Milling tool and cutting blade

Abstract

A milling tool includes a tool body defining an insert recess having a main seat floor and lower, middle, and upper seat walls. A cutting blade having a blade body is disposed in the blade recess. The blade body includes a front face and a rear face with first, second, and third major circumferential sides extending between the faces and around a circumference of the blade body. First, second, and third cutting corners are disposed between the major circumferential sides. Each of the main circumferential sides includes two side seating surfaces that extend between adjacent cutting corners and have a transition corner disposed therebetween. One of the front surface or the rear surface engages the main seat floor. Three consecutive side seat surfaces engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively. One of the lower seat wall, the middle seat wall and the upper seat wall or each of the side seat surfaces is generally planar, and the others are convex.

Description

Background Art

[0001] The present invention generally relates to cutting tools having cutting inserts, such as milling tools, adapted to receive selectively removable inserts that may be replaced or indexed.

[0002] A known tool comprises a triangular blade which may be double-sided. A known problem is that with such blades it may be difficult to produce the blade and the tool to the desired tolerances.

[0003] It is also known to manufacture six-sided inserts, known as "hexagonal-triangular" or "triangular" inserts. Such inserts have six faces, wherein the angles between the faces alternate between greater than 120 degrees and less than 120 degrees, giving the hexagonal shape a more triangular appearance due to its overall shape. However, with this design, it remains difficult to produce inserts and tools that meet the required tolerances, and typically the faces of the insert, when seated in a three-sided recess, will only form true surface contact on two of the three sides. Obtaining true surface contact between the insert and the recess requires extreme precision in both components, and any deviations due to manufacturing tolerances will result in line or point contact on only two of the faces. Summary of the Invention

[0004] More particularly, the present invention relates to a milling tool and a cutting insert for maintaining 3-point / line contact.

[0005] In at least one embodiment, a milling tool includes a tool body defining a blade recess having a main seat base and a lower seat wall, a middle seat wall, and an upper seat wall. A cutting blade having a blade body is disposed in the blade recess. The blade body includes a front face and a rear face, wherein first, second, and third main circumferential side faces extend between these faces and around the circumference of the blade body. First, second, and third cutting corners are disposed between the main circumferential side faces. Each of the main circumferential side faces includes two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween. One of the front surface or the rear surface engages the main seat base. Three continuous side seat surfaces engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively. One of the lower seat wall, the middle seat wall, and the upper seat wall, or each of the side seat surfaces, is generally planar, and the others are convex.

[0006] In at least one embodiment, a milling tool includes a tool body defining a blade recess, wherein the blade recess has a main seat base, a lower seat wall, a middle seat wall, and an upper seat wall. The lower seat wall, the middle seat wall, and the upper seat wall are generally planar. A cutting blade is disposed in the blade recess. The cutting blade has a blade body, wherein the blade body includes a front face and a rear face, wherein first, second, and third main circumferential side faces extend between the front face and the rear face and around the circumference of the blade body. First, second, and third cutting corners are disposed between the first and second main circumferential side faces, the second and third main circumferential side faces, and the third and first main circumferential side faces, respectively. Each of the main circumferential side faces includes two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween. Each side seat surface is convex. One of the front surface or the rear surface engages the main seat base. Three continuous side seat surfaces engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively.

[0007] An angle formed by the middle seat wall and the upper seat wall may be less than 120 degrees, and an angle formed by the lower seat wall and the middle seat wall may be greater than 120 degrees.

[0008] The lower seat wall, middle seat wall, and upper seat wall may be oriented generally at right angles to the main seat floor.

[0009] Each of the three continuous side seat surfaces may engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position clockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

[0010] Each of the three continuous side seat surfaces may engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a location counterclockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

[0011] In at least one embodiment, a milling tool includes a tool body defining a blade recess, the blade recess having a main seat base, a lower seat wall, a middle seat wall, and an upper seat wall. Each of the lower seat wall, the middle seat wall, and the upper seat wall is convex. A cutting blade is disposed in the blade recess. The cutting blade has a blade body, the blade body including a front and a rear face, wherein first, second, and third major circumferential side faces extend between the front and rear faces and around the circumference of the blade body. First, second, and third cutting corners are disposed between the first and second major circumferential side faces, the second and third major circumferential side faces, and the third and first major circumferential side faces, respectively. Each of the major circumferential side faces includes two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween. Each side seat surface is substantially planar. One of the front surface or the rear face engages the main seat base. Three continuous side seat surfaces engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively.

[0012] Each of the lower seat wall, the middle seat wall, and the upper seat wall may be arcuate between the corresponding cutting corner and the transition corner in a direction along the circumference of the blade body.

[0013] Each of the lower seat wall, the middle seat wall, and the upper seat wall may be arcuate between the front face and the rear face in a direction along the axis of the blade body.

[0014] Each of the lower seat wall, the middle seat wall and the upper seat wall can be arcuate between the corresponding cutting corner and the transition corner in the direction along the circumference of the blade body, and can be arcuate between the front and rear faces in the direction along the axis of the blade body.

[0015] Each of the three continuous side seat surfaces may engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position clockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

[0016] Each of the three continuous side seat surfaces may engage the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a location counterclockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

[0017] In at least one embodiment, a cutting blade for a milling tool includes a blade body having a front face and a rear face, wherein first, second, and third major circumferential side faces extend between the front face and the rear face and around the circumference of the blade body. First, second, and third cutting corners are disposed between the first and second major circumferential side faces, the second and third major circumferential side faces, and the third and first major circumferential side faces, respectively. Each of the major circumferential side faces includes two side seating surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween. Each side seating surface is convex.

[0018] Each side seating surface may be arcuate in a direction along the circumference of the insert body between the corresponding cutting corner and the transition corner.

[0019] Each side seating surface may be arcuate between the front face and the rear face in a direction along the axis of the insert body.

[0020] Each side seating surface may be arcuate between the corresponding cutting corner and the transition corner in a direction along the circumference of the blade body, and may be arcuate between the front face and the rear face in a direction along the axis of the blade body.

[0021] Each of the cutting angles may be formed at the same angle, and the angle is less than 120 degrees.

[0022] Each of the transition corners may be formed at the same angle, and the angle may be greater than 120 degrees.

[0023] Each of the cutting corners may be formed at the same angle, which is less than 120 degrees, and wherein each of the transition corners is formed at the same angle, which is greater than 120 degrees.

[0024] The cutting blades may be molded and perimeter ground.

[0025] The cutting blade may be indexable.

[0026] In at least one embodiment, a hexagonal, hexagonal shoulder milling insert is seated in a corresponding insert pocket formed in a milling tool. The insert includes a barrel-shaped peripheral contact surface, or the insert pocket includes a barrel-shaped pocket wall, which allows for deviations from nominal dimensions due to manufacturing tolerances while still maintaining proper contact between the contact surface of the milling insert and the wall of the insert pocket.

[0027]

[0006] Various aspects will become apparent to those skilled in the art from the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a perspective view of a milling tool having multiple cutting blades.

[0029] Figure 2 yes Figure 1 An enlarged portion of the tool showing one of the cutting blades seated in the blade holder.

[0030] Figure 3 is similar to Figure 2 , except that the blade holder is shown with the cutting blade removed.

[0031] Figure 4 Is a Figure 2 Front view of the cutting blade portion of the cutting tool.

[0032] Figure 5 yes Figure 2 Rear perspective view of the cutting blade.

[0033] Figure 6 yes Figure 2 Front perspective view of a cutting blade.

[0034] Figure 7 yes Figure 2 Front view of the cutting blade.

[0035] Figure 8 yes Figure 2 Side perspective view of a cutting blade.

[0036] Figure 9 yes Figure 2 Side view of the cutting blade.

[0037] Figure 10 It is along Figure 7 The line 10-10 in the Figure 2 Side cross-sectional view of a cutting blade. DETAILED DESCRIPTION

[0038] Referring now to the drawings, a cutting tool 110 is shown having a tool body 112. The tool body 112 defines a plurality of blade recesses 114. Each recess 114 includes a main seat base 116, a lower seat wall 118, a middle seat wall 120, and an upper seat wall 122. The lower seat wall 118, the middle seat wall 120, and the upper seat wall 122 are generally oriented at right angles to the main seat base 116. The lower seat wall 118 and the middle seat wall 120 are generally oriented at an angle greater than 120 degrees, and the middle seat wall 120 and the upper seat wall 122 are generally oriented at an angle less than 120 degrees. A cutting blade 124 is disposed in each recess 114.

[0039] The cutting blade 124 has a blade body 125, which includes a front face 126 and a rear face 128, wherein a first main circumferential side surface 129a, a second main circumferential side surface 129b, and a third main circumferential side surface 129c are located between the front face 126 and the rear face 128 and extend around the circumference of the blade body 125. A first cutting corner 131a, a second cutting corner 131b, and a third cutting corner 131c are disposed between the first main circumferential side surface 129a and the second main circumferential side surface 129b, the second main circumferential side surface 129b and the third main circumferential side surface 129c, and the third main circumferential side surface 129c and the first main circumferential side surface 129a. The cutting corners 131a, 131b, and 131c are generally formed at an angle of less than 120 degrees. Each of the major circumferential side surfaces 129a, 129b, and 129c includes two side seating surfaces 130 extending between adjacent cutting corners 131a, 131b, and 131c, and has transition corners 132a, 132b, and 132c disposed therebetween. Each of the transition corners 132a, 132b, and 132c is generally formed at an angle greater than 120 degrees.

[0040] The seat walls (lower seat wall 118 , middle seat wall 120 , and upper seat wall 122 ) or side seat surfaces 130 are convex.

[0041] In at least one embodiment where the side seat surfaces 130 are convex, the cutting blade 124 is seated in the recess 114 and one of the front surface 126 or the rear surface 128 engages the main seat floor 116. The three continuous side seat surfaces 130 will engage the lower seat wall 118, the middle seat wall 120, and the upper seat wall 122, which are generally planar in this example.

[0042] It should be noted that in embodiments where the cutting blade 124 is indexable, the orientation of the cutting blade 124 in the recess 114 can be selected based on the desired cutting corner 131a, 131b, or 131c to be exposed for use.

[0043] In the present example, the side seat surfaces 130 form a curved perimeter segment on the blade body 125 , and the lower seat wall 118 , the middle seat wall 120 , and the upper seat wall 122 form generally flat support walls in the recess 114 .

[0044] Using the curved perimeter segment, the cutting blade 124 and the recess 114 can be designed and manufactured to have a nominal contact point or line generally centered on the side seat surface 130 and the lower seat wall 118, the middle seat wall 120, and the upper seat wall 122 to orient the side seat surface 130 in the recess 114 to a selected optimal angle and achieve three-point or three-line contact. However, due to manufacturing variations, the cutting blade 124 can be adjusted in the recess to maintain three-point or three-line contact when necessary. For example, the cutting blade 124 can be adjusted clockwise in the recess 114 and the three-point or three-line contact position can be positioned clockwise relative to the nominal center position, or adjusted counterclockwise to be positioned counterclockwise relative to the nominal center position.

[0045] By utilizing a cutting blade 124 as described above, it is believed that this blade can be molded or molded and peripherally ground and still cooperate with the recess 114 to produce 3-point or 3-line contact even when there are slight variations in the size of the cutting blade 124 or the positions of the lower seat wall 118, middle seat wall 120 and upper seat wall 122 of the recess 114.

[0046] In at least one embodiment where the lower seat wall 118, the middle seat wall 120, and the upper seat wall 122 are convex, the cutting blade 124 is seated in the recess 114, and one of the front surface 126 or the rear surface 128 engages the main seat bottom plate 116. Three continuous side seat surfaces 130, which are generally planar in this example, will engage the lower seat wall 118, the middle seat wall 120, and the upper seat wall 122.

[0047] Note again that in embodiments where the cutting blade 124 is indexable, the orientation of the cutting blade 124 in the recess 114 can be selected based on the desired cutting corner 131a, 131b, or 131c to be exposed for use.

[0048] In the present example, the lower seat wall 118 , the middle seat wall 120 , and the upper seat wall 122 form a curved interior section on the recess 114 , and the side seat surfaces 130 form generally flat support walls on the cutting blade 124 .

[0049] Using the curved inner section, the cutting blade 124 and the recess 114 can be designed and manufactured to have a nominal contact point or line generally centered on the side seat surface 130 and the lower seat wall 118, the middle seat wall 120, and the upper seat wall 122 to orient the side seat surface 130 in the recess 114 to a selected optimal angle and achieve three-point or three-line contact. However, due to manufacturing variations, the cutting blade 124 can be adjusted in the recess to maintain three-point or three-line contact when necessary. For example, the cutting blade 124 can be adjusted clockwise in the recess 114 and the three-point or three-line contact position can be positioned clockwise relative to the nominal center position, or adjusted counterclockwise to be positioned counterclockwise relative to the nominal center position.

[0050] While the principles and modes of operation have been illustrated and described with respect to particular embodiments, it will be understood that the same may be practiced otherwise than as specifically illustrated and described without departing from the spirit or scope thereof.

Claims

1. A milling tool comprising: a tool body defining a blade recess having a main seat base, a lower seat wall, a middle seat wall, and an upper seat wall; The lower seat wall, the middle seat wall, and the upper seat wall are generally planar; as well as A cutting blade disposed in the blade recess, the cutting blade having a blade body comprising a front face and a rear face, wherein first, second and third main circumferential side faces extend between the front face and the rear face and around the circumference of the blade body, first, second and third cutting corners are disposed between the first and second main circumferential side faces, the second and third main circumferential side faces, and the third and first main circumferential side faces, respectively, each of the main circumferential side faces comprising two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween, each side seat surface being convex, one of the front surface or the rear surface engaging the main seat bottom plate, and three continuous side seat surfaces engaging the lower seat wall, the middle seat wall and the upper seat wall, respectively. 2 . The milling tool according to claim 1 , wherein the angle formed by the middle seat wall and the upper seat wall is less than 120 degrees, and wherein the angle formed by the lower seat wall and the middle seat wall is greater than 120 degrees.

3. The milling tool of claim 2, wherein the lower seat wall, the middle seat wall, and the upper seat wall are oriented generally at right angles to the main seat base.

4. The milling tool of claim 1 , wherein each of the three continuous side seat surfaces engages the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position clockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

5. The milling tool of claim 1 , wherein each of the three continuous side seat surfaces engages the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position counterclockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

6. A milling tool comprising: a tool body defining an insert recess having a main seat floor, a lower seat wall, a middle seat wall, and an upper seat wall, each of the lower seat wall, the middle seat wall, and the upper seat wall being convex; as well as A cutting blade disposed in the blade recess, the cutting blade having a blade body, the blade body including a front face and a rear face, wherein first, second and third main circumferential side faces extend between the front face and the rear face and around the circumference of the blade body, first, second and third cutting corners are disposed between the first and second main circumferential side faces, the second and third main circumferential side faces, and the third and first main circumferential side faces, respectively, each of the main circumferential side faces including two side seat surfaces, the two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween, each side seat surface being substantially planar, one of the front surface or the rear surface engaging the main seat bottom plate, and three continuous side seat surfaces engaging the lower seat wall, the middle seat wall and the upper seat wall, respectively. 7 . The milling tool according to claim 6 , wherein each of the lower seat wall, the middle seat wall, and the upper seat wall is arcuate between a corresponding cutting corner and a transition corner in a direction along the circumference of the insert body. 8 . The milling tool according to claim 6 , wherein each of the lower seat wall, the middle seat wall, and the upper seat wall is arcuate between the front face and the rear face in a direction along an axis of the insert body.

9. The milling tool according to claim 6, wherein each of the lower seat wall, the middle seat wall and the upper seat wall is arcuate between the corresponding cutting corner and the transition corner in the direction along the circumference of the insert body, and is arcuate between the front face and the rear face in the direction along the axis of the insert body.

10. The milling tool of claim 6, wherein each of the three continuous side seat surfaces engages the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position clockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

11. The milling tool of claim 6, wherein each of the three continuous side seat surfaces engages the lower seat wall, the middle seat wall, and the upper seat wall, respectively, at a position counterclockwise relative to a nominal center position of each of the lower seat wall, the middle seat wall, and the upper seat wall.

12. A cutting blade for a milling tool, comprising: A blade body comprising a front face and a rear face, wherein first, second and third major circumferential side faces extend between the front face and the rear face and around the circumference of the blade body, first, second and third cutting corners are disposed between the first and second major circumferential side faces, the second and third major circumferential side faces, and the third and first major circumferential side faces, respectively, each of the major circumferential side faces comprising two side seat surfaces extending between adjacent cutting corners and having a transition corner disposed therebetween, each side seat surface being convex.

13. The cutting blade of claim 12, wherein each side seating surface is arcuate in a direction along the circumference of the blade body between the corresponding cutting corner and transition corner.

14. The cutting blade of claim 12, wherein each side seating surface is arcuate between the front face and the rear face in a direction along the axis of the blade body.

15. The cutting blade of claim 12, wherein each side seat surface is arcuate between the corresponding cutting corner and the transition corner in the direction along the circumference of the blade body, and is arcuate between the front face and the rear face in the direction along the axis of the blade body.

16. The cutting blade of claim 12, wherein each of the cutting angles is formed at the same angle, and the angles are less than 120 degrees.

17. The cutting blade of claim 12, wherein each of the transition corners is formed at the same angle, and the angle is greater than 120 degrees.

18. The cutting blade of claim 12, wherein each of the cutting corners is formed at the same angle, and the angle is less than 120 degrees, and wherein each of the transition corners is formed at the same angle, and the angle is greater than 120 degrees.

19. The cutting blade of claim 12, wherein the cutting blade is molded.

20. The cutting blade of claim 19, wherein the cutting blade is peripherally ground.

21. The cutting blade of claim 12, wherein the cutting blade is indexable.

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