a finishing edge cutting edge 32 at the intersection between the plurality of side surfaces and the first face and / or the second face.

[0037] As Figure 3 and 4 shown, the second sidewall portion 46 and the second transition fillet 56 can extend from the radially inner edge 44 to the intersection between the first face 12 and the side surface 16. In the illustrated embodiment, the transition fillet 56 is disposed between and separates the edge facet 22 and the corner chamfer facet 30. The transition fillet 56 that extends to the side surface 16 to interrupt the edge facet 22 can help define the length of the edge facet 22 along the intersection of each side surface 16 with the first face 12. This allows each edge facet 22 to have a uniform length from the first corner portion 20 to the transition fillet 56.

[0038] As Figure 6 and 7 shown, the bottom surface 48 of the control cavity 40 can be recessed from the edge facet 22 and the adjacent contact surface 36. The recessing of the bottom surface 48 of the cavity 40 from the edge facet 22 can define the desired width of the edge facet 22 before grinding the first face 12 and the second face 14. This allows each edge facet 22 to have a uniform width from the cutting edge 18 to the control cavity 40.

[0039] In certain embodiments, the control cavity 40 reduces the amount of the first face 12 and the second face 14 that need to be ground during the manufacture of the cutting blade 10. The control cavity 40 can minimize the time and amount of grinding originally required to form the edge facet 22. According to an embodiment of the present invention, the control cavity 40 allows the edge facet 22 of each cutting edge 18 to be uniformly ground. The uniformity of the grinding of the edge facet 22 can provide a more reliable cutting edge 18 and avoid visual differences on the first face 12 and the second face 14.

[0040] According to an embodiment of the present invention, the control cavity 40 can limit the variation between the adjacent edge facets 22 and the corner chamfer facets 30 during the grinding step in the manufacturing process of the cutting blade 10. In certain embodiments, the control cavity 40 allows the edge facets 22, the corner chamfer facets 30, and the contact surfaces 36 to be uniform along each side of the first face 12 and the second face 14.

[0041] The cutting blade 10 can 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), cermet, ceramics, etc. The cutting blade 10 of the present invention can be manufactured by any suitable technique, such as carbide powder pressing, grinding, or additive manufacturing, to provide a plurality of cavities, side surfaces, contact surfaces, and facets.

[0042] Figure 8 and 9 A cutting tool system 5 according to an embodiment of the present invention is shown. The cutting tool system 5 includes a cutting tool 100 and a plurality of cutting blades 10. The cutting tool 100 includes a tool body 112, which includes a cutting end 114 having a plurality of circumferentially spaced grooves 116, and a mounting end 118 opposite to the cutting end 114. The tool body 112 is designed to be driven rotatably about a central longitudinal axis 111. In the illustrated embodiment, the cutting tool 100 is commonly referred to as a right-hand milling cutter and includes a total of seven grooves 116. However, it should be understood that the present invention is not limited to the number of grooves 116, and the present invention can be practiced with any desired number of grooves that provide the required cutting ability. Each of the grooves 116 can receive a cutting blade, which is firmly held in the groove 116 by means of a clamping stud 90. However, any other suitable method for fixing the cutting blade 10 in the groove can be used, such as, for example, an insert screw, a clamping wedge, a bolt, a pin, etc. In the illustrated embodiment, each of the grooves 116 of the cutting tool 100 receives a single cutting blade 10 to contact a workpiece 200.

[0043] When the cutting blade 10 is installed in the tool body 112 during a cutting operation, the side surface 16 of the cutting blade 10 engages the groove 116. In certain embodiments, when the cutting blade 10 is properly indexed in the tool body 112, the contact surfaces 36 of the first face 12 and the second face 14 and at least two side surfaces 16 should engage the tool body 112. According to an embodiment of the present invention, the number of times the cutting blade 10 can be indexed depends on the geometry of the cutting blade 10.

[0044] For the purposes of the foregoing description, it is to be understood that, except where specifically stated to the contrary, the present invention may assume various alternative variations and sequences of steps. In addition, except as otherwise indicated in any operating instance, or where otherwise indicated, all numbers expressing quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term "about". Thus, unless indicated to the contrary, the numerical parameters set forth are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0045] It is to be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

[0046] 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, unless expressly stated to the contrary, the use of "or" means "and / or", even though "and / or" may be expressly used in some instances. In this application, unless expressly and affirmatively limited to one referent, the articles "a", "an", and "the" include plural referents.

[0047] While specific embodiments of the invention have been described above for purposes of illustration, it will be apparent to those skilled in the art that various changes in the details of the invention may be made without departing from the invention.

Claims

1. A cutting blade, comprising: A first face; A second face opposite to the first face; A plurality of side surfaces adjacent to the first face and the second face; A plurality of cutting edges formed at the intersection between the plurality of side surfaces and the first face; A plurality of edge facets formed on the first face, wherein each of the plurality of edge facets is formed adjacent to each of the plurality of cutting edges; And A plurality of control cavities recessed in the first face, wherein each of the plurality of control cavities is adjacent to each of the edge facets, Wherein the intersection between the plurality of side surfaces and the first face further includes a plurality of corner rounding blade facets, and each of the plurality of corner rounding blade facets extends from the edge facet to the corner portion.

2. The cutting blade according to claim 1, wherein each of the plurality of control cavities includes a bottom surface recessed from the adjacent edge facet.

3. The cutting blade according to claim 1, wherein each of the plurality of control cavities includes: A bottom surface; And A first sidewall portion extending from the bottom surface adjacent to the edge facet.

4. The cutting blade according to claim 3, wherein each of the plurality of control cavities includes a first transition fillet provided between the bottom surface and the first sidewall portion.

5. The cutting blade according to claim 1, further comprising a mounting hole extending from the first face to the second face, the mounting hole including a central axis, and wherein the first face is rotationally symmetric with respect to the central axis of the mounting hole.

6. The cutting blade according to claim 1, wherein each of the plurality of cutting edges is formed along a partial length of the intersection between the plurality of side surfaces and the first face.

7. The cutting blade according to claim 1, wherein each of the plurality of edge facets includes a first side edge forming the cutting edge and a second side edge adjacent to the control cavity.

8. The cutting blade according to claim 1, wherein the length of each of the plurality of corner rounding blade facets is less than the length of each of the plurality of edge facets.

9. The cutting blade according to claim 1, further comprising a plurality of contact surfaces extending from each of the plurality of corner rounding blade facets on the first face.

10. The cutting blade according to claim 1, wherein each of the plurality of control cavities extends from a first contact surface on the first face to a second contact surface.

11. The cutting blade according to claim 1, wherein each of the plurality of control cavities extends from the edge facet to the mouth portion of the mounting hole, and the mounting hole extends from the first face to the second face.

12. The cutting blade according to claim 1, wherein the cutting blade is a tangential cutting blade.

13. The cutting blade according to claim 1, wherein the second face includes: A plurality of cutting edges formed at the intersection between the plurality of side surfaces and the second face; A plurality of edge facets formed on the second surface, wherein each of the plurality of edge facets is formed adjacent to each of the plurality of cutting edges; and A plurality of control cavities recessed in the second surface, wherein each of the plurality of control cavities abuts each of the plurality of edge facets.

14. The cutting blade according to claim 13, wherein the first surface is twisted relative to the second surface about a central axis of the cutting blade.

15. The cutting blade according to claim 13, further comprising a mounting hole extending from the first surface to the second surface, the mounting hole including a central axis, and wherein the first surface and the second surface are rotationally symmetric with respect to the central axis of the mounting hole.

16. The cutting blade according to claim 13, wherein the intersection between the plurality of side surfaces and the second surface further comprises a plurality of corner finishing edge facets, wherein each of the plurality of corner finishing edge facets extends from the edge facet to a corner portion.

17. The cutting blade according to claim 16, wherein a transition fillet is provided between each of the plurality of edge facets and each of the plurality of corner finishing edge facets.

18. A cutting tool comprising a tool body, the tool body including the cutting blade according to claim 1 mounted in a blade slot of the tool body.

19. A method of manufacturing a cutting blade as claimed in claim 1, comprising: Compressing and sintering a metal carbide powder to form a blade blank, the blade blank including a first surface, a second surface opposite the first surface, and a plurality of side surfaces adjoining the first surface and the second surface, the first surface including a plurality of control cavities recessed in the first surface; and Surface grinding a plurality of edge facets located on the first surface, between each of the control cavities and one of the plurality of side surfaces, to form cutting edges at the intersection of each of the plurality of edge facets and an adjacent side surface of the plurality of side surfaces.

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