Modular rotary cutting tool

Abstract

A rotary cutting tool including a handle and a replaceable cutting insert is disclosed. The shank includes a pocket that receives an interchangeable cutting insert. The pocket includes a base plate having a central pin receiving bore, opposing pocket centering walls, and a torque transmitting pocket drive wall. The cutting insert has a relatively long back pin receivable in the central bore of the shank. The head of the cutting insert includes an insert centering surface that contacts the pocket centering wall of the handle, and an insert drive surface that contacts the torque transmitting pocket drive wall of the handle. The handle and cutting insert features are configured and sized to provide improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

Description

Technical Field

[0001] The present invention relates to a modular rotary cutting tool comprising a shank and a replaceable cutting insert. Background Art

[0002] Drill bits with replaceable cutting tips are known. Typically, the cutting head and shank may exhibit a continuous and complementary configuration, as in fluted drill bits. Each shank typically includes structure for retaining and rotating the associated cutting head, while the associated cutting head has complementary structure for retaining and rotating the shank. Due to the stress concentrations exerted on the shank's retaining and driving structures during normal use, challenges such as deformation and failure may arise over the drill bit's service life. This can significantly limit the drill bit's service life. Summary of the Invention

[0003] A rotary cutting tool is provided that includes a shank and a replaceable cutting insert. The shank includes a pocket for receiving the interchangeable cutting insert. The pocket includes a base plate having a center pin receiving hole, opposing pocket centering walls, and a torque transfer pocket drive wall. The cutting insert has a relatively long rear pin that is receivable in the center hole of the shank. The head of the cutting insert includes a blade centering surface that contacts the pocket centering wall of the shank, and a blade drive surface that contacts the torque transfer pocket drive wall of the shank. The configuration and size of the shank and cutting insert features are controlled to provide improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

[0004] One aspect of the present invention is to provide a modular rotary cutting tool comprising a shank having a central longitudinal axis and a cutting insert removably mounted on the shank. The shank includes a front pocket having a central pin receiving hole. The cutting insert includes a pin receivable in the pin receiving hole of the shank. The front pocket includes opposing first and second pocket centering walls, first and second torque transmission pocket drive walls, and a pocket base. The first pocket centering walls define a plane, the first pocket drive walls define another plane, the first pocket centering wall plane and the first pocket drive wall plane intersecting at a pocket intersection point P located at the pocket base at a pocket wall angle A measured at the pocket intersection point P, the pocket wall angle A being greater than 90° and less than 155°, and wherein each of the first pocket drive wall and the second pocket drive wall is disposed in a plane parallel to the longitudinal axis of the shank.

[0005] Another aspect of the present invention is to provide a modular rotary cutting tool shank having a central longitudinal axis and including a center pin receiving hole and a front pocket. The front pocket includes opposing first and second pocket centering walls, first and second torque-transmitting pocket drive walls, and a pocket base. The first pocket centering wall defines a plane, the first pocket drive wall defines another plane, and the first pocket centering wall plane and the first pocket drive wall plane intersect at a pocket intersection point P located at the pocket base at a pocket wall angle A measured at the intersection point P, the pocket wall angle A being greater than 95° and less than 155°, and wherein each of the first pocket drive wall and the second pocket drive wall is disposed in a plane parallel to the longitudinal axis of the shank.

[0006] Yet another aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool, the cutting insert having a central longitudinal axis and comprising a head and a pin extending rearwardly from the head. The head comprises a first blade centering surface and a second blade centering surface, a first torque transfer blade drive surface and a second torque transfer blade drive surface, and a rear face. The first blade centering surface defines a plane, the first blade drive surface defines another plane, and the first blade centering surface plane and the first blade drive surface plane intersect at a blade intersection point P' located in the plane of the rear face at a blade surface angle A' measured at the blade intersection point P', the blade surface angle A' being greater than 90° to less than 155°, and wherein each of the first blade drive surface and the second blade drive surface is disposed in a plane parallel to the longitudinal axis of the shank.

[0007] Another aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool, the cutting insert comprising a head and a shaft having a length L P The pin, the head having a length L measured in the axial direction of the cutting insert H , the pin extends rearward from the head in the axial direction, wherein the length ratio of the pin to the head is L P :L H Greater than 1:1.

[0008] Another aspect of the present invention is to provide a cutting insert for a modular rotary cutting tool, the cutting insert having a central longitudinal axis, the cutting insert comprising a cutting head, the cutting head comprising first and second blade centering surfaces, first and second torque transfer blade drive surfaces, and a rear face. The first blade centering surface defines a plane, the first blade drive surface defines another plane, the first blade centering surface plane and the first blade drive surface plane intersect at a blade intersection point P' located in the plane of the rear face at a blade surface angle A' measured at the intersection point P', and the blade surface angle A' is greater than 90° and less than 155°. Each of the first and second blade drive surfaces is disposed in a plane parallel to the longitudinal axis of the shank.

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

[0010] Figure 1 and 2 is an isometric view of the modular rotary cutting tool of the present invention, Figure 3 and 4 It is a side view. Figure 5 is the front view, and Figure 6-8 It passes through Figure 5 The modular rotary cutting tool includes a shank and a replaceable cutting insert, shown in side cross-sectional views taken along various lines.

[0011] Figure 9 yes Figure 1-8 An isometric view of the shank of a rotary cutting tool shown in Figure 10-12 is a side view, and Figure 13 It is the front view.

[0012] Figure 14-16 yes Figure 1-8 Isometric view of the cutting insert shown in Figure 17 and 18 It is a side view. Figure 19 is the front view, and Figure 20 is the backend view.

[0013] Figure 21-23 is an isometric view of another cutting insert of the present invention, Figure 24 and 25 It is a side view. Figure 26 is the front view, and Figure 27 is the backend view.

[0014] Figures 28-30 is an isometric view of yet another cutting insert of the present invention, Figure 31 and 32It is a side view. Figure 33 is the front view, and Figure 34 is the backend view.

[0015] Figures 35-37 is an isometric view of another cutting insert of the present invention, Figure 38 and 39 It is a side view. Figure 40 is the front view, and Figure 41 is the backend view.

[0016] Figure 42 is a side view of a modular rotary cutting tool of the present invention including a shank and a replaceable cutting insert.

[0017] Figure 43 yes Figure 42 Front view of the rotating cutting tool.

[0018] Figure 44 It passes through Figure 43 A side cross-sectional view of the rotary cutting tool taken along line 44-44.

[0019] Figure 45 and 46 yes Figures 42-44 A partial side view of the shank of a rotary cutting tool shown in FIG. Figure 47 It is the front view.

[0020] Figure 48 and 49 yes Figures 42-44 A side view of the cutting insert shown in FIG. Figure 50 It is the front view.

[0021] Figure 51 It passes through Figure 50 A side cross-sectional view taken along line 51-51 showing the cutting insert and the set screw.

[0022] Figure 52 yes Figures 42-44 and a rear end view of the cutting insert shown in FIG. 50 .

[0023] Figure 53 yes Figures 48-52 A partial schematic side view of a portion of a cutting insert shown in , showing details of the pin of the cutting insert and the arrangement of the set screws.

[0024] Figure 54 is a partial schematic side view, Figure 55 It passes through Figure 54 A side cross-sectional view taken along line 55-55 of FIG. Figure 56 It passes through Figure 55A side cross-sectional view taken along line 56-56 illustrates features of an ejection tool that may be used to facilitate removal of a cutting insert from a rotary cutting tool shank according to the present invention.

[0025] Figure 57 is a partial schematic side view, Figure 58 It passes through Figure 57 A side cross-sectional view taken along line 58-58, and Figure 59 It passes through Figure 58 A side cross-sectional view taken along line 59-59 showing the insert position of the rotary cutting tool in the shank Figures 54-56 Ejection tool. DETAILED DESCRIPTION

[0026] Figure 1-20 A modular rotary cutting tool 5 in the form of a drill is shown having a shank 10 and a replaceable cutting insert 30. A central longitudinal axis is defined through the cutting tool 5 and is common to both the shank 10 and the cutting insert 30. The modular rotary cutting tool of the present invention performs a rotary cutting operation on a workpiece and may include a drill, a countersinking tool, a milling tool, a reamer tool, and the like.

[0027] The shank 10 includes a pair of grooves 11 along the side of the shank 10 and a front pocket 12. The front pocket 12 includes opposing centering walls 14 and torque-transmitting drive walls 15. Each pocket drive wall 15 intersects an adjacent one of the pocket centering walls 14. A pocket floor 16 is provided at the bottom of the pocket 12. As described more fully below, each pocket centering wall 14 and the adjacent pocket drive wall 15 define planes that intersect each other at the floor 16 at an intersection point P. As described more fully below, the location of the intersection point P and the intersecting pocket wall angle A of the centering walls 14 and the drive walls 15 are controlled to provide improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

[0028] like Figure 12 As best shown in the side view of FIG, each of the recesses 12 may be slightly inclined relative to the centering wall 14 at an angle S, which may generally be greater than 0°, such as greater than 0.1° or greater, or greater than 0.5°, or greater than 1°. The angle S may generally be less than 5°, or less than 4°, or less than 3°. The angle S may generally be in the range of 0.5° to 5°, such as 1° to 4°, or 1.5° to 3.5°, or 2° to 3°. Figure 12 As shown in , the seating angle S can be the same for each of the pocket centering walls 14. As described more fully below, the pocket drive walls 15 can be parallel to each other in a plane parallel to the central longitudinal axis of the handle 10.

[0029] like Figure 9As shown in , coolant holes 18 and 19 may be provided in the front surface of the shank 10 on opposite sides of the pocket 12 . Figure 9 The coolant holes 18 and 19 shown in FIG have different sizes. Alternatively, the coolant holes can have the same size. Figure 4 and 8 As shown in , coolant supply holes 28 may be provided through the side wall of the handle 10 .

[0030] like Figure 6-13 As best shown in the drawing, a central pin receiving bore 20 extends from the pocket floor 16 into the shank along the central longitudinal axis of the shank 10. As described more fully below, the pin receiving bore 20 includes a rear tail contact area 21 that is constructed and arranged to engage a rear end 42 of a cutting insert pin 40. As described more fully below, the pin receiving bore 20 also includes a front contact area 22 that can engage a front end 41 of the pin 40. A threaded set screw bore 24 extends through a side of the shank 10 at an angle and intersects the pin receiving bore 20. A set screw 26 can be threadably received in the set screw bore 24.

[0031] like Figure 14-20 As best shown in the figure, the cutting insert 30 has a central longitudinal axis and includes a head 31, a rear face 32 and a front tip 33. A spiral groove 34 extends along the side of the head 31. A side edge 35 is provided adjacent to the groove 34. In addition, a front cutting edge 36 is provided at the front of the cutting insert head 31. When the rotary cutting tool 5 rotates, the front cutting edge 36 can cut into the workpiece. Once the cutting insert 30 is mounted on the shank 10, the corresponding grooves 11 and 34 in the shank 10 and the cutting insert 30 will be aligned to form substantially continuous grooves 11, 34, respectively. Although two grooves are shown, any other number of grooves may be provided, for example, one groove, three grooves, etc.

[0032] The cutting insert 30 includes a centering surface 37 and a torque transfer drive surface 38 that are constructed and arranged to engage the corresponding pocket centering wall 14 and pocket drive wall 15 of the front pocket 12 of the shank 10. The insert centering surfaces 37 can be slightly angled relative to each other to match the seating angle S of the corresponding pocket centering wall 14. The insert drive surfaces 38 can be parallel to each other and to the central longitudinal axis of the insert 30 to match the parallel arrangement of the pocket drive wall 15.

[0033] The pin 40 extends rearwardly from the rear face 32 of the head 31 of the cutting insert 30. In the illustrated embodiment, the pin 40 and the head 31 may be provided as a single piece or unitary material; however, they may alternatively be provided as separate components that are joined, threaded, or otherwise mechanically fastened together. Figure 17 and18 , the pin 40 includes a front end 41 and a rear end 42. Opposing notches 44 having set screw contact surfaces 45 extend radially inward on opposite sides of the pin 40. The pin 40 includes a front portion 46 and a rear portion 48 separated by the opposing notches 44. As described more fully below, the structure and size of the cutting insert head 31 and the pin 40, including their relative dimensions, are controlled according to the present invention.

[0034] like Figure 12 As shown in FIG, the shank 10 has a shank diameter D S .like Figure 13 As shown in FIG, each pocket centering wall 14 and the adjacent pocket drive wall 15 define planes that intersect each other in the plane of the pocket floor 16 at the pocket intersection point P. The pocket wall angle A is defined at the pocket intersection point P where the planes of the pocket centering wall 14 and the pocket drive wall 15 meet. Figure 13 As shown in FIG, the pocket offset distance Y is defined as the distance measured on the pocket floor 16 in the plane of the pocket centering wall 14, extending perpendicularly from the plane of the central longitudinal axis of the handle 10 to the pocket intersection point P. Figure 12 and 13 As further shown in FIG. 1 , the pocket 12 has a centering wall width W measured at the pocket floor 16. C and the drive wall width W measured at the pocket floor 16 D As described more fully below, the planar surface area of ​​each centering wall 14 and the adjacent drive wall 15 can be selected relative to each other. By controlling the structure, arrangement, and dimensions of the above-described features, the shank of the present invention provides advantageous properties such as improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

[0035] like Figure 17 and 20 As shown in FIG, each blade centering surface 37 and the adjacent blade drive surface 38 define planes that intersect each other in the plane of the rear face 32 at the blade intersection point P'. The blade surface angle A' is defined at the blade intersection point P'. Figure 20 As shown in FIG, the insert offset distance Y' is defined as the distance measured on the rear face 32 in the plane of the centering surface 37, extending perpendicularly from the plane of the central longitudinal axis of the cutting insert 30 to the insert intersection point P'. Figure 20 As further shown in FIG. 3 , the blade has a blade centering surface width W′ measured at the rear face 32. C and the driving surface width W' measured at the rear 32 DAs described more fully below, the planar surface areas of each centering surface 37 and the adjacent drive surface 38 can be selected relative to each other. In accordance with the present invention, the insert surface angle A', the insert offset distance Y', and the other structural features described above are controlled to provide improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

[0036] Figure 21-27 A cutting insert 130 according to another embodiment of the present invention is shown. The cutting insert 130 includes a centering surface 137 and a torque transmission drive surface 138. The cutting insert 130 includes a rearwardly extending pin 140 having an opposing notch 144 extending rearwardly from a rear face 132 of the head of the cutting insert 130. Figure 27 As shown in FIG, the cutting insert 130 has a blade intersection point P', a blade surface angle A', a blade offset distance Y', a blade centering surface width W C and blade drive surface width W D .

[0037] Figure 28-34 Another cutting insert 230 according to an embodiment of the present invention is shown. The cutting insert 230 includes a centering surface 237 and a torque transmission drive surface 238. A relief channel 239 is provided between adjacent centering surfaces 237 and torque transmission drive surfaces 238. The cutting insert 230 includes a pin 240 having opposing notches 244, which extends rearwardly from the rear face 232 of the head of the cutting insert 230. Figure 34 As shown in FIG, the cutting insert 230 has a blade intersection point P', a blade surface angle A', a blade offset distance Y', a blade centering surface width W C and blade drive surface width W D .

[0038] Figures 35-41 330 according to another embodiment of the present invention is shown. The cutting insert 330 includes a centering surface 337 and a torque transmission drive surface 338. A relief channel 339 is provided between the adjacent centering surfaces 337 and the torque transmission drive surface 338. The cutting insert 330 includes a pin 340 having opposing notches 344, which extends rearward from the rear face 332 of the head of the cutting insert 330. Figure 41 As shown in FIG, the cutting insert 330 has a blade intersection point P', a blade surface angle A', a blade offset distance Y', a blade centering surface width W C and blade drive surface width W D .

[0039] Figures 42-51Another modular rotary cutting tool 405 of the present invention is shown, which includes a handle 410 and a cutting insert 430, which have several features in common with the features described in the above embodiments. The handle 410 includes a spiral groove 411 and a front recess 412. A base plate 416 is provided at the bottom of the recess 412. The recess 412 includes opposing centering walls 414 and a torque transmission drive wall 415. Figure 45 As shown in , the centering wall 415 of the recess 416 can be oriented at a seating angle S, which can be selected as described above. Coolant holes 418 are provided in the front surface of the shank 410 on the opposite side of the recess 412, which can be of the same size or different sizes. As described more fully below, the shank 410 includes a center pin receiving hole 420 having a tail contact area 421 and a front contact area 422. As shown in Figure 44 and 53 As best shown in FIG, threaded set screw hole 424 receives threaded set screw 426 and extends from one side of the shank at an angle B relative to the longitudinal axis of shank 410 to pin receiving hole 420. Ejection hole 428 extends radially through one side of shank 410 and intersects pin receiving hole 420.

[0040] The cutting insert 430 includes a head 431, a rear face 432, and a front tip 433. A spiral groove 434 is provided along one side of the cutting insert 430. A side edge 435 is provided adjacent to the groove 434, and a front cutting edge 436 is provided at the front of the head 431.

[0041] The cutting insert 430 includes a centering surface 437 and a torque transmission drive surface 438. As described in the embodiments above, the insert centering surfaces 437 can be slightly angled relative to each other to match the seating angle S of the corresponding pocket centering wall 414 of the pocket 412 of the shank 410. The insert drive surfaces 438 can be parallel to each other in a plane parallel to the central longitudinal axis of the cutting insert 430. A relief channel 439 is provided between adjacent centering surfaces 437 and torque transmission drive surfaces 438.

[0042] The cutting insert 430 includes a pin 440 having a front end 441 and a rear end 442. As described above, the pin 440 can be integrally formed with the head 431, or can be provided as a separate component that is connected or mechanically fastened to the head 431. For example, the head 431 can include a carbide material, and the pin 440 can include a steel material fastened to the head. On one side of the pin 440, there are provided opposing recesses 444 that include a set screw contact surface 445. The pin 440 includes a front portion 446 and a rear portion 448 separated by the opposing recesses 444. In the illustrated embodiment, the recesses 444 are located on opposite sides of the pin 440 that are circumferentially spaced 180° apart from each other. Alternatively, a single recess can extend 360° circumferentially around the pin 440.

[0043] like Figure 45 As shown in FIG, the handle 410 has a diameter D S , and the pocket 412 has a centering wall width W measured at the pocket floor 416 C .like Figure 46 As shown in FIG, the pocket 412 also has a driving wall width W D .like Figure 47 As shown in FIG, each pocket centering wall 414 and the adjacent pocket drive wall 415 define planes that intersect each other in the plane of the pocket floor 416 at the pocket intersection point P. The pocket wall angle A is defined at the pocket intersection point P where the planes of the pocket centering wall 414 and the pocket drive wall 415 meet. Figure 47 As shown in FIG, the pocket offset distance Y is defined as the distance measured on the pocket floor 416 in the plane of the pocket centering wall 414, extending perpendicularly from the plane of the central longitudinal axis of the handle 10 to the pocket intersection point P. Figures 45-47 As further shown in FIG. 4 , the pocket 412 has a centering wall width W measured at the pocket floor 416. C and the drive wall width W measured at the pocket floor 416 D The planar surface area of ​​each centering wall 414 and the adjacent drive wall 415 may be selected relative to each other. The planar surface area of ​​each pocket centering wall 414 may be designated as SA C , and the planar surface area of ​​each pocket drive wall 415 can be designated as SA D Pocket drive wall surface area SA D Can be controlled as the surface area SA of the concave center wall C The percentage of SA D / SA C By controlling the structure, arrangement, and dimensions of the features described above, the shank of the present invention provides advantageous properties such as improved torque transfer, stiffness, and stability during operation of the rotary cutting tool.

[0044] like Figure 50 and 52As shown in FIG, the head of the blade 430 has a blade head diameter D H , Blade centering surface width W' C and blade drive surface width W' D .like Figure 52 As shown in , each blade centering surface 437 and the adjacent blade drive surface 438 define planes that intersect each other in the plane of the rear face 432 at the blade intersection point P'. The blade surface angle A' is defined at the blade intersection point P'. Figure 52 As shown in FIG, the blade offset distance Y' is defined as the distance extending perpendicularly from the plane of the central longitudinal axis of the cutting blade 430 to the blade intersection point P' measured on the rear face 432 in the plane of the centering surface 437. Figure 52 As further shown in FIG. 4 , the blade has a blade centering surface width W′ measured at the rear face 432. C and the driving surface width W' measured at the rear 432 D The planar surface area of ​​each centering surface 437 and the adjacent driving surface 438 may be selected relative to each other. The planar surface area of ​​each blade centering surface 414 may be designated as SA' C , and the planar surface area of ​​each blade drive surface 415 may be designated as SA' D Blade drive surface area SA' D Can be controlled as blade centering surface SA' C The percentage of SA' D / SA' C According to the present invention, the insert surface angle A', the insert offset distance Y' and the other structural features described above are controlled to provide improved torque transfer, stiffness and stability during operation of the rotary cutting tool.

[0045] like Figure 51 and 53 As best shown in FIG. 4 , the pin 440 has an overall length L P and the tail length L measured from the rear of the notch 444 to the rear end 442 of the pin T The pin 440 has a diameter D P .like Figure 53 As further shown in FIG, the set screw 426 is provided at a set screw angle B measured between the central longitudinal axis of the set screw 426 and the central longitudinal axis of the pin 440. Figure 44 As shown in , the set screw angle B corresponds to a similar angle of the set screw hole 424 in the handle 410, as measured between the central longitudinal axis of the set screw hole 424 and the central longitudinal axis of the handle 410. The set screw angle B and the corresponding set screw hole angle can generally be 20 to 40 degrees, such as 25 to 35 degrees, or 28 to 32 degrees. Figure 53As schematically shown in FIG, during installation and retention of the cutting insert 430 in the shank 410, the set screw 426 generates a set screw force F at a set screw angle B along the longitudinal axis of the set screw 426. S As described more fully above, the set screw force F S With axial component F A and radial component F R The axial component is used to force the pin 440 axially into the pin receiving hole 420, and the radial component is used to radially force portions of the pin 440 against opposing surfaces of the pin receiving hole 420, thereby causing the pin 440 to bend or deform a controlled amount.

[0046] A gap G is provided between the pin 440 and the pin receiving hole 420 of the handle 410. The provision of this gap G allows the tail 448 of the pin 440 to move along the positioning screw force F. S The radial component F R Deforms a controlled amount in the radial direction. This creates a tail contact area C at the tail 448 T , the tail contact area engages with the opposite rear inner surface 421 of the pin receiving hole 420. The front contact area C at the front portion 446 of the pin 440 F The opposing front inner surface 442 of the pin receiving hole 420 may also be contacted.

[0047] The above-mentioned recess wall angle A can be greater than 90°, or greater than 125°, or greater than 135°, or greater than 140°. The recess wall angle A can be less than 155°, or less than 150°, or less than 148°, or less than 145°. The recess wall angle A can be in the range of 90° to 150°, for example, 125° to 150°, or 135° to 148°, or 140° to 145°.

[0048] The blade surface angle A' can be greater than 90°, or greater than 125°, or greater than 135°, or greater than 140°. The blade surface angle A' can be less than 155°, or less than 150°, or less than 148°, or less than 145°. The blade surface angle A' can be in the range of 90° to 150°, for example, 125° to 150°, or 135° to 148°, or 140° to 145°.

[0049] The described pocket offset distance Y may be selected to be the shank diameter D S Percentage of Y / D S The percentage can be greater than 0.5%, or greater than 1%, or greater than 2%, or greater than 2.5%, or greater than 3%, or greater than 5%. S The percentage can be less than 20%, or less than 17%, or less than 15%. SThe percentage may be in the range of 1% to 20%, such as 2.5% to 17%, or 3% to 15%, or 5% to 14%.

[0050] The blade offset distance Y' can be selected as the blade head diameter D H Percentage of Y' / D H The percentage can be greater than 0.5%, or greater than 1%, or greater than 2%, or greater than 2.5%, or greater than 3%, or greater than 5%. H The percentage can be less than 20%, or less than 17%, or less than 15%. H The percentage may range from 1% to 20%, such as from 2.5% to 17%, or from 3% to 15%, or from 5% to 14%.

[0051] The width of the concave wall is W C Can be selected as shank diameter D S Percentage of W C / D S The percentage can be greater than 15%, or greater than 16%, or greater than 18%. C / D S The percentage may be less than 30%, or less than 28%, or less than 25%, or less than 23%. C / D S The percentage may be in the range of 15% to 30%, such as 16% to 28%, or 18% to 25%, or 18% to 23%.

[0052] The width of the blade centering surface W' C The blade head diameter D can be selected H Percentage of W' C / D H The percentage may be greater than 15%, or greater than 16%, or greater than 18%. C / D H The percentage may be less than 30%, or less than 28%, or less than 25%, or less than 23%. C / D H The percentage may be in the range of 15% to 30%, such as 16% to 28%, or 18% to 25%, or 18% to 23%.

[0053] The width W of the above-mentioned cavity driving wall D The width W of the centering wall of the pocket can be selected C Percentage of W D / W C The percentage may be greater than 1%, or greater than 10%, or greater than 15%, or greater than 25%, or greater than 28%. D / W CThe percentage may be less than 100%, or less than 90%, or less than 85%, or less than 75%, or less than 60%. D / W C The percentage may range from 1% to 100%, such as from 10% to 90%, or from 15% to 85%, or from 25% to 75%, or from 28% to 60%.

[0054] The blade drive surface width W' D Optional insert centering surface width W' C Percentage of W' D / W' C The percentage may be greater than 1%, or greater than 10%, or greater than 15%, or greater than 25%, or greater than 28%. D / W' C The percentage may be less than 100%, or less than 90%, or less than 85%, or less than 75%, or less than 60%. D / W' C The percentage may range from 1% to 100%, such as from 10% to 90%, or from 15% to 85%, or from 25% to 75%, or from 28% to 60%.

[0055] Pocket drive wall surface area SA D The surface area SA of the center wall of the recess can be selected C Percentage of SA D / SA C The percentage may be greater than 30%, or greater than 34%, or greater than 50%, or greater than 70%, or greater than 75%. D / SA C The percentage may be less than 200%, or less than 190%, or less than 145%, or less than 130%, or less than 120%. D / SA C The percentage may be in the range of 40% to 170%, such as 45% to 165%, or 50% to 135%, or 65% to 125%.

[0056] Blade driving surface area SA' D Optionally, insert centering surface area SA' C SA' D / SA' C The percentage may be greater than 30%, or greater than 34%, or greater than 50%, or greater than 70%, or greater than 75%. D / SA' C The percentage may be less than 200%, or less than 190%, or less than 145%, or less than 130%, or less than 120%. D / SA' CThe percentage may be in the range of 40% to 170%, such as 45% to 165%, or 50% to 135%, or 65% to 125%.

[0057] Total blade pin length L P and blade head length L H A certain ratio can be selected. P :L H The ratio may be greater than 1:1, or greater than 1.05:1, or greater than 1.1:1. P :L H The ratio may be less than 2:1, or less than 1.9:1, or less than 1.8:1, or less than 1.5:1. P :L H The ratio may be in the range of 1:1 to 2:1, such as 1.1:1 to 1.8:1, or 1.1:1 to 1.6:1, or 1.1:1 to 1.5:1.

[0058] Pin tail length L T The total pin length L can be selected P Percentage of L T / L P The percentage may be greater than 20%, or greater than 22%, or greater than 24%, or greater than 25%. T / L P The percentage may be less than 40%, or less than 35%, or less than 33%, or less than 32%. T / L P The percentage may be in the range of 20% to 40%, such as 22% to 35%, or 24% to 33%, or 25% to 32%.

[0059] Total pin length L P and pin diameter D P A certain ratio can be selected. P :D P The ratio may be greater than 3:1, or greater than 3.2:1, or greater than 3.4:1, or greater than 3.5:1. P :D P The ratio may be less than 6:1, or less than 5:1, or less than 4:5.1, or less than 4.0:1. P :D P The ratio may be in the range of 3.0:1 to 6.0:1, such as 3.2:1 to 5:1, or 3.4:1 to 4.5:1, or 3.5:1 to 4.0:1.

[0060] Pin tail length L T and pin diameter D P A certain ratio can be selected. T :D PThe ratio may be greater than 0.95:1, or greater than 1.0:1, or greater than 1.05:1. T :D P The ratio may be less than 2.0:1, or less than 1.8:1, or less than 1.6:1, or less than 1.5:1. T :D P The ratio may range from 0.95:1 to 2.0:1, such as from 1.0:1 to 1.8:1, or from 1.0:1 to 1.6:1, or from 1.05:1 to 1.5:1.

[0061] Pin diameter D P The blade head diameter D can be selected H Percentage of D P / D H The percentage can be greater than 15%, or greater than 17%, or greater than 19%, or greater than 20%. P / D H The percentage may be less than 30%, or less than 27%, or less than 25%, or less than 24%. P / D H The percentage may be in the range of 15% to 30%, such as 17% to 27%, or 19% to 25%, or 20% to 24%.

[0062] For example, the gap G between the hole 420 and the pin 440 can be greater than 0 mm, or greater than 0.002 mm, or greater than 0.003 mm, or greater than 0.004 mm, or greater than 0.005 mm. The gap G can be less than 0.1 mm, or less than 0.08 mm, or less than 0.05 mm. The gap G can be in the range of 0.002 to 0.1 mm, or 0.003 to 0.08 mm, or 0.004 to 0.06 mm, or 0.005 to 0.05 mm.

[0063] The present pocket and insert design provides excellent torque transfer capability, stiffness, and stability under side loads. A good correlation has been found between the offset distance and performance. When the offset distance falls within the values ​​listed above, the pocket stresses are under controlled limits, thereby providing a robust design. The resulting contact area between the pocket centering wall and the insert centering surface has been found to be sufficiently large to avoid premature wear under cyclic loads. By providing the offset distance described herein, a small contact area can be provided between the pocket centering wall and the insert centering surface, which helps transfer torque and torque from the pocket drive wall to the insert drive surface. The stresses caused by the additional contact in the centering portion act in a different area than the stresses caused by the torque transferred in the drive area. However, values ​​of the offset distance that are too large will make the cross-section of the insert too small and may become the weakest point in the system.

[0064] Due to the gap G between the pin 440 and the pin receiving hole 420 and the angle B from the longitudinal axis of the set screw to the longitudinal axis of the pin, the force applied by the set screw 426 will produce a vertical component necessary for clamping, as well as a lateral component that attempts to bend the pin and may cause the insert to be clamped slightly tilted or eccentrically. The deformation of the pin 440 and the contact between its tail 448 and the opposing inner wall of the pin receiving hole 420 increase stability and reduce relative movement between the cutting insert 430 and the pocket 412, particularly when oscillating side loads are generated during drilling operations, such as when drilling holes in angled surfaces or drilling cross holes.

[0065] By utilizing high L P / D P The ratio of the pin to the hole allows for contact between the pin and the hole, and additional clamping force can be applied without generating additional stress on the pin near the seating surface. Long pins can also store more elastic deformation than short pins, which keeps the system preloaded and prevents the set screw from loosening due to vibration, wear, or thermal expansion of the components. The combination of a long pin and a small angle B allows for a longer set screw, resulting in a higher total elastic deformation (e.g., stored energy). By making the pin longer, there is sufficient contact between the pin and the hole, and due to the relatively large diameter of the pin, the stiffness of the system can be increased. This can be achieved by providing a relatively high L T :D P ratio to reduce the high voltage caused by the contact, and high L P :D P Ratio with high L T :D P The combination of ratios results in an improved design.

[0066] In addition, the selected L T :D P The ratio creates sufficient support area to keep the contact pressure with the hole to a minimum. Higher contact pressure is found on the tail section and depends on the stiffness of the pin (which is affected by L P / D P The ratio is directly affected by the gap G and the force applied by the set screw. Reducing the contact pressure allows the set screw to apply a higher force, which in turn creates a more stable connection between the blade and the pocket. The relatively high ratio also allows for reduced stress in the notch 444 area of ​​the pin 440.

[0067] Figures 54-59A knockout tool 50 is shown that can be used to remove the cutting insert of the present invention from the shank of a cutting tool, for example, for the purpose of replacement, inspection, sharpening, or repair. The knockout tool 50 includes a cam tip 52 at its end. The body of the knockout tool 50 may include a generally circular cross-section, while the cam tip includes a portion having a generally cylindrical outer surface 54 and a cam surface 56. Although not shown in the figures, the opposite end of the knockout tool 50 may include a keyed end that can be received in a corresponding recess in a set screw for tightening and loosening the set screw, and the knockout tool may be generally L-shaped to facilitate the knockout operation and set screw tightening.

[0068] like Figures 54-59 As further shown in FIG, the ejection hole 428 extends radially through the side wall of the handle 410 and intersects the pin receiving hole 420 in the area of ​​the rear end 442 of the pin 440. Figure 44 、 55 As shown in Figures 58 and 59, the rear end 442 can extend into at least 10%, or at least 20%, or at least 30%, or at least 40% of the diameter of the ejection hole 428. Although in the illustrated embodiment, the radially extending ejection hole is angled slightly, for example, 5° to 30°, or 15° to 25°, to the perpendicular to the central longitudinal axis of the handle 410, it can alternatively be disposed perpendicularly. Figure 55 and 56 In FIG, the cam tip 52 is aligned outside the ejection hole 428. Figure 58 and 59 4, the cam tip 52 has been inserted into the ejection hole 428 to a position where the cam surface 56 contacts the rear end 442 of the pin 440. Upon rotation about the central longitudinal axis of the ejection tool 50 from the position shown, the cam surface 56 is forced against the rear end 442, thereby forcing the pin 440 axially through the pin receiving hole 420 in the removal direction. The cam tip 52 thereby applies sufficient force to remove the cutting insert 430 from the shank 410.

[0069] For the purpose of this specific embodiment, it should be understood that, unless clearly indicated otherwise, the present invention can take various alternatives and step sequences. In addition, except in any operating examples or when otherwise indicated, all numerals expressing the quantity of the components used in the present specification and claims should be understood to be modified by the term "about" in all cases. Therefore, unless indicated otherwise, the numerical parameters set forth in the following description and the appended claims are approximate values ​​that can vary according to the desired properties to be obtained by the present invention. At least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be interpreted according to the number of reported significant figures and by applying ordinary rounding techniques.

[0070] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0071] Furthermore, it should be understood that any numerical range recited herein is intended to include all subranges contained therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, i.e., having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

[0072] As used herein, "including," "containing," and similar terms are understood in the context of this application to be synonymous with "comprising," and are thus open-ended and do not exclude the presence of additional, undescribed or unrecited elements, materials, ingredients, or method steps. As used herein, "consisting of" is understood in the context of this application to exclude the presence of any unspecified elements, ingredients, or method steps. As used herein, "consisting essentially of" is understood in the context of this application to include the specified elements, materials, ingredients, or method steps "as well as those that do not materially affect the basic and novel characteristics described."

[0073] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the plural encompasses the singular. For example, although reference is made herein to "a" powder composition, "a" cemented carbide body, and "an" apparent density, combinations (i.e., a plurality) of these components may be used.

[0074] Additionally, in this application, the use of "or" means "and / or" unless specifically stated otherwise, even though "and / or" may be explicitly used in certain circumstances.

[0075] Although specific aspects of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to these details can be developed based on the overall teachings of this disclosure. Therefore, the particular arrangements disclosed are intended to be illustrative only and not limiting of the scope of the invention, which is to be given by the full scope of the appended claims and any and all equivalents thereof.

Claims

1. A modular rotary cutting tool comprising: a handle having a central longitudinal axis and including a central pin receiving hole and a front recess comprising: a first recess centering wall and a second recess centering wall that are opposite; a first torque transfer pocket drive wall and a second torque transfer pocket drive wall; and a recessed floor; and a cutting insert removably mounted in a front pocket of the shank, the cutting insert including a pin receivable in a pin receiving hole of the shank, wherein the first pocket centering wall defines a plane and the first pocket drive wall defines another plane, the first pocket centering wall plane and the first pocket drive wall plane intersect at a pocket intersection point P located at the pocket floor at a pocket wall angle A measured at the intersection point P, and the pocket wall angle A is greater than 90° to less than 155°, and wherein each of the first pocket drive wall and the second pocket drive wall is disposed in a plane parallel to a longitudinal axis of the handle.

2. The modular rotary cutting tool according to claim 1, wherein the pocket wall angle A is 130° to 150°.

3. The modular rotary cutting tool according to claim 1 , wherein the intersection point P is located at a pocket offset distance Y from a plane in which the longitudinal axis of the shank lies, the pocket offset distance Y being measured at the pocket floor in the direction of the first pocket centering wall plane, and the pocket offset distance Y being the diameter D of the shank. S 1% to 20% of the total.

4. The modular rotary cutting tool according to claim 3, wherein the pocket offset distance Y is the shank diameter D S 3% to 15% of the total.

5. The modular rotary cutting tool of claim 1 , wherein the pocket has a pocket centering wall width W measured at the pocket floor. C , the pocket drive wall width W measured at the pocket bottom D , and the cavity drive wall width W D Greater than the width W of the centering wall of the cavity C 10% of.

6. The modular rotary cutting tool according to claim 5, wherein the pocket drive wall width W D is the centering wall width W C 25% to 75% of the total.

7. The modular rotary cutting tool of claim 1, wherein each of the opposing first pocket centering walls and second pocket centering walls is disposed at a seating angle S greater than 0.5° measured from a longitudinal axis of the shank.

8. The modular rotary cutting tool according to claim 7, wherein the seating angle S is 1° to 4°.

9. The modular rotary cutting tool of claim 1 , wherein the first pocket centering wall has a planar surface area SA C , the first cavity drive wall has a plane surface area SA D , and the planar surface area SA of the first recess drive wall D is the plane surface area SA of the center wall of the first recess C 50% to 135% of 10. The modular rotary cutting tool of claim 1, wherein the pin receiving bore has a substantially constant inner diameter along an axial length of the pin receiving bore.

11. The modular rotary cutting tool of claim 1 , wherein the shank includes coolant holes in a front surface of the shank on opposite sides of the front pocket.

12. The modular rotary cutting tool of claim 11, wherein the coolant holes are of the same size.

13. The modular rotary cutting tool of claim 11, wherein the coolant holes have different sizes.

14. The modular rotary cutting tool of claim 13 , wherein the shank includes an angled set screw hole adjacent to the opposing first pocket centering wall and extending through a side of the shank adjacent to a first front surface of the shank to the center pin receiving hole, and wherein one of the coolant holes having a smaller size than another of the coolant holes is located in the first front surface of the shank adjacent to the set screw hole.

15. The modular rotary cutting tool of claim 1 , wherein the cutting insert comprises: A head having a length L measured in the axial direction of the cutting insert H ; With length L P The pin extends rearward from the head in the axial direction, and the length ratio of the pin to the head is L P :L H Greater than 1:

1.

16. The modular rotary cutting tool of claim 15, wherein the pin to head ratio L P :L H It is 1.1:1 to 1.6:

1.

17. The modular rotary cutting tool of claim 15, wherein the pin includes at least one side recess located between a front end of the pin and a rear end of the pin and defining a length L of the pin. T The tail of the pin is L T Greater than the total pin length L P 20% of.

18. The modular rotary cutting tool according to claim 17, wherein the pin tail length L T is the total length of the pin L P 24% to 33%.

19. The modular rotary cutting tool according to claim 17, wherein the pin tail length L T Greater than the pin diameter D P .

20. The modular rotary cutting tool of claim 19, wherein the ratio L of the pin tail length to the pin diameter T :D P 1.0:1 to 1.6:

1.

21. The modular rotary cutting tool of claim 17, comprising two of the side recesses on opposite sides of the pin, the two side recesses being circumferentially spaced 180° apart from each other.

22. The modular rotary cutting tool of claim 1, wherein the pin has a diameter D P , the pin receiving hole has a diameter greater than the pin diameter D P Diameter D H , and a gap G is provided between the pin and the pin receiving hole.

23. The modular rotary cutting tool of claim 22, wherein the gap G is at least 0.002 mm.

24. The modular rotary cutting tool according to claim 23, wherein the gap G is 0.005 mm to 0.05 mm.

25. A shank for a modular rotary cutting tool, wherein the shank has a central longitudinal axis and includes a center pin receiving hole and a front pocket, the front pocket comprising: a first recess centering wall and a second recess centering wall that are opposite; a first torque transfer pocket drive wall and a second torque transfer pocket drive wall; as well as cavity floor, wherein the first pocket centering wall defines a plane and the first pocket drive wall defines another plane, the first pocket centering wall plane and the first pocket drive wall plane intersect at a pocket intersection point P located at the pocket floor at a pocket wall angle A measured at the pocket intersection point P, and the pocket wall angle A is greater than 90° to less than 155°, and wherein each of the first pocket drive wall and the second pocket drive wall is disposed in a plane parallel to a longitudinal axis of the handle.

26. A cutting insert for a modular rotary cutting tool, the cutting insert having a central longitudinal axis and comprising a head and a pin extending rearwardly from the head, the head comprising: a first blade centering surface and a second blade centering surface; a first torque transfer blade drive surface and a second torque transfer blade drive surface; as well as rear surface, wherein the first blade centering surface defines a plane and the first blade driving surface defines another plane, the first blade centering surface plane and the first blade driving surface plane intersect at a blade intersection point P' located in the plane of the rear surface at a blade surface angle A' measured at the intersection point P', and the blade surface angle A' is greater than 90° to less than 155°, and wherein each of the first blade driving surface and the second blade driving surface is disposed in a plane parallel to the longitudinal axis of the shank.

27. The cutting insert for a modular rotary cutting tool according to claim 26, wherein the insert surface angle A' is 130 to 150°.

28. A cutting insert for a modular rotary cutting tool according to claim 26, wherein the insert intersection point P' is located at an insert offset distance Y' from a plane in which the central longitudinal axis of the insert lies, the insert offset distance Y' being measured in the plane of the back surface in the direction of the first insert centering surface plane, and the insert offset distance Y' is the diameter D of the head H 1% to 20% of the total.

29. The cutting insert for a modular rotary cutting tool according to claim 28, wherein the insert offset distance Y' is a distance equal to the head diameter D H 3% to 15% of the total.

30. The cutting insert for a modular rotary cutting tool according to claim 26, wherein the first insert centering surface and the second insert centering surface define an insert centering surface width W' measured in the plane of the rear surface. C , the first blade driving surface and the second blade driving surface define a blade driving surface width W' measured in the plane of the rear surface D , and the blade drive surface width W' D is the blade centering surface width W' C at least 10% of the 31. The cutting insert for a modular rotary cutting tool according to claim 30, wherein the insert driving surface width W' D The width W' of the blade centering surface C 25% to 75% of the total.

32. A cutting insert for a modular rotary cutting tool according to claim 26, wherein each of the first insert centering surface and the second insert centering surface is disposed at a seating angle S of at least 0.5° measured from a longitudinal axis of the insert.

33. The cutting insert for a modular rotary cutting tool according to claim 32, wherein the seating angle S is 1° to 4°.

34. The cutting insert for a modular rotary cutting tool according to claim 26, wherein the pin has a substantially constant outer diameter along the axial length of the pin.

35. The cutting insert for a modular rotary cutting tool according to claim 26, wherein the first insert centering surface has a planar surface area SA' C , the first blade driving surface has a planar surface area SA' D , and the planar surface area SA' of the blade drive surface D is the plane surface area SA' of the first pair of surfaces C 50% to 135% of 36. A cutting insert for a modular rotary cutting tool, comprising: A head having a length L measured in the axial direction of the cutting insert H ; as well as With length L P a pin extending rearwardly from the head in the axial direction, The length ratio of the pin to the head is L P :L H Greater than 1:

1.

37. The cutting insert for a modular rotary cutting tool according to claim 36, wherein the pin to head ratio L P :L H It is 1.1:1 to 1.6:

1.

38. The cutting insert for a modular rotary cutting tool according to claim 36, wherein the pin includes at least one side recess located between a front end of the pin and a rear end of the pin and defining a length L of the pin. T The tail of T Greater than pin length L P 20% of.

39. The cutting insert for a modular rotary cutting tool according to claim 38, wherein the tail length L T is the pin length L P 24% to 33%.

40. The cutting insert for a modular rotary cutting tool according to claim 38, wherein the tail length L T Greater than the pin diameter D P .

41. The cutting insert for a modular rotary cutting tool according to claim 40, wherein the ratio L of the pin tail length to the pin diameter T :D P 1.0:1 to 1.6:

1.

42. The cutting insert for a modular rotary cutting tool according to claim 38, comprising two of the side recesses on opposite sides of the pin, the two side recesses being circumferentially spaced 180° apart from each other.

43. A cutting insert for a modular rotary cutting tool, the cutting insert having a central longitudinal axis, the cutting insert comprising a cutting head, the cutting head comprising: a first blade centering surface and a second blade centering surface; a first torque transfer blade drive surface and a second torque transfer blade drive surface; as well as rear surface, wherein the first blade centering surface defines a plane and the first blade driving surface defines another plane, the first blade centering surface plane and the first blade driving surface plane intersect at a blade intersection point P' located in the plane of the rear surface at a blade surface angle A' measured at the intersection point P', and the blade surface angle A' is greater than 90° to less than 155°, and wherein each of the first blade driving surface and the second blade driving surface is disposed in a plane parallel to the longitudinal axis of the shank.

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