Cutting tools and related methods

Abstract

A cutting tool includes a body having a first end and a second end opposite the first end. The first end may have one or more cutting elements positioned thereon adjacent to one or more fluid orifices (e.g., holes) positioned to facilitate ejection of fluid out of the body and adjacent to the cutting elements. The second end may have a chamber defined therein in fluid communication with one or more apertures via one or more conduits defined to extend from the chamber to the one or more apertures. In some embodiments, the first end may have a slot defined therein, and the cutting element may be positioned on an edge of the slot. In some embodiments, the body of the cutting tool may be made via an additive layer manufacturing process to form a body having aperture (s), conduit (s), and chamber (s).

Description

Technical Field

[0001] This invention relates to a cutting tool and a method for manufacturing and using the cutting tool. Background Technology

[0002] Examples of cutting tool assemblies can be found in U.S. Patent Nos. 8,123,442, 8,637,127, 8,734,068, 8,807,888, 9,168,601, and 10,195,678, and U.S. Patent Application Publications Nos. 2024109131, 2021 / 053128, 2020 / 0254545, and 2020 / 0246889. For example, cutting tools can be used for metalworking. Some cutting tools may be stationary. Other types of cutting tools may be movable (e.g., rotatable, etc.). For example, cutting tools can be used to process workpieces to form devices, parts, or components. Summary of the Invention

[0003] We have determined that tools that utilize cooling channels to aid in tool cooling during use may be geometrically limited due to the manufacturing techniques that allow drilling to form holes within the tool. This is particularly true for circular tools that may rely on drilling or electrical discharge machining (EDM) using green machinery to create holes or cooling channels within the tool. Holes typically formed in such tools are often used to facilitate fluid flow, which can help cool the tool during use to prevent overheating. The fluid used can also help remove chips that may be present on the workpiece during use, allowing for tool cleaning during operation. Fluid flow and how fluid is directed through the tool may be limited by the tool's geometric design constraints and how those constraints can restrict the ability to drill or EDM to create fluid discharge openings.

[0004] We have developed a cutting tool that provides higher-performance coolant delivery, which also better aids in chip removal. Embodiments can provide an improved coolant conduit flow path configuration that delivers higher-performance coolant to the tool, increasing tool productivity and significantly improving tool life. Embodiments can be configured to significantly improve coolant flow rate and volume. For example, some embodiments can provide a significant increase in coolant channel size, avoiding or minimizing the use of sharp corners and / or abrupt turns, which reduces coolant flow resistance, allowing for a higher-velocity coolant flow from the tool to aid cleaning, and also allowing for a higher cooling rate from the coolant. The body of the cutting tool can be defined such that the direction of coolant flow can be better controlled for fluid jetting from the cutting tool body, thereby also more effectively removing chips from the cut. Furthermore, embodiments can be provided that provide a lighter-weight tool that can be manufactured using less material.

[0005] We were surprised to find that embodiments designed using this type of lightweight tool allow for lower manufacturing costs while still providing tools with sufficient strength, stiffness, and toughness for industrial use, along with significantly better coolant flow and chip removal characteristics. In addition to lower capital costs and a more environmentally friendly approach (e.g., by using less metal to form the tool), the embodiments also allow for the use of cutting tools with longer lifespans and provide improved manufacturing flexibility (e.g., by requiring less downtime and / or maintenance).

[0006] A cutting tool may include a body made of carbide, tungsten carbide, sintered carbide, sintered tungsten carbide, tool steel, steel, or other suitable types of metal. The cutting tool may also include one or more cutting elements that can be attached to the body of the cutting tool, such that each cutting element is integral with the body (e.g., brazed to the body). The cutting elements may be made of polycrystalline diamond (PCD), tungsten carbide, carbide materials, or other suitable materials. The body of the cutting tool may include a first end having one or more cutting elements positioned thereon. A second end of the body opposite the first end may include a chamber for receiving coolant fluid. The body may be formed to define at least one conduit extending from the chamber to one or more orifices located adjacent to the one or more cutting elements to guide coolant fluid flow from the chamber to the one or more orifices, such that coolant fluid passes through the body and exits the one or more orifices. The one or more orifices may be defined to guide fluid to an outer surface of the body of the cutting tool to remove chips that may be present on the tool during tool use.

[0007] One or more conduits may be configured such that they do not have sharp corners or abrupt turns. In some embodiments, one or more conduits may be configured, for example, to provide a smooth path for fluid transfer from the chamber to one or more orifices. We have found that such features help reduce resistance to coolant flow to provide improved coolant fluid flow, which may allow fluid to be ejected from one or more orifices at a greater flow rate.

[0008] In some embodiments, a first end of the cutting tool body may be shaped to have a plurality of grooves. Each cutting edge of a groove may have a cutting element positioned thereon (e.g., attached thereon via brazing or the like). The cutting element may be made of a material harder than the material of the body. For example, the body of the cutting tool may be formed of sintered carbide, carbide, or steel, and each cutting element may be made of PCD.

[0009] In a first aspect, a cutting tool is provided. The cutting tool may include a body having an outer surface, a first end, and a second end opposite the first end. A portion of the outer surface adjacent to the first end may have one or more recesses defined therein to receive one or more cutting elements. At least one orifice may be defined in the outer surface adjacent to the one or more recesses. The second end of the body may have a chamber defined therein to receive coolant fluid. The second end may also have an orifice in fluid communication with the chamber. The body may have at least one conduit defined therein to connect the chamber to the at least one orifice, such that coolant fluid supplied to the chamber can be passed to the at least one orifice for ejection onto the outer surface via the at least one orifice.

[0010] In some embodiments, the at least one hole may include a plurality of spaced-apart holes.

[0011] In a second aspect, the body of the cutting tool may include a plurality of ribs positioned within the chamber to divide the chamber into sectors. In some embodiments, each of the ribs may have the same shape and size. In other embodiments, the ribs may have different shapes or sizes to define sectors of different sizes or shapes. In other embodiments, multiple sets of different ribs may be present, wherein each set of ribs may have different sizes or shapes.

[0012] In a third aspect, the at least one conduit may be defined such that it extends from the chamber to the at least one hole without any sharp edges or abrupt turns. An abrupt turn may be an angle greater than 60° in the conduit. Such an abrupt turn may be provided by drilling, and embodiments may define at least one conduit such that drilling may be unnecessary or not required.

[0013] In a fourth aspect, the body of the cutting tool can be formed via an additive manufacturing process to define the opening, the chamber, the at least one conduit, and the at least one hole. In some embodiments, the additive manufacturing process is an adhesive spraying process. Other embodiments may use another type of additive manufacturing process.

[0014] In a fifth aspect, the body of the cutting tool may be made of sintered carbide, sintered tungsten carbide, carbide material, or steel. Other embodiments may utilize other materials.

[0015] In a sixth aspect, the cutting tool may include one or more cutting elements. In some embodiments, the one or more cutting elements may be attached to the body via one or more recesses, such that each cutting element is integral with the body. Each of the cutting elements may be made of a material harder than the material of the body. In some embodiments, the cutting elements may be made of PCD, cubic boron nitride, ceramic material, or other suitable material.

[0016] In a seventh aspect, the chamber may extend from the second end to an intermediate portion of the body between the first end and the second end. The chamber may have an interface with the at least one conduit, the interface being opposite an opening of the body. The chamber may be defined within the body such that at least 20% of the volume of the body between the interface and the opening is empty space for receiving coolant fluid.

[0017] In an eighth aspect, the cutting tool may include a hub positioned within the cavity and a plurality of ribs extending from the hub to the body to define an inner wall of the cavity to define different sectors of the cavity. The sectors may have the same shape or different sizes.

[0018] In the ninth aspect, the cutting tool of the first aspect may include one or more features of the second, third, fourth, fifth, sixth, seventh, and / or eighth aspects. Therefore, it should be understood that other embodiments may include other features. Examples of additional features can be understood from the exemplary embodiments of the cutting tool discussed herein.

[0019] In a tenth aspect, a method of manufacturing and / or using a cutting tool is provided. The method may include forming a body of the cutting tool, such that the body includes an outer surface, a first end, and a second end. The body may be formed such that a portion of the outer surface adjacent to the first end has one or more recesses defined therein to receive one or more cutting elements, and further has at least one hole defined in the outer surface adjacent to the one or more recesses. The body may be formed such that the second end has a chamber defined therein to receive coolant fluid, and the second end further has an orifice in fluid communication with the chamber. The body may be formed such that the body has at least one conduit defined therein to fluidly connect the chamber to the at least one hole, such that coolant fluid supplied to the chamber can be transferred to the at least one hole for emission onto the outer surface via the at least one hole. The method may further include attaching one or more cutting elements to the outer surface of the body via the one or more recesses, such that each cutting element is integral with the body.

[0020] In some embodiments, the cutting element may be attached via brazing or other suitable attachment mechanism. For example, one or more cutting elements may be attached to the body via brazing, and one or more recesses may be defined in at least one cutting edge of the body. The cutting element(s) may be positioned within the recess(s) and become integral with the body after attachment.

[0021] In some embodiments of the method, the body may be formed via an additive manufacturing process. For example, the body may be formed via an adhesive spraying process or other suitable additive manufacturing processes.

[0022] In the eleventh aspect, the method can be performed such that the material of the body is a pre-selected type of material. For example, the body can be composed of sintered carbide, sintered tungsten carbide, carbide material, or steel. For example, the formation of the body can be provided by using powder or particles of such a material used in additive manufacturing processes.

[0023] In a twelfth aspect, the method can be performed such that the body is formed such that the chamber extends from the second end to an intermediate portion of the body between the first end and the second end. The chamber may be formed to have an interface with the at least one conduit, the interface being opposite an opening of the body. The chamber may be defined within the body such that at least 20% of the volume of the body between the interface and the opening is empty space for receiving coolant fluid.

[0024] In a thirteenth aspect, the body may be configured such that the at least one conduit extends from the chamber to the at least one orifice without any bends greater than 60°. The one or more conduits may also be defined such that the fluid flow path defined by the at least one conduit has no sharp edges.

[0025] In the fourteenth aspect, the method of the tenth aspect may include one or more features of the eleventh, twelfth, and / or thirteenth aspects. For example, embodiments of the method may be performed to form exemplary embodiments of a cutting tool. Embodiments of the method may also include additional steps, such as allowing fluid to pass through a chamber and at least one conduit, to use the cutting tool to aid in cooling the tool and removing debris from the tool. Therefore, it should be appreciated that other embodiments of the method may include additional steps or other features. Examples of such additional steps and / or features may be appreciated from the discussion of the exemplary embodiments discussed herein.

[0026] These and other embodiments will be described in more detail herein and in the accompanying drawings illustrating exemplary embodiments. Therefore, other details, objects, and advantages will become apparent from the following description of certain currently preferred embodiments of the invention and certain currently preferred methods of carrying out the same process. Attached Figure Description

[0027] Exemplary embodiments of the cutting tool and its manufacturing and use methods are shown in the accompanying drawings. It should be understood that the same reference numerals used in the drawings can identify the same parts.

[0028] Figure 1 This is a perspective view of a first exemplary embodiment of the cutting tool, wherein the cutting element 6 is removed to better show the recess 3r.

[0029] Figure 2 This is another perspective view of a first exemplary embodiment of the cutting tool, wherein the cutting element 6 is removed to better show the recess 3r.

[0030] Figure 3 This is an end view of the second end 3d, illustrating a first exemplary embodiment of the cutting tool.

[0031] Figure 4 Along the first exemplary embodiment of the cutting tool Figure 3 The cross-sectional view shown is taken by line GG.

[0032] Figure 5 Along the first exemplary embodiment of the cutting tool Figure 3 The cross-sectional view shown is taken by line KK.

[0033] Figure 6 Along the first exemplary embodiment of the cutting tool Figure 3 The cross-sectional view shown is taken by line LL.

[0034] Figure 7 This is a perspective view of a first exemplary embodiment of a cutting tool having a cutting element 6 positioned in a recess 3r.

[0035] Figure 8 This is a flowchart illustrating a first exemplary embodiment of a method for manufacturing and / or using a cutting tool. Detailed Implementation

[0036] refer to Figures 1 to 7The cutting tool 1 may include a body 3. The body may be made of metal or other suitable materials. For example, the body 3 may be made of steel, tool steel, sintered carbide, sintered tungsten carbide, carbide material, or other suitable materials. The body 3 may be formed as a coolant fluid passage system 9 included within the body 3 and has an outer surface 3a shaped such that a first end 3c of the body has one or more recesses 3r to hold one or more cutting elements 6 thereon or therein, and has one or more holes 3h in fluid communication with the coolant fluid passage system 9 for ejecting coolant fluid out of the body 3 and onto the outer surface 3a to remove debris (e.g., chips) and to promote cooling during use of the cutting tool 1. The recesses 3r and at least some holes 3h may be positioned in or on one or more grooves 3f defined in the body, adjacent to and / or at the first end 3c of the body.

[0037] The body 3 may also have a second end 3d opposite the first end 3c. In some embodiments, the second end 3d may be a tapered end that narrows in width as it extends from the middle portion 3b of the body to the distal side of the second end 3d. In other embodiments, the second end 3d may be an inverted tapered shape, wherein the width or diameter of the second end 3d is greater at its distal edge than at a more inward portion of the second end 3d, the more inward portion of the second end being positioned closer to the middle portion 3b of the second end than at its distal edge.

[0038] The middle portion 3b of the main body 3 can be positioned between the first end and the second ends 3c and 3d of the main body 3. In some embodiments, the main body can be elongated, such that the main body has a length and a diameter or width smaller than its length. In some embodiments, the main body 3 can be cylindrical or tubular, such that the cross-sectional shape of the main body 3 can be circular or oval. In other embodiments, the main body can have a polygonal cross-section instead of an oval or circular cross-section.

[0039] The second end 3d of the body 3 may be defined to include a chamber 5 in fluid communication with an opening 3g defined distal to the second end 3d. The chamber 5 may be entirely within the second end 3d, or may extend from the second end 3d into a location within the middle portion 3b of the body 3. The body 3 may have an inner wall defined therein to define the shape of the chamber 5 within the body.

[0040] The body 3 may be formed with one or more ribs 3e at and / or adjacent to the second end 3d of the body within the chamber 5 to help provide structural support, stiffness, and strength to the body, while also providing a large space that can define the chamber 5 of the body. In some embodiments, each rib 3e may extend between opposite sides of the chamber 5. In other embodiments, each rib 3e may extend from a central element defined within the chamber 5 to one side of the chamber 5, such that the rib 3e extends like a spoke from a central hub 4 defined within the central region of the chamber 5. The ribs 3e may be formed such that they all have uniform dimensions and thickness. Alternatively, some ribs 3e may have a different thickness than the others to provide ribs 3e of different sizes within the chamber 5.

[0041] Ribs 3e may be defined within chamber 5 to extend to the inner wall or between different sides of the inner wall defining chamber 5 (e.g., ribs 3e may extend to opposite sides of chamber 5). Ribs 3e may be positioned to define different sectors 5a of chamber 5. Different sectors 5a may be separated from each other via ribs 3e positioned within chamber 5 and / or central hub 4. Different sectors 5a may extend from orifice 3g to interface 8, at which chamber fluid connection is made to one or more conduits 7 within body 3 for conveying coolant fluid from orifice 3g to orifice 3h. Ribs 3e may be positioned such that each sector has a similar shape and size, such that each sector 5a has a similar or identical shape or size. Alternatively, ribs 3e may be positioned such that different sectors 5a have different shapes or sizes (e.g., portions of different sizes constituting the empty space of chamber 5).

[0042] The chamber 5 and the orifice 3g, which is in fluid communication with the chamber 5 at the second end 3d of the body 3, may be components of a coolant fluid passage system 9 defined within the body 3. The body 3 may have one or more pipes 7 defined within the body 3 to extend from the chamber 5. Each pipe may have a first end in fluid communication with a corresponding orifice 3h defined in the outer surface 3a of the body 3 and a second end in fluid communication with the chamber 5. One or more pipes 7 may be components of the coolant fluid passage system 9. The orifice 3h may also be considered an element of the coolant fluid passage system.

[0043] At least one of the pipes 7 may have an interface 8 with the chamber 5 within an intermediate portion 3b of the body between the first end 3c and the second end 3d of the body. Coolant fluid within the chamber 5 may be transferred at the interface into one or more pipes 7, such that coolant fluid can be transferred through the pipes(one or more) to the orifice 3h for ejection from the orifice 3h and to the outer surface. In embodiments where multiple pipes 7 may be present, different pipes may extend from at least one supply pipe 7 positioned between the interface 8 with the chamber 5 and the pipe 7 extending from the corresponding orifice 3h to the supply pipe. In other embodiments, a single pipe 7 may be defined as having a plurality of branches extending from the interface to different orifices 3h to supply coolant fluid from the interface 8 to the different orifices 3h.

[0044] The orifice 3h can be circular, oval, or have other shapes (e.g., hexagonal, rectangular, pentagonal, octagonal, etc.). The orifice 3h can be sized and configured to emit coolant at a preselected area on the outer surface 3a and / or at a preselected velocity or range of preselected velocities. The orifices 3h can be the same size or different sizes. For example, an orifice closer to the distal edge of the first end can be smaller or larger than one or more orifices 3h closer to the middle portion 3b of the body. The orifices can also have different orientations or shapes to facilitate the guidance of coolant fluid to different portions of the outer surface 3a of the tool. In some embodiments, the orifice 3h can be arranged and positioned to guide coolant fluid for directing a spray or jet of coolant fluid out of one or more conduits 7 and onto the hotter edge of the curved slotted portion of the first end 3c of the body 3.

[0045] In some embodiments, one or more conduits 7 may be defined as providing a smooth passage for the coolant fluid to help minimize any flow resistance the fluid may experience as it travels from chamber 5 to orifice 3h via one or more conduits 7. For example, none of the conduits 7 may have any sharp edges or abrupt turns that could, for example, provide significant resistance to the flow of the coolant fluid. A sharp turn may be a turn that can have a protruding edge, which can cause turbulence when the fluid enters the sharp turn. A sharp edge may be part of the conduit that reaches a point of bend or curvature in the passage of the conduit adjacent to the passage of the conduit. In contrast to such a sharp turn with one or more sharp edges, at least one conduit 7 may be formed in the body to avoid having any such sharp edges and also to avoid having any sharp turns. For example, one or more conduits 7 may be formed as bends or smooth radial transitions with smooth, continuous curves without any sharp edges. For example, drilling for forming any conduit 7 may be avoided to help avoid forming any sharp edges to form one or more conduits 7.

[0046] Avoiding sharp turns allows for a smooth, curved transition of fluid through the body 3 and out through one or more orifices 3h. In some embodiments, one or more conduits 7 may be defined such that they extend from the chamber 5 to the orifices 3h without any bends or turns greater than 60°. In such embodiments, any such bends or turns in the conduits through which fluid passes may be continuous arcuate bends or turns that avoid sharp turns and also avoid sharp edges, resulting in a smooth transition in the direction of fluid flow as fluid is transferred from the chamber 5 to the orifices 3h.

[0047] The internal portion of the defining pipe(s) 7 of the main body 3 can also be smooth, making the pipe(s) 7 smooth. Smooth surfaces can also help reduce friction or resistance to fluid flow.

[0048] The body 3 can be shaped and formed to define a coolant fluid passage system 9, such that the body can retain and facilitate the flow of coolant fluid through the body 3 and out of the orifice 3h. In some embodiments, the coolant fluid can be a liquid. For example, the coolant fluid may include oil, cutting oil, synthetic cutting oil, synthetic oil, or another suitable type of oil or other suitable type of coolant liquid.

[0049] We have surprisingly found that the utilization of the chamber 5, which may extend from the second end 3d to the middle portion 3b of the body 3, can be sized to be a large portion of the width or diameter of the body 3, such that the main portion of the second end 3d and the middle portion 3b of the body 3 is an empty space of the chamber 5. In some embodiments, for example, the chamber 5 can be sized such that more than 20% of the volume of the second end 3d of the body is free of metal and is an empty space of the chamber 5. In some embodiments, the second end 3d and the middle portion 3b of the body can be shaped such that the chamber 5 is sized such that more than 20% of the volume of the body between the interface 8 and the opening 3g is an empty space (e.g., without structure), the middle portion of the body defining the inner end of the chamber 5 opposite the opening 3g and at the interface 8 of (one or more) pipes 7. For example, 20% to 40% of this portion of the body (e.g., from the interface 8 of the middle portion 3b of the body and the opening 3g of the second end 3d) can be without structure to provide more internal volume for coolant fluid. As another example, 20% to 30% of this portion of the body (e.g., the port 8 from the middle portion 3b of the body and the opening 3g from the second end 3d) may be unstructured to provide more internal volume for the coolant fluid. This type of size of the chamber 5 can also help to significantly reduce the mass or weight of the body 3.

[0050] This type of internal structure of the body 3 can provide a large volume of space to receive more coolant fluid to cool the body 3 when using a cutting tool. This can also provide more coolant fluid supply to one or more pipes 7 to provide more coolant fluid to the orifice 3h at a greater speed or flow rate, which can provide enhanced cooling and a greater flow of coolant fluid to the outer surface 3a of the body for the removal of debris (e.g., chips).

[0051] Furthermore, it was surprisingly found that the construction of this large chamber 5 still provides sufficient strength and rigidity to support the industrial use of the tool 1 during workpiece cutting. Traditionally, heavy, solid metal blocks are typically used to help provide sufficient strength and rigidity so that the cutting tool can withstand the forces applied when it processes a workpiece. However, we were surprised to find that a substantially lightweight structure can be used instead to provide increased cooling and chip removal capabilities without sacrificing the strength and durability of the body 3 for industrial applications. This is a surprising and unexpected result, contrary to conventional approaches. Moreover, it facilitates lighter-weight cutting tools 1 that may require significantly less material compared to conventional designs, which can provide improved environmental effects and significantly reduce the cost of manufacturing such tools. For example, in some embodiments, the tool body 3 can be formed with 20%–40% less material compared to a conventional design for a tool of similar size.

[0052] We were surprised to find that the embodiments can provide reduced capital costs associated with tool 1, while also reducing the environmental impact associated with manufacturing tool 1, and improving tool utilization efficiency by providing a higher velocity jet of coolant fluid from orifice 3h for chip removal and enhanced cooling, which can reduce wear and increase the life of the cutting tool.

[0053] Recesses 3r may be defined in the first end 3c of the body 3 to facilitate the positioning and attachment of cutting elements 6 within or on those recesses 3r. Cutting elements 6 may be, for example, brazed to the outer surface 3a in those recesses 3r, such that the cutting elements 6 are attached to the body, making them integral with the body 3. Recesses 3r may be notches, grooves, or other types of recessed structures defined on the outer surface 3a for positioning and / or retaining one or more cutting elements 6. Cutting elements 6 may be made of a material harder than that of the body 3. For example, cutting elements 6 may be made of PCD, and the body 3 may be made of steel, sintered carbide, carbide material, tungsten carbide, sintered tungsten carbide, or other suitable materials.

[0054] Through additive manufacturing, the body 3 can be defined as a coolant fluid passage system 9 comprising an opening 3g, a chamber 5 having a chamber sector 5a, an interface 8, one or more conduits 7, and an orifice 3h. This process allows the coolant fluid passage system 9 to provide a smooth surface passage for coolant fluid to flow through the body 3, avoiding sharp edges or abrupt bends that are typically present due to drilling or EDM machining using cutting tools. Surprisingly, we have found that utilizing this additive manufacturing process also helps to allow the formation of the body 3, enabling the use of less material in the manufacture of the body 3 and providing a lighter-weight body with a larger volume of space for coolant fluid, as described above. Available additive manufacturing processes can include powder bed melting, laser deposition, or binder jetting. In embodiments where binder jetting can be used, the body formed via this process can be heated for a pre-selected curing period to cure the formed body 3. Thereafter, one or more cutting elements 6 can be attached to the body via recesses 9 (e.g., via brazing or other suitable attachment processes).

[0055] Figure 8 An exemplary method for manufacturing and / or using an embodiment of a cutting tool 1 is shown. In a first step S1, the cutting tool body 3 may be formed to define at least one cutting edge positioned adjacent to a first end 3c of the body 3. At least one hole 3h may be defined in the body 3 adjacent to each cutting edge, the at least one hole being in fluid communication with the chamber 5 via at least one conduit 7 extending between the chamber 5 defined in a second end 3d of the body 3 and one or more holes 3h. The body 3 may be formed via an additive manufacturing process. In some embodiments where an adhesive may be used (e.g., in an adhesive spraying process), the formed body may be subjected to heating at a preselected curing temperature for a preselected curing time to cure the formed body 3. In other embodiments where laser or other types of additive manufacturing processes may be used, the body may not need to undergo curing after its formation.

[0056] In the second step S2, one or more cutting elements 6 may be attached to each cutting edge. A recess 3r may be defined in the outer surface 3a of the body to position each cutting element 6. The body 3 may be formed to define one or more recesses (e.g., at least one groove, notch, or other type of outer surface structure) to facilitate receiving and attaching (one or more) cutting elements. The cutting elements 6 may be made of a material harder than the material of the body 3 of the cutting tool 1 (e.g., the body 3 may be made of steel, carbide material, sintered carbide material, or sintered tungsten carbide, etc., and (one or more) cutting elements 6 may be made of PCD or other suitable materials).

[0057] The first step S1 and the second step S2 can be used in embodiments of manufacturing a cutting tool. A third step S3 may be included for use of the cutting tool 1. In the third step S3 (shown in dashed lines), the formed tool 1 can be coupled to a device for processing a workpiece, such that coolant fluid passes through a coolant fluid passage system 9 (e.g., orifice 3g, chamber 5 having chamber sector 5a, interface 8, one or more pipes 7 and holes 3h) during use of the tool 1 to cool the cutting tool 1 and also remove chips or other debris that may be located on the outer surface 3a of the tool 1 during use. In some embodiments, the workpiece may be made of metal.

[0058] Embodiments of the method may also include other steps. For example, the cutting tool 1 may undergo cleaning, polishing, or other treatments as part of the manufacturing method for forming the cutting tool 1. In conjunction with the formed cutting tool, the method may also include other steps besides the third step S3, such as providing coolant fluid to the cutting tool 1 and / or supplying coolant fluid.

[0059] As described above, we have found, surprisingly, that the embodiments can provide reduced capital costs associated with cutting tool 1, while also reducing the environmental impact associated with manufacturing tool 1, and improving tool utilization efficiency by providing a higher-velocity jet of coolant fluid exiting the orifice 3h for chip removal and enhanced cooling, which reduces wear and increases tool life. This is unexpected for us because the method used for this improvement results in a significant reduction in the mass of the cutting tool 1 that can be formed. This is particularly surprising for embodiments of cutting tool 1, which are constructed and configured as a reamer or tool configured to form an opening or hole in a workpiece or to enlarge an opening or hole in a workpiece.

[0060] It should be understood that the exemplary embodiments discussed herein can be adapted to consider a specific set of design criteria. For example, the size and shape of the body, the size and shape of the cutting element 6, the size and shape of the fluid conduit segment, the orifice 3g, the chamber 5 or the hole 3h, and the type of material used for the cutting tool 1 can be any of many different options. For example, the type of material used for the body 3 of the cutting tool 1 (e.g., carbide, sintered carbide, tungsten carbide, steel, etc.) and the type of material used for the cutting element 6 (e.g., carbide material, PCD, tungsten carbide, etc.) can be any of many suitable materials (e.g., cubic boron nitride, ceramic material, other types of hard materials, etc.). As another example, the shape of the body 3, (one or more) grooves 3f, recesses 3r, holes 3h, conduits 7, chambers 5, second ends 3d, ribs 3e, or cutting element 6 can be adapted to meet a specific set of design criteria. Therefore, although certain currently preferred embodiments of the cutting tools and embodiments of methods for manufacturing and using the cutting tools have been shown and described above, it should be clearly understood that the invention is not limited thereto, but may be implemented and practiced in other ways different within the scope of the appended claims.

Claims

1. A cutting tool comprising: a body having an outer surface, a first end, and a second end; a portion of the outer surface adjacent the first end having one or more recesses defined therein to receive one or more cutting elements, at least one aperture defined in the outer surface adjacent the one or more recesses; the second end having a chamber defined therein to receive a coolant fluid, the second end further having a mouth in fluid communication with the chamber; the body having at least one conduit defined therein to fluidly connect the chamber to the at least one aperture, such that coolant fluid fed into the chamber can be delivered to the at least one aperture for emission onto the outer surface via the at least one aperture.

2. The cutting tool of claim 1, wherein the at least one aperture comprises a plurality of spaced apart apertures.

3. The cutting tool of claim 2, wherein the body has a plurality of ribs positioned in the chamber to divide the chamber into sectors.

4. The cutting tool of claim 3, wherein each of the ribs has the same shape and size.

5. The cutting tool of claim 1, wherein the at least one conduit extends from the chamber to the at least one aperture without any sharp edges or any abrupt turns.

6. The cutting tool of claim 5, wherein an abrupt turn is a bend in the conduit of greater than 60°.

7. The cutting tool of claim 5, wherein the body is formed via an additive manufacturing process to define the mouth, the chamber, the at least one conduit, and the at least one aperture.

8. The cutting tool of claim 7, wherein the additive manufacturing process is a binder jetting process.

9. The cutting tool of claim 1, wherein the body is composed of cemented carbide, cemented tungsten carbide, a carbide material, or steel.

10. The cutting tool of claim 1, comprising the one or more cutting elements, each of the cutting elements composed of a material that is harder than a material of the body.

11. The cutting tool of claim 1, wherein the one or more cutting elements are attached to the body via the one or more recesses such that each cutting element is integral with the body.

12. The cutting tool of claim 1, wherein the chamber extends from the second end to an intermediate portion of the body between the first end and the second end, the chamber having an interface with the at least one conduit that is opposite the mouth of the body, the chamber defined in the body such that at least 20% of a volume of the body between the interface and the mouth is empty space for receiving the coolant fluid.

13. The cutting tool of claim 1, wherein a hub is positioned within the chamber and a plurality of ribs extend from the hub to an inner wall of the body that defines the chamber to define different sectors of the chamber.

14. A method of making and / or using a cutting tool, the method comprising: forming a body of a cutting tool such that the body comprises: an outer surface, a first end, and a second end; a portion of the outer surface adjacent the first end has one or more recesses defined therein to receive one or more cutting elements, at least one aperture is defined in the outer surface adjacent the one or more recesses; the second end has a chamber defined therein to receive a coolant fluid, the second end also has a port in fluid communication with the chamber; the body is formed such that the body has at least one conduit defined therein to fluidly connect the chamber to the at least one aperture, such that coolant fluid fed into the chamber can be delivered to the at least one aperture for emission onto the outer surface via the at least one aperture; one or more cutting elements are attached to the outer surface of the body via the one or more recesses, such that each cutting element is integral with the body.

15. The method of claim 14, wherein the one or more cutting elements are attached to the body via brazing, and the one or more recesses are defined in at least one cutting edge of the body.

16. The method of claim 14, wherein the body is formed via an additive manufacturing process.

17. The method of claim 14, wherein the body is formed via a binder jetting process.

18. The method of claim 14, wherein the body is comprised of cemented carbide, cemented tungsten carbide, carbide material, or steel.

19. The method of claim 14, wherein the body is formed such that the chamber extends from the second end to an intermediate portion of the body between the first end and the second end, the chamber has an interface with the at least one conduit, the interface is opposite the port of the body, the chamber is defined in the body such that at least 20% of a volume of the body between the interface and the port is empty space for receiving the coolant fluid.

20. The method of claim 14, wherein the body is formed such that the at least one conduit extends from the chamber to the at least one aperture without an angular turn greater than 60°.

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