Cutting device and cutting insert with chip breaking function

Abstract

A cutting device can include a cutting insert having at least one chip breaking mechanism. The chip breaker mechanism can include an elliptical bump supported by the inner rib. For example, the elliptical ridge can be positioned adjacent a corner of the cutting insert body. The elliptical bump is also positionable adjacent the tapered cutting edge, and a plurality of grooves including outer and inner grooves having different radii are spaced apart from each other by a flange or step. Embodiments can also include a variable land positioned adjacent and outwardly from the outer recess to facilitate chip breaking.

Description

Technical Field

[0001] This invention relates to cutting tools (e.g., computer numerical control (CNC) machine tools, milling machines, etc.) and cutting inserts for cutting tools (e.g., machining chip breakers for turning, etc.). Background Technology

[0002] Examples of cutting tools can be found in U.S. Patents 11,839,920, 11,529,687, 11,090,736, 10,710,167, 10,576,552, 10,166,606, 10,076,788, 9,937,567, 8,840,347, 8,807,888, 8,764,354, 8,702,354, 8,616,810, 8,092,126, 7,625,161, 7,467,915, and 7,407,350, as well as U.S. Patent Application Publications 2024 / 0278332, 2024 / 0198433, 2024 / 0024958, and 2022 / 0 347762, 2022 / 0339710, 2022 / 0097145, 2021 / 0402488, 2019 / 0039152, 2019 / 0184468, 2019 / 0061012, 2016 / 0082518, 2015 / 0375303, 2015 / 0078844, 2013 / 0272808, 2013 / 0064613, 2009 / 0226269, and 2008 / 0193231. For example, cutting tools can be used for metalworking. Some cutting tools can be fixed. Other types of cutting tools can be movable (e.g., rotatable, etc.). Cutting tools can be used to manipulate a workpiece to remove material from the workpiece to shape the workpiece and / or define one or more holes in the workpiece. Summary of the Invention

[0003] It has been determined that some cutting tools may not be able to break chips sufficiently during cutting operations. For example, in some cases, the depth of cut and feed rate may need to be specifically tailored to a particular cutting tool. Inadequate chip breaking can lead to performance degradation or poor work quality. For instance, insufficient chip breaking can result in poor surface finish, higher temperatures at the cutting edge (which can lead to significant wear on the cutting inserts and other increased maintenance), and longer downtime for chip removal during operation.

[0004] Cutting tools and cutting tool inserts that provide enhanced chip-breaking capabilities have been developed, allowing implementations to be used more effectively across a wider range of feed rates, depths of cut, and other operating parameters. Implementations of the cutting inserts may be considered chip breakers or may include at least one chip-breaking mechanism.

[0005] For example, an embodiment may utilize at least one chip-breaking mechanism, which may include an elliptical ridge supported by an inner rib. The elliptical ridge may be positioned adjacent to a corner of the cutting insert body. The elliptical ridge may also be positioned adjacent to a tapered cutting edge and includes a plurality of grooves, including outer and inner grooves of different radii, spaced apart from each other by flanges or steps. The embodiment may also include a variable cutting band adjacent to and positioned outward from the outer groove to facilitate chip breaking and increase the strength of the cutting edge, while also reducing the cutting force of the cutting edge.

[0006] The size and configuration of the embodiment can be designed such that the first face of the cutting insert body (e.g., the top of the body) has one or more chip-breaking mechanisms (e.g., ridges, ribs, inner and outer grooves, variable cutting edges, etc.) on each side and / or corner adjacent to the first face of the body. The size and configuration of the embodiment can also be designed such that the second face of the cutting insert (e.g., the bottom opposite the top) has one or more chip-breaking mechanisms (e.g., ridges, ribs, inner and outer grooves, variable cutting edges, etc.) on each side and / or corner adjacent to the second face of the body.

[0007] The implementation scheme provides a more versatile cutting tool that facilitates cutting in various turning operations using a variety of materials, feed rates, and depths of cut. The cutting insert implementation scheme can be formed as a single, integral body including one or more of a raised portion, supporting inner ribs, inner and outer grooves, and / or variable cutting edge elements.

[0008] The implementation may also include other features or elements. The cutting insert can have any of a variety of different geometries. For example, the body of the cutting insert can be triangular, rectangular, rhomboid, pentagonal, or have other suitable shapes. The cutting insert can have a body formed of steel, ceramic material, metal, carbide material, tungsten carbide, or other suitable materials.

[0009] In a first aspect, a cutting insert for a cutting apparatus is provided. The cutting insert may include a body having a top and a bottom. The body may also have a plurality of sides and a plurality of corners. Each of the sides may extend from the top to the bottom, and each of the corners may extend from the top to the bottom. The sides may include a first side, a second side, and a third side, and the corners may include a first corner, a second corner, and a third corner, wherein the first corner may be located between the first side and the second side, the second corner may be located between the second side and the third side, and the third corner may be adjacent to the third side.

[0010] The top of the main body may have a raised portion and a rib located near the first corner, such that the raised portion near the first corner is positioned between the outer edge of the first corner and the rib located near the first corner.

[0011] In some embodiments, the top of the body may have additional ridges and ribs. In other embodiments, the top and bottom of the body may each include at least one ridge and rib.

[0012] In some embodiments, each protrusion may be elliptical in shape. For example, in some embodiments, the diameter or width of each protrusion may be between 0.3 mm and 1 mm or other suitable sizes, and have a generally elliptical hemispherical shape.

[0013] In some embodiments, each rib may be arcuate or have another suitable shape (e.g., a linearly extending wall). When the rib is located on top of the body, each rib may have at least one groove or recess defined in the top of the rib. When the rib is located on the bottom of the body, each rib may have at least one groove or recess defined in the bottom of the rib. In some embodiments, the rib may be integral with the inside of a rib adjacent to a raised portion. In other embodiments, the rib may contact a raised portion adjacent to the rib.

[0014] The cutting insert can be made of metal, ceramic material, alloy, steel, carbide material, tungsten carbide, cubic boron nitride (CBN) material or other suitable material.

[0015] In a second aspect, the side may include a fourth side, and the corner may include a fourth corner. The third corner may be located between the third and fourth sides, and the fourth corner may be located between the fourth side and the first side. In such embodiments, the body may have a generally rectangular shape (e.g., a square-like shape, a rhombus-like shape, a rectangular type shape, or a generally polygonal shape with rounded corners, etc.).

[0016] In a third aspect, the body may consist of only three sides, and the third corner may be located between the third side and the first side. In such embodiments, the body may be generally triangular in shape, or may have another type of polygonal shape, with rounded corners, etc.

[0017] In a fourth aspect, for an embodiment having four or more corners, the top of the main body may also have a raised portion and a rib positioned near the second corner, such that the raised portion near the second corner is positioned between the outer edge of the second corner and the rib positioned near the second corner; a raised portion and a rib positioned near the third corner, such that the raised portion near the third corner is positioned between the outer edge of the third corner and the rib positioned near the third corner; and a raised portion and a rib positioned near the fourth corner, such that the raised portion near the fourth corner is positioned between the outer edge of the fourth corner and the rib positioned near the fourth corner.

[0018] In other embodiments that may have only three corners, the top of the body may have a bulge and a rib positioned adjacent to the second corner, such that the bulge is positioned between the outer edge of the second corner and the rib; and a bulge and a rib positioned adjacent to the third corner, such that the bulge is positioned between the outer edge of the third corner and the rib.

[0019] In a fifth aspect, for an embodiment having four or more corners, the bottom of the main body may have a raised portion and a rib positioned adjacent to a first corner, such that the raised portion positioned adjacent to the first corner is located between the outer edge of the first corner and the rib positioned adjacent to the first corner; a raised portion and a rib positioned adjacent to a second corner, such that the raised portion positioned adjacent to the second corner is located between the outer edge of the second corner and the rib positioned adjacent to the second corner; a raised portion and a rib positioned adjacent to a third corner, such that the raised portion positioned adjacent to the third corner is located between the outer edge of the third corner and the rib positioned adjacent to the third corner; and a raised portion and a rib positioned adjacent to a fourth corner, such that the raised portion positioned adjacent to the fourth corner is located between the outer edge of the fourth corner and the rib positioned adjacent to the fourth corner.

[0020] In other embodiments that may have only three corners, the bottom of the body may have a raised portion and a rib positioned adjacent to the first corner, such that the raised portion is positioned between the outer edge of the first corner and the rib; a raised portion and a rib positioned adjacent to the second corner, such that the raised portion is positioned between the outer edge of the second corner and the rib; and a raised portion and a rib positioned adjacent to the third corner, such that the raised portion is positioned between the outer edge of the third corner and the rib.

[0021] In a sixth aspect, the top of the body may have an inner groove and an outer groove defined on each of the adjacent sides. The inner groove may have a different radius than the outer groove. In some embodiments, the bottom of the body may have a similar configuration. For example, the bottom of the body may have an inner groove and an outer groove defined on each of the adjacent sides, wherein the inner groove of the bottom may have a different radius than the outer groove of the bottom.

[0022] In a seventh aspect, the top may have a first channel defined adjacent to a central region of a first side; a second channel defined adjacent to a central region of a second side; a third channel defined adjacent to a central region of a third side; and a fourth channel defined adjacent to a central region of a fourth side. In an embodiment that may have only three sides, the top may have a first channel defined adjacent to a central region of a first side; a second channel defined adjacent to a central region of a second side; and a third channel defined adjacent to a central region of a third side.

[0023] In some embodiments, the bottom may have a similar configuration. For example, the bottom may have a first channel defined adjacent to a central region on a first side; a second channel defined adjacent to a central region on a second side; a third channel defined adjacent to a central region on a third side; and a fourth channel defined adjacent to a central region on a fourth side. In embodiments that may have only three sides, the bottom may have a first channel defined adjacent to a central region on a first side; a second channel defined adjacent to a central region on a second side; and a third channel defined adjacent to a central region on a third side.

[0024] In some embodiments, the top may further include multiple inner and outer recesses. For example, the top may have a first inner and a first outer recess defined to extend from near a protrusion located adjacent to a first corner to a first channel; a second inner and a second outer recess defined to extend from near the first channel to near a protrusion located adjacent to a second corner; a third inner and a third outer recess defined to extend from near a protrusion located adjacent to a second corner to a second channel; and a fourth inner and a fourth outer recess defined to extend from near the second channel to a protrusion located adjacent to a third corner. The area includes: a fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from the vicinity of the protrusion located near the third corner to the third channel; a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from the vicinity of the third channel to the vicinity of the protrusion located near the fourth corner; a seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from the vicinity of the protrusion located near the fourth corner to the fourth channel; and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from the vicinity of the fourth channel to the vicinity of the protrusion located near the first corner.

[0025] In some embodiments, the bottom may also have a similar configuration of inner and outer grooves. For example, the bottom may have a first inner groove and a first outer groove defined as a first channel extending from near a protrusion located adjacent to a first corner to the bottom; a second inner groove and a second outer groove defined as extending from near the first channel to near a protrusion located adjacent to a second corner of the bottom; a third inner groove and a third outer groove defined as extending from near a protrusion located adjacent to a second corner of the bottom to a second channel; and a fourth inner groove and a fourth outer groove defined as extending from near the second channel of the bottom to near a protrusion located adjacent to a third corner of the bottom. Near; a fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from near a protrusion located near a third corner of the bottom to a third channel at the bottom; a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from near a third channel at the bottom to near a protrusion located near a fourth corner; a seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from near a protrusion located near a fourth corner of the bottom to a fourth channel at the bottom; and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from near a fourth channel at the bottom to near a protrusion located near a first corner at the end.

[0026] In an eighth aspect, the top may also have a tapered cutting edge extending along a first side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the first side near the top; a tapered cutting edge extending along a second side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the second side near the top; a tapered cutting edge extending along a third side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the third side near the top; and a tapered cutting edge extending along a fourth side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the fourth side near the top.

[0027] In an embodiment that may have only three sides, the top may have a tapered cutting edge extending along a first side adjacent to a tapered cutting edge extending along the first side near the top; a tapered cutting edge extending along a second side adjacent to a tapered cutting edge extending along the second side near the top; and a tapered cutting edge extending along a third side adjacent to a tapered cutting edge extending along the third side near the top.

[0028] In some embodiments, the bottom may have a similar configuration to the top, such that the bottom also has a tapered cutting edge extending along a first side, adjacent to a tapered cutting edge extending along the first side near the bottom; a tapered cutting edge extending along a second side, adjacent to a tapered cutting edge extending along the second side near the bottom; a tapered cutting edge extending along a third side, adjacent to a tapered cutting edge extending along the third side near the bottom; and a tapered cutting edge extending along a fourth side, adjacent to a tapered cutting edge extending along the fourth side near the bottom. In embodiments where only three sides are possible, the bottom may have a tapered cutting edge extending along a first side, adjacent to a tapered cutting edge extending along the first side near the bottom; a tapered cutting edge extending along a second side, adjacent to a tapered cutting edge extending along the second side near the bottom; and a tapered cutting edge extending along a third side, adjacent to a tapered cutting edge extending along the third side near the bottom.

[0029] In a ninth aspect, the body may have a central hole, and the top may have at least one seat surface defined adjacent to an opening communicating with the central hole. The bottom may also have at least one seat surface adjacent to an opening defined with the central hole.

[0030] In the tenth aspect, the cutting insert of the first aspect may include one or more features from the second, third, fourth, fifth, sixth, seventh, eighth, and / or ninth aspects. Embodiments may also include other features or elements. Examples of such features or elements can be understood from the exemplary embodiments discussed herein.

[0031] In the eleventh aspect, a cutting device is provided. The cutting device may include a component having a holder and a cutting insert attached to the holder. In some embodiments, the cutting insert may be an embodiment of the cutting insert of the first aspect or the ninth aspect.

[0032] For example, in some embodiments of the device, the cutting blade may include a body having a top and a bottom. The body may also have multiple sides and multiple corners. Each of the sides may extend from the top to the bottom, and each of the corners may extend from the top to the bottom. The sides may include a first side, a second side, and a third side, and the corners may include a first corner, a second corner, and a third corner. The first corner may be located between the first side and the second side, the second corner may be located between the second side and the third side, and the third corner may be adjacent to the third side. The top of the body may also have a protrusion positioned adjacent to the first corner and a rib positioned adjacent to the first corner, such that the protrusion positioned adjacent to the first corner is positioned between the outer edge of the first corner and the rib positioned adjacent to the first corner.

[0033] In some embodiments, the body of the cutting insert may include a fourth side, and the corner of the body of the cutting insert may include a fourth corner, such that a third corner is located between the third and fourth sides, and a fourth corner is located between the fourth and first sides. In other embodiments that may have only three sides, the third corner may be located between the third and first sides.

[0034] In some embodiments, the top of the body may have additional protrusions and ribs. For example, the top may have a protrusion and a rib positioned near a second corner, such that the protrusion near the second corner is positioned between the outer edge of the second corner and the rib positioned near the second corner; a protrusion and a rib positioned near a third corner, such that the protrusion near the third corner is positioned between the outer edge of the third corner and the rib positioned near the third corner; and a protrusion and a rib positioned near a fourth corner, such that the protrusion near the fourth corner is positioned between the outer edge of the fourth corner and the rib positioned near the fourth corner. As discussed above, the bottom may also have a similar configuration of protrusions and ribs near different corners.

[0035] In a twelfth aspect, the top of the body may include channels and / or grooves. For example, the top of the body of the cutting blade may have a first channel defined adjacent to a central region of a first side; a second channel defined adjacent to a central region of a second side; a third channel defined adjacent to a central region of a third side; and a fourth channel defined adjacent to a central region of a fourth side. The top of the body of the cutting blade may also have a first inner groove and a first outer groove defined to extend from near a protrusion located adjacent to a first corner to the first channel; a second inner groove and a second outer groove defined to extend from near the first channel to near a protrusion located adjacent to a second corner; a third inner groove and a third outer groove defined to extend from near a protrusion located adjacent to a second corner to the second channel; and a fourth inner groove and a fourth outer groove defined to extend from near the second channel to near a protrusion located adjacent to a third corner. Near the raised portion; a fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from near the raised portion located near the third corner to the third channel; a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel to near the raised portion located near the fourth corner; a seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from near the raised portion located near the fourth corner to the fourth channel; and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from near the fourth channel to near the raised portion located near the first corner.

[0036] In a thirteenth aspect, the cutting insert may also have at least one tapered cutting edge. For example, embodiments may include a cutting insert having a top having a tapered cutting edge extending along a first side and a tapered cutting edge extending along the first side adjacent to the top; a tapered cutting edge extending along a second side and a tapered cutting edge extending along the second side adjacent to the top; a tapered cutting edge extending along a third side and a tapered cutting edge extending along the third side adjacent to the top; and / or a tapered cutting edge extending along a fourth side and a tapered cutting edge extending along the fourth side adjacent to the top.

[0037] Other embodiments of the cutting apparatus may also include other features or elements. Examples of other features or elements that may be included in embodiments of the cutting apparatus can be understood from the exemplary embodiments discussed herein.

[0038] 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

[0039] The accompanying drawings illustrate exemplary embodiments of a cutting device, cutting insert, chip breaker, and methods of manufacture and use thereof. It should be understood that the same reference numerals used in the drawings can identify the same parts.

[0040] Figure 1 This is a perspective view of an exemplary embodiment of a cutting tool 1 having a cutting blade 4.

[0041] Figure 2 This is a perspective view of a first exemplary embodiment of the cutting blade 4.

[0042] Figure 3 This is a top view of a first exemplary embodiment of the cutting blade 4.

[0043] Figure 4 This is a front view of a first exemplary embodiment of the cutting insert 4. The rear view of the first exemplary embodiment of the cutting insert 4 is... Figure 4 A mirror image of the front view.

[0044] Figure 5 This is a left-side view of a first exemplary embodiment of the cutting blade 4. The right-side view of the first exemplary embodiment of the cutting blade 4 is... Figure 5 A mirror image of the left-side view.

[0045] Figure 6 It is along Figure 3The cross-sectional view of the first exemplary embodiment of the cutting blade 4, taken by line AA, is shown. Figure 6 Also included is an enlarged view of the exemplary chip-breaking mechanism 6.

[0046] Figure 7 This is a perspective view of a first exemplary embodiment of the cutting blade 4.

[0047] Figure 8 This is a perspective view of a second exemplary embodiment of the cutting blade 4.

[0048] Figure 9 This is a perspective view of a third exemplary embodiment of the cutting blade 4. Detailed Implementation

[0049] refer to Figures 1 to 9 The cutting tool 1 may include an elongated member 2, which includes a holder 3 positioned to hold and clamp a cutting blade 4. For example, the holder 3 may be attached to a distal end of the member 2. The holder 3 may be configured to hold the cutting blade 4 via one or more fasteners (e.g., screws, bolts, etc.).

[0050] The cutting insert 4 may have a body 5 attached to the holder 3. The body 5 of the cutting insert 4 may have a central hole 9, the size and configuration of which are designed to allow fasteners or other attachment elements to pass through the hole 9 for attaching the cutting insert 4 to the holder 3. The cutting insert may also be clamped in place by a clamping element that may contact or otherwise engage a seat surface 5z defined adjacent to the central hole 9. The clamping mechanism helps attach the cutting insert 4 to the holder 3 such that the cutting insert is immovable relative to the holder 3.

[0051] The holder 3 holds the cutting blade 4 so that it does not move when engaged with the workpiece to cut it. In some embodiments, for example, the workpiece may rotate or turn while the holder 3 moves linearly along the surface of the workpiece, for example, with the cutting blade 4 held in a non-rotational position. The cutting provided can help shape and / or finish the workpiece. In some embodiments, the cutting blade 4 may be attached to a movable tool holder of a CNC machine tool or other type of cutting machine tool. In such embodiments, the tool holder 3 may be linearly movable as the workpiece rotates. In other embodiments, the tool holder may be held in a fixed position, and the workpiece may rotate and / or move linearly relative to the cutting blade for cutting.

[0052] In some embodiments, the tool holder 3 and component 2 may include internal coolant conduits for distributing coolant to the cutting insert 4. In other embodiments, an external coolant distribution device may be positioned to output coolant to the cutting insert 4 during cutting operations.

[0053] The cutting insert 4 may include one or more chip breaker mechanisms 6 to aid in chip breaking during a cutting operation (e.g., cutting a workpiece). For example, the body 5 of the cutting insert 4 may be a one-piece body formed having one or more chip breaker mechanisms 6 defined thereon. The body 5 may be made of metal, ceramic material, alloy, steel, carbide material, tungsten carbide, cubic boron nitride (CBN) material, or other suitable material.

[0054] The body 5 of the cutting blade 4 may have a plurality of sides 5s extending between the top 5t and the bottom 5b of the body. The body 5 may also include corners 5c positioned between adjacent sides 5s (each of the corners 5c may be positioned between two directly adjacent sides 5s). The corners 5c may also extend between the bottom 5b and the top 5t of the body 5. In some embodiments, the body 5 may have a rectangular shape (e.g., a rhomboid shape, a square shape, or other types of rectangular shapes). Other embodiments of the body 5 may have a triangular shape, a pentagonal shape, or other types of polygonal shapes.

[0055] In some embodiments, the body 5 may have a first side 5s, a second side 5s, a third side 5s, and a fourth side 5s, and a first corner 5c between the first side 5s and the second side 5s, a second corner 5c between the second side 5s and the third side 5s, a third corner 5c between the third side 5s and the fourth side 5s, and a fourth corner 5c between the fourth side 5s and the first side 5s. The corners 5c may be rounded, such that each corner 5c defines a curved surface extending between the top 5t and the bottom 5b and between adjacent sides 5s where the corner 5c is positioned. For example, Figures 2 to 7 An exemplary embodiment of a body 5 having such sides and corners is illustrated.

[0056] Other embodiments may have a first side 5s, a second side 5s and a third side 5s, a first corner 5c between the first side 5s and the second side 5s, a second corner between the second side 5s and the third side 5s, and a third corner 5c between the third side 5s and the first side 5s. Figure 8 and Figure 9 The exemplary implementation illustrates an example of such an implementation.

[0057] Other embodiments of the main body 5 may utilize more than four sides and more than four corners. For example, embodiments may have five sides 5s and five corners 5c, six sides 5s and six corners 5c, or other numbers of sides 5s and corners 5c. The shape of the main body 5 may be any number of other shapes and sizes.

[0058] The top 5t and bottom 5b of the body 5 of the cutting blade 4 may have similar or identical contours. For example, the top 5t may include a contour that includes the opening of the hole 9 and a plurality of seat surfaces 5z positioned around the inner hole 9, the size of which is designed to receive the clamping element of the retaining clamp 3 of the clamping member. As described above, the top 5t may also be considered as a first surface of the body 5, and the bottom 5b may be considered as a second surface opposite to the first surface of the body 5.

[0059] Each side 5s may have multiple features defined at the top portion of that side (e.g., the top 5t may include one or more features at or adjacent to the side 5s). For example, each side 5s may have an upper cutting edge 5L defined at the upper outer cutting edge 5e of the side 5s, which is located at or adjacent to the top 5t of the body 5. The cutting edge 5L may be shaped to include a recessed intermediate portion 7c positioned between a first side portion 7a and a second side portion 7b of the cutting edge 5L. The cutting edge 5L may extend adjacent to the cutting edge 5e of the side, which may be tapered.

[0060] The first side portion 7a of the cutting edge 5L can extend from near the corner 5c to the middle portion 7c of the cutting edge 5L at a preselected angle or concave curvature, and the second side portion 7b can extend from the middle portion 7c to the corner 5c opposite to the first side portion 7a at a preselected angle or curvature, thereby defining a variable-sized cutting edge 5L for each side 5 of the top 5t of the adjacent body. The cutting edge 5e can extend below the cutting edge 5L and is also tapered similarly to the cutting edge 5L.

[0061] Each side 5s may also have at least one channel 5f, which is positioned adjacent to or at the middle portion 7c of the cutting edge 5L to help guide chips away from the cutting blade 4. Each channel 5f may be angled and / or otherwise shaped to help facilitate the guiding of chips away from the cutting blade 4.

[0062] The top 5t may also include other elements. For example, for each side 5s of the body 5, there may be an outer groove 5g and an inner groove 5v positioned between the cutting edge 5L and the hole 9. The outer groove 5g may be positioned along the side from near the first end of the side 5s that contacts the corner 5c to the opposite end of the side 5s that is adjacent to a different corner 5c. The outer groove 5g may be located between the cutting edge 5L and the inner groove 5v. The inner groove 5v may also be positioned from near the first end of the side 5s that contacts the corner 5c to the opposite end of the side 5s that is adjacent to a different corner 5c.

[0063] The second inner groove 5v may have a different radius than the first outer groove 5g. For example, the radius of the first outer groove 5g may be larger than the radius of the second inner groove 5v. In some embodiments, the radius of the first outer groove 5g may be between 0.1 mm and 0.25 mm, and the radius of the second inner groove 5v may be between 0.05 mm and 0.1 mm.

[0064] A step 5k may also be defined between an inner groove 5v and an outer groove 5g. The step 5k may be a planar or curved upper portion of the top 5t adjacent to each side 5s, extending along the inner groove 5v and the outer groove 5g. The top 5t may be defined such that multiple pairs of inner grooves 5v and outer grooves 5g can be located adjacent to each side 5s. A step 5k may be defined between the multiple pairs of adjacent inner grooves 5v and outer grooves 5g, and this step may also be defined in different portions of the top 5t of different sides 5s adjacent to the body 5. Each step 5k may extend from the inside of the outer groove 5g to the outside of the inner groove 5v. The top 5t may have a corresponding cutting edge 5L adjacent to or located on each side 5s, at least one outer groove 5g, at least one step 5k, and at least one inner groove 5v extending between corners 5c located at opposite ends of adjacent sides 5s.

[0065] The top 5t may also include chip-breaking mechanisms 6 adjacent to each corner 5c between the ends of the adjacent side 5s. Each chip-breaking mechanism 6 may include an outer bulge 5h positioned adjacent to an inner rib 5r, the inner rib being positioned and defined to reinforce the inner side of the bulge 5h. In some embodiments, the upper end of the rib 5r may have a groove or recess defined therein to provide improved rigidity or stiffness in some embodiments.

[0066] The raised portion 5h can be positioned between the outer periphery of the corner 5c and the rib 5r. In some embodiments, an inclined raised portion feed surface 5w can extend along the top 5t at a preselected angle ɵ from the corner 5c adjacent to the raised portion 5h to facilitate engagement of the raised portion 5h with the workpiece for chip breaking during the cutting operation. The size and configuration of the raised portion 5h and the inclined raised portion feed surface 5w can be determined from... Figure 6 The enlarged sectional view shown is the best way to understand this.

[0067] As from Figure 6 Ideally, the inclined raised feed surface can extend at a preselected angle relative to the horizontal plane HZ to a depth position 6d in the recess between the outermost surfaces of corner 5c. The depth position can be positioned such that depth position 6d is located at a preselected depth D3 from the top surface of corner 5c. This preselected depth D3 can be between 0.14 mm and 0.10 mm (e.g., 0.12-0.11 mm, etc.).

[0068] The upper surface of the corner can extend from the outer edge of the corner a preselected outer distance D2 to an inward position, at which the inclined raised portion feed surface 5w extends along a preselected angle ɵ to a depth position 6d into the body 5 to a preselected depth D3. The preselected angle can be greater than 0° to 20° (e.g., 5°-20°, 5°-15°, etc.) or other suitable angles. The upper surface of the corner 5c that extends from the outer edge of the corner a preselected outer distance D2 to an inward position starting from the inclined raised portion feed surface 5w can be a planar surface, which can define a flange adjacent to the raised portion 5h, such that the depth position 6d of the recess formed by the inclined raised portion feed surface 5w is located between the formed flange 5p and the raised portion 5h. The flange 5p can extend a preselected outer distance D2, which can be greater than 0.05 mm and 0.3 mm (e.g., 0.1-0.2 mm).

[0069] The depth position 6d can be positioned such that the depth position 6d is located at a preselected depth D3 at the flange 5p of the corner 5c. As described above, the preselected depth D3 can be between 0.14 mm and 0.10 mm (e.g., 0.12-0.11 mm, etc.).

[0070] The raised portion 5h can be formed to extend from the depth position 6d to the apex or top of the raised portion, such that the apex of the raised portion is a preselected distance D1 from the outer edge of the corner 5c. The preselected distance D1 from the outer edge of the adjacent raised portion 5h to the corner 5c can be between 1.0 mm and 0.5 mm (e.g., 0.8-0.9 mm, etc.).

[0071] Each side 5s may have a corresponding inner groove 5v and outer groove 5g, which extend from near a corner 5c at a first end of the side 5s to a relative corner 5c at a second end of the adjacent side 5s opposite to its first end. In some embodiments, at least one channel 5f may be located adjacent to the middle region of the inner groove 5v and outer groove 5g. In such embodiments, each side 5s may have a first set of inner grooves 5v and outer grooves 5g, which extend from a corner 5c at a first end of the adjacent side 5s and a protrusion 5h and a rib located near the corner 5c to the channel 5f, and a second set of inner grooves 5v and outer grooves 5g, which extend from the channel 5f to a corner 5c at a second end of the adjacent side 5s and a protrusion 5h and a rib 5r located near the corner 5c.

[0072] Each of the ridges 5h in the top 5t can be elliptical in shape. In some embodiments, the diameter or width of the ridge can be between 0.3 mm and 1 mm or other suitable sizes, and has a generally elliptical hemispherical shape adjacent to an inner rib 5r positioned at or integral with the ridge, and is arcuate or curved as it extends along the inner side of the adjacent rib 5r of the ridge 5h from one side of the adjacent corner 5c to the opposite side of the adjacent corner 5c. In some embodiments, the rib 5r can be 0.3 mm to 1 mm long and 0.1 mm to 0.4 mm thick. In other embodiments, the rib 5r can have other shapes and sizes (e.g., more linear or more polygonal shapes and / or different sizes, etc.), and the ridges 5h can also have different shapes and sizes (e.g., more hemispherical or polygonal shapes, different widths or diameters, etc.).

[0073] The top 5t may also have one or more seat surfaces 5z positioned inwardly between the recess 5v on each side 5s and the inner hole 9. The seat surfaces 5z may surround the periphery of the hole 9. The seat surfaces 5z may be recessed relative to the recess 5v and are configured to provide a seat surface accommodating high depths of cut and high material feed rates. The seat surfaces 5z may also include decorative items or other markings to help identify the type of cutting insert and / or other features of the cutting insert 4.

[0074] The bottom 5b of the main body 5 may have the same outline as the top 5t. The outline defined by each side 5s in the bottom 5b may be the same as the outline defined by the side 5s in the top 5t, such that the top 5t is a mirror image of the bottom 5b of the main body.

[0075] For example, the bottom 5b of the body 5 may include a profile including the opening of the hole 9 and a plurality of seat surfaces 5z positioned around the inner hole 9, the size of which is designed to receive the clamping element of the fixed clamp 3 of the clamping member.

[0076] Each side 5s may have a plurality of features defined at the bottom portion of the side 5s, and / or the bottom 5b may have a plurality of features defined therein adjacent to each side 5s. For example, the bottom 5b may have a cutting edge 5L defined at each side 5s at the outer cutting edge 5e of the side 5s, which is located at or adjacent to the bottom 5b of the body 5. The cutting edge 5L may be shaped to include a recessed intermediate portion 7c positioned between a first side portion 7a and a second side portion 7b of the cutting edge 5L. The cutting edge 5L may extend adjacent to the cutting edge 5e of the side, which may be tapered.

[0077] The first side portion 7a of the cutting edge 5L can extend from near the corner 5c to the middle portion 7c of the cutting edge 5L at a preselected angle or concave curvature, and the second side portion 7b can extend from the middle portion 7c to the corner 5c opposite to the first side portion 7a at a preselected angle or curvature, thereby defining a variable-sized cutting edge 5L for each side 5 of the bottom 5b adjacent to the body. The cutting edge 5e can extend adjacent to the cutting edge 5L and is also tapered similarly to the cutting edge 5L.

[0078] Each side 5s may also have at least one channel 5f, which is positioned or located at the middle portion 7c of the cutting band 5L adjacent to the bottom 5b of the side 5s to help guide chips away from the cutting blade 4. Each channel 5f may be inclined and / or otherwise shaped to help facilitate the guiding of chips away from the cutting blade 4.

[0079] For each side 5s of the body 5, the bottom 5b may further include an outer groove 5g and an inner groove 5v positioned between the cutting edge 5L and the hole 9. The outer groove 5g may be positioned along the side 5s from near the first end of the side 5s that contacts the corner 5c to the opposite end of the side 5s that is adjacent to a different corner 5c. The outer groove 5g may be located between the cutting edge 5L and the inner groove 5v. The inner groove 5v may also be positioned from near the first end of the side 5s that contacts the corner 5c to the opposite end of the side 5s that is adjacent to a different corner 5c. The second inner groove 5v may have a different radius than the first outer groove 5g. For example, the radius of the first outer groove 5g may be larger than the radius of the second inner groove 5v. In some embodiments, the radius of the first outer groove 5g may be between 0.1 mm and 0.25 mm, and the radius of the second inner groove 5v may be between 0.05 mm and 0.1 mm.

[0080] A step 5k at the bottom 5b may also be defined between an inner groove 5v and an outer groove 5g at the bottom 5b of the body 5. The step 5k may be a flat or curved upper portion of the bottom 5b adjacent to each side 5s, extending along the inner groove 5v and the outer groove 5g. Multiple pairs of inner grooves 5v and outer grooves 5g may be located adjacent to each side 5s. A step 5k may be defined between adjacent pairs of inner grooves 5v and outer grooves 5g, and this step may also be defined in different portions of the bottom 5b adjacent to different sides 5s of the body 5. For example, each step 5k may extend along the bottom 5b from the inside of the outer groove 5g to the outside of the inner groove 5v. The bottom 5b may have a corresponding cutting edge 5L, at least one outer groove 5g, at least one step 5k, and at least one inner groove 5v adjacent to or at each side 5s, the at least one inner groove extending between corners 5c located at opposite ends of adjacent sides 5s.

[0081] The bottom 5b may also include chip-breaking mechanisms 6 adjacent to each corner 5c between the ends of the adjacent side 5s. Each chip-breaking mechanism 6 may include an outer bulge 5h positioned adjacent to an inner rib 5r, the inner rib being positioned and defined to reinforce the inner side of the bulge 5h. In some embodiments, each rib 5r may have a groove defined therein to provide improved rigidity or stiffness in some embodiments.

[0082] Each ridge 5h of the bottom 5b may be positioned between the outer periphery of the corresponding corner 5c and the rib 5r of the bottom 5b for the body 5. Each of the ridges 5h of the bottom 5b may also be elliptical in shape. In some embodiments, the diameter or width of the ridge 5h of the bottom 5b may be between 0.3 and 1 mm or other suitable size, and has a generally elliptical hemispherical shape adjacent to the inner rib 5r, which is positioned at or integral with the ridge, and is arcuate or curved as it extends along the inner side of the adjacent rib 5r of the ridge 5h from one side of the adjacent corner 5c to the opposite side of the adjacent corner 5c. In some embodiments, the rib 5r of the bottom 5b may be 0.3 mm to 1 mm long and 0.1 mm to 0.4 mm thick. In other embodiments, the ribs 5r of the bottom 5b may have other shapes and sizes (e.g., more linear or more polygonal and / or different sizes, etc.), and the ridges 5h of the bottom 5b may also have different shapes and sizes (e.g., more hemispherical or polygonal, with different widths or diameters, etc.).

[0083] In some embodiments, the inclined raised feed surface 5w of the bottom 5b may extend along the bottom 5b at a preselected angle ɵ from the corner 5c adjacent to the raised portion 5h to facilitate engagement of the raised portion 5h with the workpiece for chip breaking during the cutting operation. For example, the inclined raised feed surface 5w may extend along a preselected angle ɵ relative to the horizontal plane HZ to a depth position 6d of the recess in the bottom surface of the corner 5c. The depth position may be positioned such that the depth position 6d is located at a preselected surface depth D3 from the corner 5c. This preselected depth D3 may be between 0.14 mm and 0.10 mm (e.g., 0.12-0.11 mm, etc.), extending inward into the body 5 relative to the bottom surface of the corner 5c located at or adjacent to the bottom 5b.

[0084] The flange 5p extends from the outer edge of the corner 5c a preselected outer distance D2 to an inward position at the bottom 5b, where the inclined raised feed surface 5w extends along a preselected angle ɵ to a depth position 6d into the body 5 to a preselected depth D3. The preselected angle can be greater than 0° to 20° (e.g., 5°-20°, 5°-15°, etc.) or other suitable angles. The surface of the corner 5c that extends from the outer edge of the corner a preselected outer distance D2 to the inclined raised feed surface 5w, defining the inward position of the flange 5p, can be a planar surface that defines the flange 5p adjacent to the raised portion 5h, such that the depth position 6d of the recess formed by the inclined raised feed surface 5w is located between the formed flange 5p and the raised portion 5w. The flange 5p can extend a preselected outer distance D2, which can be greater than 0.05 mm and 0.3 mm (e.g., 0.1-0.2 mm).

[0085] The raised portion 5h can be formed to extend from the depth position 6d to the apex of the raised portion, such that the apex of the raised portion is a preselected distance D1 from the outer edge of the corner 5c. The preselected distance D1 from the outer edge of the adjacent raised portion 5h to the corner 5c can be between 1.0 mm and 0.5 mm (e.g., 0.8-0.9 mm, etc.).

[0086] The bottom region of each side 5s may also have a corresponding inner groove 5v and outer groove 5g, which extend from near a corner 5c at the first end of the side 5s to a relative corner 5c at the second end of the adjacent side 5s opposite to its first end. In some embodiments, at least one channel 5f may be located adjacent to the middle region of the inner groove 5v and outer groove 5g. In such embodiments, each side 5s may have a first set of inner grooves 5v and outer grooves 5g, which extend from a corner 5c at the first end of the adjacent side 5s and a protrusion 5h and rib located near the corner 5c to the channel 5f, and a second set of inner grooves 5v and outer grooves 5g, which extend from the channel 5f to a corner 5c at the second end of the adjacent side 5s and a protrusion 5h and rib 5r located near the corner 5c.

[0087] The bottom 5b may also have one or more seat surfaces 5z positioned inwardly between the recess 5v of each side 5s and the inner hole 9. The seat surfaces 5z may surround the periphery of the hole 9. The seat surfaces 5z may be recessed relative to the recess 5v of the bottom 5b and are configured to provide a seat surface that can accommodate high depths of cut and high material feed rates. The seat surfaces 5z of the bottom 5b may also include decorative items or other markings to help identify the type of cutting insert and / or other features of the cutting insert 4.

[0088] As from Figure 8 and Figure 9As can be seen, the main body 5 can have other types of shapes and sizes. Some embodiments may also include a plurality of channels 5f, which are positioned in the middle region of the middle portion of the blade strip 5L adjacent to the middle portion of each side 5s (see, for example, see...). Figure 9 ).

[0089] Embodiments of the cutting insert 4 may include a body 5 having a plurality of features to provide a chip breaker 6. In some embodiments, the cutting insert for a cutting device may include a body 5 having a top 5t and a bottom 5b. The top 5t may also be referred to as a first face, and the bottom 5b may also be referred to as a second face opposite to the first face.

[0090] The main body 5 may have multiple sides 5s and multiple corners 5c. Each of the sides 5s may extend from the top 5t to the bottom 5b, and each of the corners 5c may extend from the top 5t to the bottom 5b. The sides 5s may include a first side 5s, a second side 5s, and a third side 5s, and the corners 5c may include a first corner 5c, a second corner 5c, and a third corner 5c. The first corner 5c may be between the first side 5s and the second side 5s, the second corner 5c may be between the second side 5s and the third side 5s, and the third corner 5c may be adjacent to the third side 5s (e.g., between the third side 5s and the fourth side 5s or between the third side 5s and the first side 5s). In embodiments that may have a fourth side 5s, a fourth corner 5c may also be present, which may be positioned between the third side 5s and the fourth side 5s. As described above, other embodiments having other shapes (e.g., pentagons, hexagons, etc.) may also have additional sides 5s and corners 5c.

[0091] The top 5t of the main body 5 may have a raised portion 5h positioned adjacent to the first corner 5c and a rib 5r positioned adjacent to the first corner 5c, such that the raised portion 5h positioned adjacent to the first corner 5c is located between the outer edge of the first corner 5c and the rib 5r positioned adjacent to the first corner 5c. In some embodiments, a flange 5p may be present, positioned between the raised portion 5h adjacent to the first corner 5c and the first corner 5c, and an inclined raised portion feed surface 5w may be present, extending from the flange 5p to the raised portion 5h (e.g., at a preselected angle ɵ relative to the horizontal plane HZ).

[0092] The top 5t may also include other protrusions 5h and ribs. For example, the top 5t may include a protrusion located adjacent to the second corner 5c and a rib 5r located adjacent to the second corner 5c, such that the protrusion 5h located adjacent to the second corner 5c is positioned between the outer edge of the second corner 5c and the rib 5r located adjacent to the second corner 5c. In some embodiments, a flange 5p may be present, positioned between the protrusion 5h adjacent to the second corner 5c and the second corner 5c, and an inclined protrusion feed surface 5w may be present, extending from the flange 5p to the protrusion 5h (e.g., at a preselected angle ɵ relative to the horizontal plane HZ).

[0093] The top 5c may also include a raised portion 5h positioned adjacent to the third corner 5c and a rib 5r positioned adjacent to the third corner 5c, such that the raised portion 5h positioned adjacent to the third corner 5c is located between the outer edge of the third corner 5c and the rib 5r positioned adjacent to the third corner. In some embodiments, a flange 5p may be present, positioned between the raised portion 5h adjacent to the third corner 5c and the third corner 5c, and an inclined raised portion feed surface 5w may be present, extending from the flange 5p to the raised portion 5h (e.g., at a preselected angle ɵ relative to the horizontal plane HZ).

[0094] The top may also include a raised portion 5h positioned adjacent to the fourth corner 5c and a rib 5r positioned adjacent to the fourth corner 5c, such that the raised portion 5h positioned adjacent to the fourth corner 5c is located between the outer edge of the fourth corner 5c and the rib 5r positioned adjacent to the fourth corner 5c. In some embodiments, a flange 5p may be present, positioned between the raised portion 5h adjacent to the fourth corner 5c and the fourth corner 5c, and an inclined raised portion feed surface 5w may be present, extending from the flange 5p to the raised portion 5h (e.g., at a preselected angle ɵ relative to the horizontal plane HZ).

[0095] The bottom 5b of the main body 5 may also include similar features. For example, the bottom 5b of the main body may include a raised portion 5h positioned near a first corner 5c and a rib 5r positioned near a first corner 5c, such that the raised portion 5h positioned near a first corner 5c is located between the outer edge of the first corner 5c and the rib 5r positioned near a first corner 5c. The bottom 5b may also include a raised portion 5h positioned near a second corner 5c and a rib 5r positioned near a second corner 5c, such that the raised portion 5h positioned near a second corner 5c is located between the outer edge of the second corner 5c and the rib 5r positioned near a second corner 5c. The bottom 5b may also include a raised portion 5h positioned near a third corner 5c and a rib 5r positioned near a third corner 5c, such that the raised portion 5h positioned near a third corner 5c is located between the outer edge of the third corner 5c and the rib 5r positioned near a third corner. The bottom 5b may also include a raised portion 5h located near the fourth corner 5c and a rib 5r located near the fourth corner 5c, such that the raised portion 5h located near the fourth corner 5c is positioned between the outer edge of the fourth corner 5c and the rib 5r located near the fourth corner 5c.

[0096] The top 5t of the main body 5 may also have a first channel 5f, which is defined in the middle region adjacent to a first side 5s; a second channel 5f, which is defined in the middle region adjacent to a second side 5s; a third channel 5f, which is defined in the middle region adjacent to a third side 5s; and a fourth channel 5f, which is defined in the middle region adjacent to a fourth side 5s. The bottom 5b of the main body 5 may also have a first channel 5f, which is defined in the middle region adjacent to a first side 5s; a second channel 5f, which is defined in the middle region adjacent to a second side 5s; a third channel 5f, which is defined in the middle region adjacent to a third side 5s; and a fourth channel 5f, which is defined in the middle region adjacent to a fourth side 5s.

[0097] The top 5t of the main body 5 may also have multiple inner grooves 5v and outer grooves 5g. For example, the top 5t of the main body 5 may have a first inner groove 5v and a first outer groove 5g, which are defined to extend from near a protrusion 5h located adjacent to a first corner 5c to a first channel 5f, and a second inner groove 5v and a second outer groove 5g, which are defined to extend from near a first channel 5f to near a protrusion 5h located adjacent to a second corner 5c. A first step 5k of the top 5t may be defined to extend between the inner side of the first outer groove 5g and the outer wall of the first inner groove 5v, and a second step 5k of the top 5t may be defined to extend between the inner side of the second outer groove 5g and the outer wall of the second inner groove 5v.

[0098] The top 5t may also have a third inner groove 5v and a third outer groove 5g, the third inner groove and the third outer groove being defined to extend from near the protrusion 5h located adjacent to the second corner 5c to the second channel 5f, and a fourth inner groove 5v and a fourth outer groove 5g, the fourth inner groove and the fourth outer groove being defined to extend from near the second channel 5f to near the protrusion 5h located adjacent to the third corner 5c. A third step 5k of the top 5t may be defined to extend between the inner side of the third outer groove 5g and the outer wall of the third inner groove 5v, and a fourth step 5k of the top 5t may be defined to extend between the inner side of the fourth outer groove 5g and the outer wall of the fourth inner groove 5v.

[0099] The top 5t may further include a fifth inner groove 5v and a fifth outer groove 5g, the fifth inner groove and the fifth outer groove being defined to extend from near the protrusion 5h located adjacent to the third corner 5c to the third channel 5f, and a sixth inner groove 5v and a sixth outer groove 5g, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel 5f to near the protrusion 5h located adjacent to the fourth corner 5c. A fifth step 5k of the top 5t may be defined to extend between the inner side of the fifth outer groove 5g and the outer wall of the fifth inner groove 5v, and a sixth step 5k of the top 5t may be defined to extend between the inner side of the sixth outer groove 5g and the outer wall of the sixth inner groove 5v.

[0100] The top 5t may further include a seventh inner groove 5v and a seventh outer groove 5g, which are defined to extend from near the protrusion 5h located adjacent to the fourth corner 5c to the fourth channel 5f, and an eighth inner groove 5v and an eighth outer groove 5g, which are defined to extend from near the fourth channel 5f to near the protrusion 5h located adjacent to the first corner. A seventh step 5k of the top may be defined to extend between the inner side of the seventh outer groove 5g and the outer wall of the seventh inner groove 5v, and an eighth step 5k of the top may be defined to extend between the inner side of the eighth outer groove 5g and the outer wall of the eighth inner groove 5v.

[0101] The bottom 5b of the main body 5 may also have a plurality of inner grooves 5v and outer grooves 5g. For example, the bottom 5b of the main body 5 may have a first inner groove 5v and a first outer groove 5g, which are defined to extend from near a protrusion 5h located adjacent to a first corner 5c to a first channel 5f, and a second inner groove 5v and a second outer groove 5g, which are defined to extend from near a first channel 5f to near a protrusion 5h located adjacent to a second corner 5c. A first step 5k of the bottom 5b may be defined to extend between the inner side of the first outer groove 5g and the outer wall of the first inner groove 5v, and a second step 5k of the bottom 5b may be defined to extend between the inner side of the second outer groove 5g and the outer wall of the second inner groove 5v.

[0102] The bottom 5b may also have a third inner groove 5v and a third outer groove 5g, the third inner groove and the third outer groove being defined to extend from near the protrusion 5h located adjacent to the second corner 5c to the second channel 5f, and a fourth inner groove 5v and a fourth outer groove 5g, the fourth inner groove and the fourth outer groove being defined to extend from near the second channel 5f to near the protrusion 5h located adjacent to the third corner 5c. A third step 5k of the bottom 5b may be defined to extend between the inner side of the third outer groove 5g and the outer wall of the third inner groove 5v, and a fourth step 5k of the bottom 5b may be defined to extend between the inner side of the fourth outer groove 5g and the outer wall of the fourth inner groove 5v.

[0103] The bottom 5b may further include a fifth inner groove 5v and a fifth outer groove 5g, the fifth inner groove and the fifth outer groove being defined to extend from near the protrusion 5h located adjacent to the third corner 5c to the third channel 5f, and a sixth inner groove 5v and a sixth outer groove 5g, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel 5f to near the protrusion 5h located adjacent to the fourth corner 5c. A fifth step 5k of the bottom 5b may be defined to extend between the inner side of the fifth outer groove 5g and the outer wall of the fifth inner groove 5v, and a sixth step 5k of the bottom 5b may be defined to extend between the inner side of the sixth outer groove 5g and the outer wall of the sixth inner groove 5v.

[0104] The bottom 5b may further include a seventh inner groove 5v and a seventh outer groove 5g, the seventh inner groove and the seventh outer groove being defined to extend from near the protrusion 5h located adjacent to the fourth corner 5c to the fourth channel 5f, and an eighth inner groove 5v and an eighth outer groove 5g, the eighth inner groove and the eighth outer groove being defined to extend from near the fourth channel 5f to near the protrusion 5h located adjacent to the first corner. A seventh step 5k of the bottom 5b may be defined to extend between the inner side of the seventh outer groove 5g and the outer wall of the seventh inner groove 5v, and an eighth step 5k of the bottom 5b may be defined to extend between the inner side of the eighth outer groove 5g and the outer wall of the eighth inner groove 5v.

[0105] The top 5t may also have a tapered cutting edge 5L extending along a first side 5s, the tapered cutting edge 5L being adjacent to the tapered cutting edge 5e extending along the first side 5s near the top 5t; a tapered cutting edge 5L extending along a second side 5s, the tapered cutting edge 5L being adjacent to the tapered cutting edge 5e extending along the second side 5s near the top 5t; a tapered cutting edge 5L extending along a third side 5s, the tapered cutting edge 5L being adjacent to the tapered cutting edge 5e extending along the third side 5s near the top 5t; and a tapered cutting edge 5L extending along a fourth side 5s, the tapered cutting edge 5L being adjacent to the tapered cutting edge 5e extending along the fourth side 5s near the top 5t.

[0106] The bottom 5b may also have a tapered cutting edge 5L and a tapered cutting edge 5e. For example, the bottom 5b may include a tapered cutting edge 5L extending along a first side 5s adjacent to a tapered cutting edge 5e extending along the first side 5s near the bottom; a tapered cutting edge 5L extending along a second side 5s adjacent to a tapered cutting edge 5e extending along the second side 5s near the bottom; a tapered cutting edge 5L extending along a third side 5s adjacent to a tapered cutting edge 5e extending along the third side 5s near the bottom 5b; and a tapered cutting edge 5L extending along a fourth side 5s adjacent to a tapered cutting edge 5e extending along the fourth side 5s near the bottom 5b.

[0107] Of course, in some implementations that may have only three sides (e.g., Figure 8 or Figure 9 In one embodiment, the bottom 5b and the top 5t may not include a tapered cutting edge 5L extending along the fourth side 5s, which is adjacent to a tapered cutting edge 5e extending along the fourth side 5s. Such embodiments may have only a first side, a second side, and a third side 5s; a first corner, a second corner, and a third corner 5c; and a first inner groove, a second inner groove, a third inner groove, a fourth inner groove, a fifth inner groove, and a sixth inner groove 5v, and a first outer groove, a second outer groove, a third outer groove, a fourth outer groove, a fifth outer groove, and a sixth outer groove 5g. Such embodiments may also have only at least one first channel 5f, at least one second channel 5f, and at least one third channel 5f.

[0108] Other body configurations may have more than four sides 5s, more than four corners 5c, and more than four ridges 5h and ribs 5r, as well as more channels 5f, cutting edges 5L, and cutting edges 5e. For example, the body may have a generally pentagonal or hexagonal shape, with five or six sides 5s and five or six corners 5c.

[0109] Surprisingly, the positioning and configuration of the ridge 5h and rib 5r provide improved chip breaking, which helps accommodate a wide range of depths of cut and material feed rates. For example, it was surprisingly found that the ridge 5h at the adjacent corner 5h, reinforced by adjacent ribs, provides improved chip breaking for a wide range of depths of cut at lower feed rates. For a wide range of depths of cut, the ridge 5h and rib 5r also promote effective chip breaking at high feed rates. The advantages of this improved chip breaking are further enhanced by utilizing the inner groove 5v and outer groove 5g, which promotes effective chip breaking at both low and high feed rates and both low and high depths of cut settings.

[0110] It was also found that the tapered cutting edges 5e and the cutting band 5L at the top and bottom of the side 5s can promote chip breaking of the cutting band 5L over a wide range of cutting depths at both low and high feed rates, while also increasing the strength of the cutting edge 5e.

[0111] The embodiments of the cutting insert 4 can be used in cutting operations with a wide range of feed rates and depths of cut, which provides enhanced operational flexibility and efficiency. For example, the frequency of tool changes during operation can be reduced. Furthermore, the embodiments allow for more uniform wear, resulting in longer tool life. Some embodiments allow for a wide variety of features used in many different types of cutting operations, where the cutting insert remains stationary or moves linearly along the rotating workpiece to cut it, thus providing enhanced operational flexibility and efficiency.

[0112] For example, a method of cutting a workpiece may include attaching a cutting blade 4 to a holder 3 to engage the cutting blade with the workpiece for cutting. In some embodiments, the holder 3 may be a holder of a cutting machine tool, a CNC machine tool, or other type of equipment configured to cut a workpiece to form a part or component.

[0113] When the cutting insert 4 contacts the workpiece to cut it, the workpiece can rotate. In some embodiments, for example, the cutting insert 4 can be attached to the holder 3 as the holder 3 moves linearly along the rotating workpiece. When the workpiece is cut via contact with at least one cutting edge 5e of the cutting insert 4, chips can be broken off by the chip breaking mechanism 6. In some embodiments, such chip breaking can be facilitated by at least one of the protrusions 5h, at least one of the inclined protruding feed surfaces 5w, at least one of the ribs 5r, at least one of the inner grooves 5v, at least one of the outer grooves 5g, at least one of the channels 5f, at least one of the cutting edges 5L, and at least one of the cutting edges 5e.

[0114] Implementation schemes that can perform such methods enable more efficient and effective cutting of workpieces for a wide range of cutting or finishing applications that may include a wide range of depths of cut and feed rates.

[0115] It should be understood that the exemplary embodiments discussed herein can be adapted to consider a particular set of design criteria. For example, the size and shape of the body of the cutting insert 4, the channel 5f, the generally elliptical ridge 5h, the rib 5r, the size and shape of the inner groove 5v and the outer groove 5g, and the material type for the body 5 of the cutting insert 4 can be any of many different options. For example, the material type for the body 5 of the cutting insert 4 can be carbide, cemented carbide, tungsten carbide, ceramic material, steel, tool steel, etc. As yet another example, the movable member 5 can be a linearly movable shaft, rod, bar, or track for moving the cutting insert 4 when it is attached to the holder 3 in a non-moving manner (e.g., when the holder causes the cutting insert to move linearly along the workpiece, the cutting insert does not rotate). Therefore, although certain currently preferred embodiments of the cutting apparatus, cutting inserts, and methods for manufacturing and using them have been shown and described above, it should be clearly understood that the invention is not limited thereto, but can be implemented and practiced differently in other ways within the scope of the appended claims.

Claims

1. A cutting insert for a cutting device, comprising: The main body has a top and a bottom. The main body has multiple sides and multiple corners, each of the sides extending from the top to the bottom, and each of the corners extending from the top to the bottom. The sides include a first side, a second side, and a third side, and the corners include a first corner, a second corner, and a third corner. The first corner is located between the first side and the second side, the second corner is located between the second side and the third side, and the third corner is adjacent to the third side. The top of the main body has a raised portion and a rib located near the first corner, such that the raised portion near the first corner is positioned between the outer edge of the first corner and the rib located near the first corner.

2. The cutting insert of claim 1, wherein the side includes a fourth side, and the corner includes a fourth corner, the third corner is located between the third side and the fourth side, and the fourth corner is located between the fourth side and the first side.

3. The cutting blade of claim 1, wherein the top of the body further comprises: The raised portion and the rib located near the second corner are positioned such that the raised portion near the second corner is positioned between the outer edge of the second corner and the rib located near the second corner. The raised portion and the rib adjacent to the third corner are positioned such that the raised portion is located between the outer edge of the third corner and the rib adjacent to the third corner; and The raised portion and the rib located near the fourth corner are positioned such that the raised portion near the fourth corner is positioned between the outer edge of the fourth corner and the rib located near the fourth corner.

4. The cutting blade of claim 3, wherein the bottom of the body has: The raised portion and the rib located near the first corner are positioned such that the raised portion near the first corner is positioned between the outer edge of the first corner and the rib located near the first corner. The raised portion and the rib located near the second corner are positioned such that the raised portion near the second corner is positioned between the outer edge of the second corner and the rib located near the second corner. The raised portion and the rib adjacent to the third corner are positioned such that the raised portion is located between the outer edge of the third corner and the rib adjacent to the third corner; and The raised portion and the rib located near the fourth corner are positioned such that the raised portion near the fourth corner is positioned between the outer edge of the fourth corner and the rib located near the fourth corner.

5. The cutting blade of claim 3, wherein the tip further comprises: An inner groove and an outer groove are defined on each of the adjacent sides, the inner groove having a different radius than the outer groove.

6. The cutting blade of claim 3, wherein the tip further comprises: A first channel is defined in the middle area adjacent to the first side; The second channel is defined in the middle area adjacent to the second side; A third channel is defined in the middle area adjacent to the third side; as well as A fourth channel is defined in the middle region adjacent to the fourth side.

7. The cutting blade of claim 6, wherein the tip further comprises: A first inner groove and a first outer groove, the first inner groove and the first outer groove being defined to extend from near the raised portion located adjacent to the first corner to the first channel, and a second inner groove and a second outer groove, the second inner groove and the second outer groove being defined to extend from near the first channel to near the raised portion located adjacent to the second corner; A third inner groove and a third outer groove, the third inner groove and the third outer groove being defined to extend from near the protrusion located adjacent to the second corner to the second channel, and a fourth inner groove and a fourth outer groove, the fourth inner groove and the fourth outer groove being defined to extend from near the second channel to near the protrusion located adjacent to the third corner; A fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from near the protrusion located adjacent to the third corner to the third channel; and a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel to near the protrusion located adjacent to the fourth corner; and A seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from near the protrusion located adjacent to the fourth corner to the fourth channel, and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from near the fourth channel to near the protrusion located adjacent to the first corner.

8. The cutting insert of claim 7, wherein the top further comprises a tapered cutting edge extending along the first side, the tapered cutting edge adjacent to a tapered cutting edge adjacent to the top along the first side; a tapered cutting edge extending along the second side, the tapered cutting edge adjacent to a tapered cutting edge adjacent to the top along the second side; a tapered cutting edge extending along the third side, the tapered cutting edge adjacent to a tapered cutting edge adjacent to the top along the third side; and a tapered cutting edge extending along the fourth side, the tapered cutting edge adjacent to a tapered cutting edge adjacent to the top along the fourth side.

9. The cutting blade of claim 8, wherein the bottom of the body has: The raised portion and the rib located near the first corner are positioned such that the raised portion near the first corner is positioned between the outer edge of the first corner and the rib located near the first corner. The raised portion and the rib located near the second corner are positioned such that the raised portion near the second corner is positioned between the outer edge of the second corner and the rib located near the second corner. The raised portion and the rib adjacent to the third corner are positioned such that the raised portion is located between the outer edge of the third corner and the rib adjacent to the third corner; and The raised portion and the rib located near the fourth corner are positioned such that the raised portion near the fourth corner is positioned between the outer edge of the fourth corner and the rib located near the fourth corner. A first channel is defined in the middle area adjacent to the first side; The second channel is defined in the middle area adjacent to the second side; A third channel is defined in the middle area adjacent to the third side; as well as A fourth channel is defined in the middle region adjacent to the fourth side.

10. The cutting blade of claim 9, wherein the bottom of the body has: A first inner groove and a first outer groove, the first inner groove and the first outer groove being defined to extend from near the raised portion located adjacent to the first corner to the first channel, and a second inner groove and a second outer groove, the second inner groove and the second outer groove being defined to extend from near the first channel to near the raised portion located adjacent to the second corner; A third inner groove and a third outer groove, the third inner groove and the third outer groove being defined to extend from near the protrusion located adjacent to the second corner to the second channel, and a fourth inner groove and a fourth outer groove, the fourth inner groove and the fourth outer groove being defined to extend from near the second channel to near the protrusion located adjacent to the third corner; A fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from near the protrusion located adjacent to the third corner to the third channel; and a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel to near the protrusion located adjacent to the fourth corner; and A seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from near the protrusion located adjacent to the fourth corner to the fourth channel, and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from near the fourth channel to near the protrusion located adjacent to the first corner.

11. The cutting blade of claim 10, wherein the bottom further comprises: A tapered cutting edge extending along a first side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the first side near the bottom; a tapered cutting edge extending along a second side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the second side near the bottom; a tapered cutting edge extending along a third side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the third side near the bottom; and a tapered cutting edge extending along a fourth side, the tapered cutting edge being adjacent to a tapered cutting edge extending along the fourth side near the bottom.

12. The cutting blade of claim 1, wherein the third corner is located between the third side and the first side, and wherein the top of the body further comprises: A raised portion and a rib positioned adjacent to the second corner are provided, such that the raised portion adjacent to the second corner is positioned between the outer edge of the second corner and the rib positioned adjacent to the second corner; and The raised portion and the rib located near the third corner are positioned such that the raised portion near the third corner is positioned between the outer edge of the third corner and the rib located near the third corner.

13. The cutting blade of claim 1, wherein the body has a central hole and the top has at least one seat surface defined adjacent to an opening communicating with the central hole.

14. The cutting blade of claim 13, wherein the bottom has at least one seat surface defined adjacent to an opening communicating with the central hole.

15. The cutting blade as claimed in claim 1, wherein the body is rectangular or rhomboid in shape.

16. A cutting device, comprising: Component, the component having a clamp; A cutting insert, the cutting insert being attached to the holder, the cutting insert comprising: The main body has a top and a bottom. The main body has multiple sides and multiple corners, each of the sides extending from the top to the bottom, and each of the corners extending from the top to the bottom. The sides include a first side, a second side, and a third side, and the corners include a first corner, a second corner, and a third corner. The first corner is located between the first side and the second side, the second corner is located between the second side and the third side, and the third corner is adjacent to the third side. The top of the main body has a raised portion and a rib located near the first corner, such that the raised portion near the first corner is positioned between the outer edge of the first corner and the rib located near the first corner.

17. The cutting apparatus of claim 16, wherein the side of the body of the cutting insert includes a fourth side, and the corner of the body of the cutting insert includes a fourth corner, the third corner being located between the third side and the fourth side, and the fourth corner being located between the fourth side and the first side; and The top of the body further comprises: The raised portion and the rib located near the second corner are positioned such that the raised portion near the second corner is positioned between the outer edge of the second corner and the rib located near the second corner. The raised portion and the rib adjacent to the third corner are positioned such that the raised portion is located between the outer edge of the third corner and the rib adjacent to the third corner; and The raised portion and the rib located near the fourth corner are positioned such that the raised portion near the fourth corner is positioned between the outer edge of the fourth corner and the rib located near the fourth corner.

18. The cutting apparatus of claim 17, wherein the top of the body of the cutting blade further comprises: A first channel is defined in the middle area adjacent to the first side; The second channel is defined in the middle area adjacent to the second side; A third channel is defined in the middle area adjacent to the third side; as well as A fourth channel is defined in the middle region adjacent to the fourth side.

19. The cutting apparatus of claim 18, wherein the top of the body of the cutting blade further comprises: A first inner groove and a first outer groove, the first inner groove and the first outer groove being defined to extend from near the raised portion located adjacent to the first corner to the first channel, and a second inner groove and a second outer groove, the second inner groove and the second outer groove being defined to extend from near the first channel to near the raised portion located adjacent to the second corner; A third inner groove and a third outer groove, the third inner groove and the third outer groove being defined to extend from near the protrusion located adjacent to the second corner to the second channel, and a fourth inner groove and a fourth outer groove, the fourth inner groove and the fourth outer groove being defined to extend from near the second channel to near the protrusion located adjacent to the third corner; A fifth inner groove and a fifth outer groove, the fifth inner groove and the fifth outer groove being defined to extend from near the protrusion located adjacent to the third corner to the third channel; and a sixth inner groove and a sixth outer groove, the sixth inner groove and the sixth outer groove being defined to extend from near the third channel to near the protrusion located adjacent to the fourth corner; and A seventh inner groove and a seventh outer groove, the seventh inner groove and the seventh outer groove being defined to extend from near the protrusion located adjacent to the fourth corner to the fourth channel, and an eighth inner groove and an eighth outer groove, the eighth inner groove and the eighth outer groove being defined to extend from near the fourth channel to near the protrusion located adjacent to the first corner.

20. The cutting apparatus of claim 19, wherein the top of the body of the cutting blade further comprises: A tapered cutting edge extending along the first side and a tapered cutting edge extending along the first side adjacent to the top; a tapered cutting edge extending along the second side and a tapered cutting edge extending along the second side adjacent to the top; a tapered cutting edge extending along the third side and a tapered cutting edge extending along the third side adjacent to the top; and a tapered cutting edge extending along the fourth side and a tapered cutting edge extending along the fourth side adjacent to the top.

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