Cutting tool and method for repositioning cutting insert in toolholder

Abstract

A cutting tool includes a toolholder and a circular cutting insert for mounting on a recessed base plate of the toolholder. The toolholder includes a toolholder recess base plate having an aperture, and a plurality of grooves disposed radially about the aperture in the recess base plate, wherein adjacent grooves are radially offset by a groove offset angle x. The circular cutting insert includes an upper surface having a cutting edge, a lower surface opposite the upper surface, an outboard surface between the upper surface and the lower surface, an inboard surface defining an aperture extending from the upper surface to the lower surface, and a plurality of lugs disposed radially around the aperture. In an alternative embodiment, the cutting tool includes an anti-rotation disk having a plurality of grooves rather than the toolholder recess base plate.

Description

[0001] Priority claim

[0002] This application is a continuation-in-part of application serial number 17 / 240,019 filed on April 26, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present application relates to the field of cutting tools comprising circular cutting inserts, and in particular to anti-rotation mechanisms of such cutting tools. Background Art

[0004] The cutting blade used in cutting tools such as milling cutters is usually installed in complementary recesses spaced around the periphery of the tool body. The cutting blade is usually fixed in its corresponding recess by inserting a screw through an aperture arranged in the center of the cutting blade. During the cutting operation, such cutting blades are usually subjected not only to compression and vibration forces, but also to a certain amount of torque due to the angle between the cutting edge of the cutting blade and the workpiece. For cutting blades of non-circular shape, such torque will not cause the rotation of the cutting blade due to the interference type fit between the angled outer sidewall of such cutting blade and the complementary wall of the recess receiving the cutting blade. In contrast, a circular cutting blade can rotate in its corresponding recess because such mechanical interference will not naturally occur between the outer sidewall of the circular cutting blade and the wall of the recess receiving the circular cutting blade.

[0005] In order to prevent such undesired rotation of the circular cutting insert, several anti-rotation mechanisms have been previously developed.

[0006] In an example, a single lug is provided on a recess of a toolholder to engage with one of a plurality of grooves on a circular cutting insert, thereby holding the circular cutting insert from rotating. When a corresponding portion of the cutting edge of the circular cutting insert is worn by the cutting operation, the circular cutting insert is repositioned so that the lug engages with another of the plurality of grooves to expose the unworn portion of the cutting edge of the circular cutting insert to the cutting operation. Depending on the desired depth of cutting, such circular cutting inserts are provided with different numbers of grooves (e.g., 4, 6, 8). However, during machining, heavy feeds often result in damage to or even removal of a single lug from the recess, thereby reducing the life of the circular cutting insert and destroying the toolholder.

[0007] In another example, multiple lugs (e.g., 4, 6, 8) are provided on the recess of the toolholder to engage with a corresponding plurality of grooves (e.g., 4, 6, 8) on the circular cutting insert, thereby overcoming the problem of damaging a single lug. However, the toolholder is limited to use with cutting inserts having the same number of grooves as the number of lugs on the recess of the toolholder.

[0008] Therefore, there is a need for an anti-rotation mechanism for a circular cutting insert that overcomes the problems of the prior art. Summary of the invention

[0009] In one embodiment, a cutting tool includes a toolholder and a circular cutting insert for mounting on a recessed base plate of the toolholder. The toolholder includes a toolholder recessed base plate having a hole therein, and a plurality of grooves radially arranged around the hole in the recessed base plate, wherein adjacent grooves are radially offset by a groove offset angle x. The circular cutting insert includes an upper surface having a cutting edge, a lower surface opposite the upper surface, an outer surface between the upper surface and the lower surface, an inner surface defining an orifice extending from the upper surface to the lower surface, and a plurality of lugs radially arranged around the orifice, wherein adjacent lugs are radially offset by a lug offset angle y, and wherein the ratio of y:x is an integer greater than or equal to 2.

[0010] In another embodiment, a method for repositioning a circular cutting insert in a toolholder recess includes loosening the circular cutting insert from the toolholder recess, rotating the circular cutting insert to a rotation angle z, and securing the circular cutting insert in the toolholder recess. The rotation angle z may be, for example, about 45 degrees, about 60 degrees, or about 90 degrees.

[0011] In yet another embodiment, a toolholder includes a recessed base having a bore therein, and a plurality of grooves in the recessed base radially arranged around the bore, wherein adjacent grooves are radially offset by a groove offset angle x.

[0012] In yet another embodiment, a circular cutting blade comprises an upper surface having a cutting edge, a lower surface opposite the upper surface, an outer surface between the upper surface and the lower surface, an inner surface defining an orifice extending from the upper surface to the lower surface, and a plurality of lugs radially arranged around the orifice, wherein adjacent lugs are radially offset by a lug offset angle y.

[0013] In yet another embodiment, a cutting tool includes: a toolholder including a recess having a recessed bottom plate; an anti-rotation disk mounted on the recessed bottom plate; and a circular cutting insert for mounting on the anti-rotation disk. The anti-rotation disk has an anti-rotation disk support surface having a plurality of grooves radially arranged around a central hole, wherein adjacent grooves are radially offset by a groove offset angle x. The circular cutting insert includes an upper surface having a cutting edge; a lower surface opposite the upper surface, the lower surface including a platform extending around a periphery of the lower surface; an outer side surface between the upper surface and the lower surface; an inner side surface defining an aperture extending from the upper surface to the lower surface; and a plurality of lugs radially arranged around the aperture, wherein adjacent lugs are radially offset by a lug offset angle y, wherein the ratio of y:x is an integer greater than or equal to 2, and wherein the plurality of lugs are located in a recessed cavity recessed relative to the platform.

[0014] In yet another embodiment, a method for repositioning a circular cutting insert in a toolholder recess includes partially or completely releasing the circular cutting insert from an anti-rotation disk support surface of an anti-rotation disk, rotating the circular cutting insert by a rotation angle z, and securing the circular cutting insert in the toolholder recess. The rotation angle z may be, for example, about 45 degrees, about 60 degrees, or about 90 degrees.

[0015] In yet another embodiment, a toolholder includes a recess having a recess floor and an anti-rotation disk disposed on the recess floor. The anti-rotation disk has an anti-rotation disk mounting surface having a plurality of grooves radially arranged about a central hole, wherein adjacent grooves are radially offset by a groove offset angle x; and wherein the plurality of grooves are raised relative to a base of the anti-rotation disk mounting surface of the anti-rotation disk.

[0016] In yet another embodiment, a circular cutting blade comprises an upper surface having a cutting edge, a lower surface opposite the upper surface, an outer surface between the upper surface and the lower surface, an inner surface defining an orifice extending from the upper surface to the lower surface, and a plurality of lugs radially arranged around the orifice, wherein adjacent lugs are radially offset by a lug offset angle y.

[0017] Other embodiments of the disclosed cutting tool will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A cutting tool according to an exemplary embodiment of the present specification includes a tool holder, a circular cutting insert, and a fastener.

[0019] Figure 2 yes Figure 1 A top view of the recessed portion of the tool holder.

[0020] Figure 3 yes Figure 2 A top perspective view of a recessed portion of FIG. 1 , including section line AA.

[0021] Figure 4 yes Figure 1 Top view of a circular cutting insert.

[0022] Figure 5 yes Figure 4 Bottom view of a circular cutting blade.

[0023] Figure 6 yes Figure 4 A bottom perspective view of a circular cutting insert including section line BB.

[0024] Figure 7 yes Figure 3 and 6 A cross-sectional view along section lines AA and BB.

[0025] Figure 8 yes Figure 3 and 6 A cross-sectional view of the fastener taken along section lines CC and DD and containing the fastener in a fully tightened state.

[0026] Fig. 9 yes Figure 3 and 6 A cross-sectional view of the fastener taken along section lines CC and DD and including a fastener in a partially loosened state.

[0027] Fig.10 A cutting tool according to an exemplary embodiment of the present specification includes a tool holder, a circular cutting insert, a fastener, and an anti-rotation disk.

[0028] Fig.11 yes Fig.10 A top view of the recessed portion of the tool holder.

[0029] Fig.12 yes Fig.11 A top perspective view of a recessed portion.

[0030] Fig.13 It is partially loosened Fig.10 Partial cross-sectional view of the tool holder.

[0031] Fig.14 It is partially loosened Fig.10 Another partial cross-sectional view of the tool holder.

[0032] Fig.15 It is in a completely tightened state Fig.10 A cross-sectional view of the tool holder. DETAILED DESCRIPTION

[0033] Figure 1 A cutting tool 10 according to an exemplary embodiment of the present specification is shown. The cutting tool 10 includes a tool holder 100 and a circular cutting insert 200. The cutting tool 10 may further include a fastener 300.

[0034] like Figure 1 The toolholder 100 shown in FIG. 1 is exemplary. It should be understood that the toolholder 100 of the present specification may include any toolholder 100 capable of holding the circular cutting insert 200 of the present specification.

[0035] refer to Figure 1, the tool holder 100 includes a tool holder body 102. As shown, the tool holder body 102 has the form of a tool holder body for a milling cutter, but may have the shape of a tool holder body for any other cutting tool capable of holding the circular cutting insert 200 of the present specification. The tool holder body 102 may, for example, include a tool holder shank 104 and a tool holder face 106. The tool holder material may be made of any material not inconsistent with the objectives of the present specification.

[0036] refer to Figure 1 , the toolholder body 102 includes a toolholder recess 110. The toolholder recess 110 may include any structure configured to receive the circular cutting insert 200 of the present specification. As shown, the toolholder recess 110 may be formed into the toolholder body 102. The toolholder recess 110 is configured to hold the circular cutting insert 200 therein. The toolholder body 102 may further include one or more additional toolholder recesses 110 for holding one or more additional circular cutting inserts 200.

[0037] refer to Figure 1 , the toolholder recess 110 includes a recess floor 112 having a hole 114 therein. The hole 114 may be threaded for receiving a threaded fastener 300. The toolholder recess 110 may further include a recess sidewall 115 for supporting the circular cutting insert 200 during a cutting operation.

[0038] refer to Figure 2 and 3 , the plurality of grooves 120 in the recessed bottom plate 112 are radially arranged around the hole 114. As shown, the plurality of grooves 120 are arranged around only a portion of the entire periphery of the hole 114. Alternatively, the plurality of grooves 120 may be arranged around the entire periphery of the hole 114. Adjacent grooves 120 in the plurality of grooves 120 are radially offset by a groove offset angle x.

[0039] The plurality of grooves 120 may be formed as raised islands 116 that are raised relative to the base 118 of the recess floor 112. Figures 1 to 3 , the raised island 116 may be positioned around only a portion of the hole 114. Alternatively, the raised island 116 may be positioned around the entire perimeter of the hole 114. The base 118 may generally be in the form of a substantially planar surface. The raised island 116 may facilitate the manufacturability of the recessed floor 112. During the manufacture of the recessed floor 112, the raised island 116 may initially be formed without the plurality of grooves 120. Thereafter, the plurality of grooves 120 may be formed (e.g., machined) into the raised island 116 in a subtractive manufacturing manner.

[0040] refer to Figure 2 , 37, the plurality of grooves 120 may be defined by a plurality of segments 121 positioned between the plurality of grooves 120. Each segment 121 may include a first segment engagement surface 122 and a second segment engagement surface 123 opposite the first segment engagement surface 122. Thus, the first segment engagement surface 122 of one segment 121 and the second segment engagement surface 123 of an adjacent segment 121 may define a groove 120 positioned therebetween.

[0041] The upper edge of the first segment engagement surface 122 and the upper edge of the second segment engagement surface 123 can define a maximum angular segment width 126, which is defined according to the number of degrees around the hole 114. In one aspect, the maximum angular segment width 126 of each segment 121 can be less than the groove offset angle x to promote maximum density of the segments 121 positioned on the recess floor 112 and avoid interference of the segments 121 with the cutting insert 200.

[0042] Each segment 121 can further include an inner end 124 proximate the hole 114 and an outer end 125 opposite the inner end 124. In one aspect, the first segment engagement surface 122, the second segment engagement surface 123, the inner end 124, and the outer end 125 can include inclined surfaces to increase the resistance of the segment 121 to damage during operation of the cutting tool 10. In one aspect, the outer end 125 can have a greater width than the inner end 124 to promote a reduced maximum angular segment width 126 of each segment 121.

[0043] Figures 4 to 6 An exemplary circular cutting insert 200 according to the present description is shown.

[0044] Cutting blade 200 can be formed by any material that is not inconsistent with the purpose of this specification. Exemplary materials include cemented carbide, carbide, polycrystalline diamond, polycrystalline cubic boron nitride, ceramic, cermet, steel or other alloys. In a specific example, the matrix is ​​formed by cemented carbide. The cemented carbide matrix may include tungsten carbide (WC). WC can exist in any amount that is not inconsistent with the purpose of this specification. For example, WC can exist in an amount of at least 70 weight %, at least 80 weight %, or at least 85 weight %. In addition, the metal binder of cemented carbide can include cobalt or cobalt alloy. For example, cobalt can be present in the cemented carbide matrix in an amount in the range of 1 weight % to 15 weight %. In some embodiments, cobalt is present in the cemented carbide matrix in an amount in the range of 5-12 weight % or 6-10 weight %. In addition, the cemented carbide matrix can present a binder-enriched zone that starts at the surface of the matrix and extends inward from the surface of the matrix. The cemented carbide matrix may also include one or more additives, such as one or more of the following elements and / or compounds thereof: titanium, niobium, vanadium, tantalum, chromium, zirconium and / or hafnium. In some embodiments, titanium, niobium, vanadium, tantalum, chromium, zirconium and / or hafnium form solid solution carbides with the WC of the matrix. For example, the matrix may include one or more solid solution carbides in an amount within the range of 0.1-5 wt %. In addition, the cemented carbide matrix may, for example, include nitrogen. On the one hand, the cutting insert 200 may be a coated body, including one or more coatings.

[0045] The circular cutting insert 200 includes an upper surface 210 having a cutting edge 211, a lower surface 220 opposite to the upper surface 210, an outer side surface 230 between the upper surface 210 and the lower surface 220, and an inner side surface 240 defining an aperture 241 extending from the upper surface 210 to the lower surface 220. When the circular cutting insert 200 is mounted on the tool holder body 102 of the tool holder 100, the lower surface 220 of the circular cutting insert 200 engages with the recess bottom plate 112 of the tool holder 100, and the outer side surface 230 approaches the recess side wall 115 of the tool holder 100.

[0046] like Figures 4 to 6 As shown in the illustrated example of , the upper surface 210 may be generally planar and terminate in a circular cutting edge 211 surrounding the upper surface 210. However, the upper surface 210 is not necessarily limited to the form shown.

[0047] refer to Figures 4 to 6 , the radius of the upper surface 210 may be greater than the radius of the lower surface 220. In addition, the outer surface 230 may have a shape complementary to the shape of the recess sidewall 115, typically a frustoconical shape. However, the outer surface 230 is not necessarily limited to the frustoconical shape shown.

[0048] The inner surface 240 defines an aperture 241 disposed centrally through the circular cutting insert 200. Figure 7 and 8 As shown, a fastener 300 (eg, a screw) may be inserted through the aperture 241 and the hole 114 to secure the cutting insert 200 to the toolholder 100 within the toolholder recess 110 .

[0049] refer to Figure 5 and 6 , a plurality of lugs 221 on the lower surface 220 are radially arranged around the orifice 241. Preferably, the plurality of lugs 221 are arranged around the entire periphery of the orifice 241. Adjacent lugs in the plurality of lugs 221 are radially offset by a lug offset angle y. In one aspect, the ratio of the lug offset angle y to the groove offset angle x is an integer greater than or equal to 2. Preferably, as in the example shown, the ratio of the lug offset angle y to the groove offset angle x is 2. In an alternative example, the ratio of the lug offset angle y to the groove offset angle x may be 3. In another alternative example, the ratio of the lug offset angle y to the groove offset angle x may be 4.

[0050] By selecting the ratio of the lug offset angle y to the groove offset angle x to be an integer greater than or equal to 2, multiple lugs 221 can be positioned within multiple grooves 120 so that the cutting insert 200 can rotate relative to the toolholder recess 110 by a small amount defined by the groove offset angle x. Therefore, the minimum rotation amount of the cutting insert 200 is limited by the groove offset angle x rather than the lug offset angle y. It is easier to manufacture multiple grooves 120 with a small groove offset angle x than to manufacture multiple lugs 221 with a small lug offset angle y. Therefore, by limiting the minimum rotation of the cutting insert to only up to the groove offset angle x, the present specification provides a cutting tool 10 that minimizes the difficulty of manufacturing the cutting insert 100 while having a low minimum rotation of the cutting insert 100.

[0051] On the one hand, the groove offset angle is in the range of 7 to 17 degrees. In the first example, the groove offset angle is in the range of 7 to 9 degrees, preferably 7.5 degrees. In the second example, the groove offset angle is in the range of 9 to 11 degrees, preferably 10 degrees. In the third example, the groove offset angle is in the range of 14 to 16 degrees, preferably 15 degrees. A groove offset angle of about 7.5 degrees or about 15 degrees is beneficial because a groove offset angle of 7.5 degrees or 15 degrees enables the cutting insert 200 to rotate in standard amounts of 90 degrees, 60 degrees, and 45 degrees, which provides 4 rotations (360 degrees / 90 degrees), 6 rotations (360 degrees / 60 degrees), and 8 rotations (360 / 45 degrees). A groove offset angle of 7.5 degrees will provide additional flexibility in the rotation angle of the cutting insert when repositioning, and a groove offset angle of 15 degrees will provide ease of manufacturing of lugs and grooves in the cutting insert and the recess bottom plate. A groove offset angle of about 10 degrees will enable the cutting insert 200 to be rotated in amounts of, for example, 90, 60 and 40 degrees, which provides 4 rotations (360 / 90), 6 rotations (360 / 60) and 9 rotations (360 / 40).

[0052] The cutting insert 200 will allow replacement of conventional circular cutting inserts having a defined number of grooves therein for engaging with a corresponding number of lugs on a toolholder recess. Thus, the cutting insert 200 will eliminate or reduce the need to produce multiple cutting inserts having different numbers of grooves to meet different requirements regarding cutting depth and number of rotations of the cutting insert when repositioning.

[0053] In one aspect, the lug offset angle is in the range of 14 to 32 degrees. In a first example, the lug offset angle is in the range of 14 to 16 degrees, preferably 15 degrees. In a second example, the lug offset angle is in the range of 19 to 21 degrees, preferably 20 degrees. In a third example, the lug offset angle is in the range of 29 to 31 degrees, preferably 30 degrees.

[0054] Lug offset angles of about 15, about 20, or about 30 degrees are beneficial because these lug offset angles are twice the groove offset angles of about 7.5, about 10, and about 15, and thus alternating grooves in the recess floor can engage with the lugs of the cutting insert to ensure high anti-rotation capability of the cutting insert. Lug offset angles of three times the number of grooves, i.e., about 22.5, about 30, or about 45 degrees, or lug offset angles of four times the number of grooves, i.e., about 30, about 40, or about 60 degrees, etc., may also work, but will result in less engagement between the grooves in the recess floor and the lugs of the cutting insert.

[0055] In addition, a 30 degree lug offset angle is beneficial because a 30 degree lug offset provides sufficient clearance between the lugs to facilitate manufacturing during the process of machining the lugs at the bottom of the cutting insert. Smaller lug offset angles of about 20 degrees or about 15 degrees can also work, but machining of the lugs will become increasingly challenging.

[0056] The lower surface 220 may include a platform 222 extending around the perimeter of the lower surface 220. The platform 222 may be used to engage with the base 118 of the recess floor 112 to support the cutting insert 200 when the cutting insert 200 is secured in the toolholder recess 110. The platform 222 may generally be in the form of a generally planar surface. The platform width 223 of the platform 222 may be sufficient to support the cutting insert 200 when it is secured in the toolholder recess 110.

[0057] The plurality of lugs 221 on the lower surface 220 may be positioned in a recessed cavity 224 that is recessed relative to the platform 222. By positioning the plurality of lugs 221 in the cavity 224, the cutting insert 200 may be primarily supported by the platform 222 when secured in the tool holder recess 110, and the plurality of lugs 221 may primarily serve to prevent the cutting insert 200 from accidentally rotating in the tool holder recess 110.

[0058] Each lug 221 can be defined by the structure of the cutting insert 200, which extends from a valley 225 to a peak 226 to an adjacent valley 225, the valley having a height 227 and a length 228. The height 227 corresponds to the depth of the groove 120 in the recess floor 112. Thus, the lug has a first lug engagement surface corresponding to the first segment engagement surface 122 and a second lug engagement surface corresponding to the second segment engagement surface 123. The lug can define a maximum angular lug width 229, which is defined according to the number of degrees around the aperture 241. In one aspect, the maximum angular segment width 229 of each lug 221 can be less than the groove offset angle x to promote maximum density of the lugs 221 and the segments 121 and avoid interference of the lugs 221 with the segments 121 during placement of the cutting insert 200 in the recess floor 112 of the toolholder 100.

[0059] refer to Figure 8 and 9 , the present specification includes a method for repositioning a circular cutting insert 200 in a toolholder recess 110 . Figure 8 The cutting insert 200 is shown fully secured within the toolholder pocket 110 by the fastener 300 . Fig. 9The cutting insert 200 is shown partially released from the toolholder recess 110 so that the plurality of lugs 221 can be disengaged from the plurality of grooves 120 by lifting the cutting insert 200 away from the recess floor 112. Alternatively, the cutting insert 200 can be fully released from the toolholder recess 110. Once the plurality of lugs 221 are disengaged from the plurality of grooves 120, the circular cutting insert can be rotated up to a rotation angle z and then the cutting insert 200 can be fully secured within the toolholder recess 110 again by the fastener 300.

[0060] In the case where the groove offset angle is about 15 degrees in the first example, the cutting blade 200 can be rotated up to the rotation angle z in increments of 15 degrees. Therefore, the cutting blade 200 can be rotated up to, for example, a rotation angle z of about 45 degrees to provide a total of 8 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 60 degrees to provide a total of 6 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 90 degrees to provide a total of 4 rotations before replacing the cutting blade.

[0061] In the case where the groove offset angle is about 10 degrees in the second example, the cutting blade 200 can be rotated up to the rotation angle z in increments of 10 degrees. Therefore, the cutting blade 200 can be rotated up to, for example, a rotation angle z of about 40 degrees to provide a total of 9 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 60 degrees to provide a total of 6 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 90 degrees to provide a total of 4 rotations before replacing the cutting blade.

[0062] In the case where the groove offset angle is about 7.5 degrees in the third example, the cutting blade 200 can be rotated up to the rotation angle z in increments of 7.5 degrees. Therefore, the cutting blade 200 can be rotated up to, for example, a rotation angle z of about 22.5 degrees to provide a total of 16 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 30 degrees to provide a total of 12 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 45 degrees to provide a total of 8 rotations before replacing the cutting blade.

[0063] Thus, the toolholder 100 and cutting insert 200 of the present specification provide a single cutting tool 10 that provides a durable and effective anti-rotation mechanism while providing the user with the flexibility to select a total number of desired rotations (e.g., 4 rotations, 6 rotations, 8 rotations) depending on the desired depth of cut for the machining operation.

[0064] refer to Figure 10-15, shows a cutting tool 10' according to another exemplary embodiment of the present specification. Similar reference numerals in the cutting tool 10' are used to represent similar elements of the cutting tool 10. The cutting tool 10' is the same as the cutting tool 10, except that Figure 1-9 The recess 110 of the toolholder 100 in the illustrated embodiment has been replaced with a toolholder 100' having a recess 110' and an anti-rotation disk 400. Thus, the circular cutting insert 200, the fastener 300 are the same in the cutting tool 10'. The anti-rotation disk 400 can facilitate the manufacturability of the recess bottom plate 112 of the toolholder 100 in the earlier embodiment. In addition, the anti-rotation disk 400 can be retrofitted into the recess 110 of some conventional toolholders.

[0065] like Fig.10 The toolholder 100' shown in FIG. 1 is exemplary. It should be understood that the toolholder 100' of the present specification may include any toolholder 100' capable of holding the circular cutting insert 200 of the present specification.

[0066] refer to Fig.10 , the tool holder 100' includes a tool holder body 102. As shown, the tool holder body 102 has the form of a tool holder body for a milling cutter, but may have the shape of a tool holder body for any other cutting tool capable of holding the circular cutting insert 200 of the present specification. The tool holder body 102 may, for example, include a tool holder shank 104 and a tool holder face 106. The tool holder material may be made of any material not inconsistent with the objectives of the present specification.

[0067] refer to Fig.10 , the toolholder body 102 includes a toolholder recess 110'. The toolholder recess 110' may include any structure configured to receive the circular cutting insert 200 of the present specification. As shown, the toolholder recess 110' may be formed into the toolholder body 102. The toolholder recess 110' is configured to hold the circular cutting insert 200 therein. The toolholder body 102' may further include one or more additional toolholder recesses 110' for holding one or more additional circular cutting inserts 200.

[0068] refer to Fig.10 , the toolholder recess 110' includes a recess floor 112' having a hole 114 therein. Unlike the recess floor 112 in the earlier embodiments, the recess floor 112' is substantially planar and does not include a plurality of grooves 120. The hole 114 may be threaded for receiving a threaded fastener 300. The toolholder recess 110' may further include a recess sidewall 115 for supporting a circular cutting insert 200 during a cutting operation.

[0069] refer to Fig.11 and 12, the anti-rotation disk 400 includes a plurality of grooves 420 radially arranged around a central hole 414 formed in the anti-rotation disk support surface 412. The central hole 414 has substantially the same size as the hole 114 of the recess bottom plate 112, so that when the anti-rotation disk 400 is properly installed in the recess 110, the central hole 414 is substantially aligned with the hole 114. Similarly, the anti-rotation disk 400 includes a pair of countersunk holes 428 positioned opposite the central hole 414, which align with the threaded hole 113 ( Fig.10 ) are substantially aligned. The anti-rotation disk 400 can be securely attached to the toolholder recess 110' by means of threaded fasteners (not shown) that can be screwed into the holes 113, 428. The anti-rotation disk 400 has a bottom surface 413 ( Fig.13 ), the bottom surface is compatible with the recess bottom plate 112 of the tool holder recess 110' when the anti-rotation disk 400 is properly mounted on the recess bottom plate 112. As shown, the plurality of grooves 420 are arranged around only a portion of the entire periphery of the central hole 414. Alternatively, the plurality of grooves 420 may be arranged around the entire periphery of the central hole 414. Adjacent grooves 420 in the plurality of grooves 420 are radially offset by a groove offset angle x.

[0070] The plurality of grooves 420 may be formed as raised islands 416 that are raised relative to the base 418 of the anti-rotation disk support surface 412. Figures 10 to 12 , the raised island 416 may be positioned around only a portion of the central hole 414. Alternatively, the raised island 416 may be positioned around the entire periphery of the central hole 414. The base 418 may generally be in the form of a generally planar surface. During manufacture of the anti-rotation disk support surface 412, the raised island 416 may initially be formed without the plurality of grooves 420. Thereafter, the plurality of grooves 420 may be machined into the raised island 416.

[0071] refer to Fig.11 and 12 , the plurality of grooves 420 may be defined by a plurality of segments 421 positioned between the plurality of grooves 420. Each segment 421 may include a first segment engagement surface 422 and a second segment engagement surface 423 opposite the first segment engagement surface 422. Thus, the first segment engagement surface 422 of one segment 421 and the second segment engagement surface 423 of an adjacent segment 421 may define a groove 420 positioned therebetween.

[0072] The upper edge of the first segment engagement surface 422 and the upper edge of the second segment engagement surface 423 can define a maximum angular segment width 426, which is defined according to the number of degrees around the central hole 414. In one aspect, the maximum angular segment width 426 of each segment 421 can be less than the groove offset angle x to promote maximum density of the segments 421 positioned on the anti-rotation disk support surface 412 and avoid interference of the segments 421 with the cutting insert 200.

[0073] Each segment 421 may further include an inner end 424 proximate the central hole 414 and an outer end 425 opposite the inner end 424. In one aspect, the first segment engagement surface 422, the second segment engagement surface 423, the inner end 424, and the outer end 425 may include inclined surfaces to increase the resistance of the segment 421 to damage during operation of the cutting tool 10'. In one aspect, the outer end 425 may have a greater width than the inner end 424 to promote a reduced maximum angular segment width 426 of each segment 421.

[0074] refer to Fig.13 and 15 , the present description includes methods for repositioning a circular cutting insert 200 in a toolholder recess 110 ′. Fig.15 The cutting insert 200 is shown fully secured within the toolholder recess 110 ′ by the fastener 300 . Fig.13 and 14 The cutting insert 200 is shown partially released from the toolholder recess 110 so that the plurality of lugs 221 can be disengaged from the plurality of grooves 120 by lifting the cutting insert 200 away from the recess floor 112. Alternatively, the cutting insert 200 can be completely released from the toolholder recess 110'. Once the plurality of lugs 221 are disengaged from the plurality of grooves 420, the circular cutting insert 200 can be rotated up to the rotation angle z, and then the cutting insert 200 can be fully fastened in the toolholder recess 110' again by the fastener 300.

[0075] In the case where the groove offset angle x is about 15 degrees in the first example, the cutting blade 200 can be rotated up to the rotation angle z in increments of 15 degrees. Therefore, the cutting blade 200 can be rotated up to, for example, a rotation angle z of about 45 degrees to provide a total of 8 rotations before replacing the cutting blade. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 60 degrees to provide a total of 6 rotations before replacing the cutting blade 200. Alternatively, the same cutting blade 200 can be rotated up to a rotation angle z of about 90 degrees to provide a total of 4 rotations before replacing the cutting blade 200.

[0076] In the case where the groove offset angle x is about 10 degrees in the second example, the cutting insert 200 can be rotated in increments of 10 degrees up to the rotation angle z. Therefore, the cutting insert 200 can be rotated up to, for example, a rotation angle z of about 40 degrees to provide a total of 9 rotations before replacing the cutting insert 200. Alternatively, the same cutting insert 200 can be rotated up to a rotation angle z of about 60 degrees to provide a total of 6 rotations before replacing the cutting insert 200. Alternatively, the same cutting insert 200 can be rotated up to a rotation angle z of about 90 degrees to provide a total of 4 rotations before replacing the cutting insert 200.

[0077] In the case where the groove offset angle x is about 7.5 degrees in the third example, the cutting insert 200 can be rotated in increments of 7.5 degrees up to the rotation angle z. Therefore, the cutting insert 200 can be rotated up to, for example, a rotation angle z of about 22.5 degrees to provide a total of 16 rotations before replacing the cutting insert 200. Alternatively, the same cutting insert 200 can be rotated up to a rotation angle z of about 30 degrees to provide a total of 12 rotations before replacing the cutting insert 200. Alternatively, the same cutting insert 200 can be rotated up to a rotation angle z of about 45 degrees to provide a total of 8 rotations before replacing the cutting insert 20.

[0078] Thus, the toolholder 100' and cutting insert 200 of the present specification provide a single cutting tool 10' that provides a durable and effective anti-rotation mechanism while providing the user with the flexibility to select a total number of desired rotations (e.g., 4 rotations, 6 rotations, 8 rotations) depending on the desired depth of cut for the machining operation.

[0079] Although various embodiments of the disclosed cutting tool have been shown and described, modifications may occur to one skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

[0080] Reference numerals list

[0081] Cutting tools10

[0082] Knife holder 100

[0083] Tool holder body 102

[0084] Tool holder handle 104

[0085] Tool holder surface 106

[0086] Tool holder recess 110

[0087] Recessed bottom plate 112

[0088] Hole 114

[0089] Recess side wall 115

[0090] Raised island 116

[0091] Base 118

[0092] Groove 120

[0093] Section 121

[0094] First section engagement surface 122

[0095] Second section engagement surface 123

[0096] Inner end 124

[0097] Outer end 125

[0098] Maximum angular segment width 126

[0099] Cutting insert 200

[0100] Upper surface 210

[0101] Cutting edge 211

[0102] Lower surface 220

[0103] Lug 221

[0104] Platform 222

[0105] Platform width 223

[0106] Recessed cavity 224

[0107] Valley 225

[0108] Peak 226

[0109] Height 227

[0110] Length 228

[0111] Maximum corner lug width 229

[0112] Outer surface 230

[0113] Inner surface 240

[0114] Orifice 241

[0115] Fastener 300

[0116] Cutting tool 10'

[0117] Knife holder 100'

[0118] Tool holder body 102'

[0119] Tool holder handle 104

[0120] Tool holder surface 106

[0121] Tool holder recess 110'

[0122] Recessed base 112'

[0123] Threaded hole 113

[0124] Hole 114

[0125] Recess side wall 115

[0126] Anti-rotation disc 400

[0127] Anti-rotation disc support surface 412

[0128] Bottom surface 413

[0129] Center hole 414

[0130] Raised island 416

[0131] Base 418

[0132] Groove 420

[0133] Segment 421

[0134] First section engagement surface 422

[0135] Second section engagement surface 423

[0136] Inner end 424

[0137] Outer end 425

[0138] Maximum angular segment width 426

[0139] Countersunk hole 428

[0140] Groove offset angle x

[0141] Rotation angle z

Claims

1. A cutting tool comprising: A tool holder comprising: a recess having a recess floor; an anti-rotation disk mounted on the recess floor, the anti-rotation disk having an anti-rotation disk support surface having a plurality of grooves radially arranged about the central hole, wherein adjacent grooves are radially offset by a groove offset angle x; and A circular cutting blade, which is used to be mounted on the anti-rotation disk, the circular cutting blade comprising: an upper surface having a cutting edge; a lower surface, opposite the upper surface, the lower surface including a platform extending around a perimeter of the lower surface; an outer surface between the upper surface and the lower surface; an inner side surface defining an aperture extending from the upper surface to the lower surface; and A plurality of lugs are radially arranged about the aperture, wherein adjacent lugs are radially offset by a lug offset angle y, wherein the ratio of y:x is an integer greater than or equal to 2, and wherein the plurality of lugs are located in a recessed cavity that is recessed relative to the platform. 2 . The cutting tool according to claim 1 , wherein the groove offset angle x is in the range of 7 degrees to 17 degrees.

3. The cutting tool according to claim 1, wherein the ratio of y:x is 2, 3 or 4. The cutting tool according to claim 1 , wherein the ratio of y:x is 2.

5. A method for repositioning the circular cutting insert in the tool holder of the cutting tool according to claim 1, the method comprising: partially or completely releasing the circular cutting insert from the anti-rotation disk support surface of the anti-rotation disk; Rotating the circular cutting blade to a rotation angle z; as well as The circular cutting insert is secured in the recess of the toolholder. The method of claim 5 , wherein the rotation angle z is approximately 45 degrees. The method of claim 5 , wherein the rotation angle z is approximately 60 degrees. The method of claim 5 , wherein the rotation angle z is approximately 90 degrees.

9. A tool holder, comprising: a recess having a recess floor; as well as An anti-rotation disk is arranged on the bottom plate of the recess, the anti-rotation disk having an anti-rotation disk mounting surface, the anti-rotation disk mounting surface having a plurality of grooves radially arranged around the central hole, wherein adjacent grooves are radially offset by a groove offset angle x; and wherein the plurality of grooves are protruding relative to the base of the anti-rotation disk mounting surface of the anti-rotation disk.

10. The toolholder of claim 9, further comprising a circular cutting insert for mounting on the anti-rotation disk.

11. The toolholder of claim 10, wherein the circular cutting insert comprises: an upper surface having a cutting edge; a lower surface, opposite the upper surface, the lower surface including a platform extending around a perimeter of the lower surface; an outer surface between the upper surface and the lower surface; an inner surface defining an aperture extending from the upper surface to the lower surface; as well as A plurality of lugs are radially arranged about the aperture, wherein adjacent lugs are radially offset by a lug offset angle y, wherein the ratio of y:x is an integer greater than or equal to 2, and wherein the plurality of lugs are located in a recessed cavity that is recessed relative to the platform.

12. The toolholder of claim 11, wherein the ratio of y:x is 2, 3 or 4.

13. The toolholder of claim 11, wherein the ratio of y:x is 2.

14. The toolholder of claim 10, wherein the groove offset angle x is in the range of 7 degrees to 17 degrees.

Images