Cutting device and related method

Abstract

A cutting device for cutting a workpiece may include a cutting body having a first chip removal groove. The first chip removal groove may extend from a distal end of the cutting body such that it extends helically along the outer surface of the cutting body from the distal end of the cutting body for a first length at a helix angle. The cutting body may also have second chip removal grooves positioned to extend from the distal end of the cutting body to an intermediate position, such that each second chip removal groove terminates in a corresponding first chip removal groove at an interface. In some embodiments, the cutting tip portion having the distal end may be modular and removably connected to a shaft portion having an intermediate portion of the body.

Description

Technical Field

[0001] This invention relates to a cutting tool that can be used in conjunction with drilling, reaming, milling or other cutting applications, as well as cutting inserts and methods for manufacturing and using the cutting tool. Background Technology

[0002] Examples of cutting tools configurable to cut into a workpiece can be found in U.S. Patents 3,045,513, 4,722,644, 4,756,650, 8,926,236, and 11,819,931; U.S. Patent Application Publications 2018 / 0065190 and 2023 / 0226619; Japanese Patent Application Publications JP2009083092 and JP2010162644; German Patent Application Publications DE102022212000 and DE102023202061; and British Patent GB 2,497,117. Some types of cutting tools may be stationary, while others may be configured to rotate and / or move linearly to cut into a workpiece, thereby forming grooves, channels, openings, holes, or other types of openings in the workpiece. Cutting may also be provided to aid in completing such holes. For example, cutting tools can be used to manipulate workpieces to form devices, parts, or components. Summary of the Invention

[0003] We have determined that cutting tools often experience reduced material processing rates because the tool's cutting elements are unable to guide chips away from the cutting interface that may exist between the tool and the workpiece, and are unable to remove material from the workpiece. For certain types of hole-forming cutting applications, the type of cutting edge used can also affect the straightness of the formed hole.

[0004] We have developed an implementation of a cutting tool for use in a cutting apparatus to remove material from a workpiece, which allows for improved material removal machining while also providing improved ability to form straight holes. The implementation can also be configured to facilitate a robust body between the tool shank and the cutting head. The implementation also provides additional space for fluid conduits (e.g., coolant channels) in at least some portions of the cutting tool body.

[0005] Some implementations can be configured such that the cutting tip of the cutting tool has different apex angles at different heights or positions. Different cutting edges can promote improved cutting operations, thereby allowing for higher throughput of the workpiece. Different cutting apex angles and chip flute configurations can be provided to adjust the volume of chips (e.g., debris, workpiece material cut from the workpiece, etc.) that may be cut during the cutting operation.

[0006] For example, the cutting tip may have a predefined chip-removal groove arrangement defined to extend from the cutting tip portion with a different cutting apex angle to the middle portion of the cutting tool body, to help facilitate the removal of chips that may form when material cut from the workpiece during the cutting operation forms chips. The middle portion of the body may be configured such that it has a different chip-removal groove arrangement than the cutting tip region. For example, fewer helically extending chip-removal grooves may be defined in the middle portion of the body compared to the cutting tip portion.

[0007] As another example, a cutting tip can be provided that interlocks with the shaft portion of a cutting tool, making the cutting tip a removable element. Then, after the original cutting tip wears out during use, the modular cutting tip can be replaced with a new cutting tip without simultaneously replacing the shaft portion.

[0008] The shaft portion to which the cutting tip is attached may have fewer chip removal grooves than the cutting tip portion. For example, in some embodiments, the cutting tip portion may have a first, second, third, and fourth chip removal groove, while the shaft portion may have a first and second chip removal groove. An interface may exist between the end of the shaft portion and the cutting tip portion. At this interface, the first chip removal groove of the shaft portion may be in fluid communication with the outlets of the first and second chip removal grooves of the cutting tip portion, while the second chip removal groove of the shaft portion may be in fluid communication with the outlets of the third and fourth chip removal grooves of the cutting tip portion. The inlets of the first, second, third, and fourth chip removal grooves of the cutting tip portion may be located at the distal end of the cutting tip portion, opposite the end of the cutting tip portion attached to the shaft portion at the interface.

[0009] After the cutting tip portion wears down, one or more fasteners can be adjusted to remove the worn cutting tip portion, thereby allowing a new cutting tip portion to be attached to the shaft portion. In other embodiments, the shaft portion and the cutting tip portion can be integrally formed parts of the body or cutting tool, such that the cutting tip portion cannot be removed from the shaft portion. For example, the body of the shaft portion and the cutting tip portion can be made of a single type of steel (e.g., tool steel, high-speed steel, etc.). The distal end of the cutting tip portion may also include one or more cutting elements positioned thereon for engaging the workpiece to cut it.

[0010] In some embodiments, each end portion of the chip flute adjacent to the cutting end of the cutting tip portion may have a recess defined therein to receive and retain a cutting element. The cutting tip portion may also include one or more centrally positioned cutting elements for engaging a workpiece. In other embodiments, the body of the cutting tip portion may be configured to cut a workpiece, and may not use a cutting element.

[0011] In a first aspect, a cutting device may be provided. The cutting device may include a body having a cutting tip portion removably connected to a shank portion. The cutting tip portion may define a first end of the body, while the shank portion may have an intermediate portion between the cutting tip portion and a second end portion of the body opposite the cutting tip portion. The shank portion may have a plurality of chip-removing grooves defined on an outer surface of the intermediate portion of the body. Each chip-removing groove of the shank portion may extend from adjacent to the cutting tip portion to the second end portion along a first preselected helix angle. The chip-removing grooves of the shank portion may include a first chip-removing groove and a second chip-removing groove of the shank portion. The cutting tip portion may have a plurality of chip-removing grooves extending from the first end of the body to the intermediate portion of the body. The chip-removing grooves of the cutting tip portion may include a first chip-removing groove, a second chip-removing groove, a third chip-removing groove, and a fourth chip-removing groove of the cutting tip portion.

[0012] A first chip removal groove on the cutting tip portion extends from a first end of the body to an interface, where it is fluidly connected to a first chip removal groove on the shank portion, allowing chips passing along the first chip removal groove on the cutting tip portion to be transferred to the first chip removal groove on the shank portion. A second chip removal groove on the cutting tip portion extends from a first end of the body to an interface, where it is fluidly connected to a first chip removal groove on the shank portion, allowing chips passing along the second chip removal groove on the cutting tip portion to be transferred to the first chip removal groove on the shank portion. A third chip removal groove on the cutting tip portion extends from a first end of the body to an interface, where it is fluidly connected to a second chip removal groove on the shank portion, allowing chips passing along the third chip removal groove on the cutting tip portion to be transferred to the second chip removal groove on the shank portion. The fourth chip removal groove of the cutting tip portion can extend from the first end of the body to the interface, where the fourth chip removal groove of the cutting tip portion is fluidly connected to the second chip removal groove of the shank portion, so that chips passing along the fourth chip removal groove of the cutting tip portion can be transferred to the second chip removal groove of the shank portion.

[0013] In a second aspect, the first preselected helix angle is between 5° and 30°, and the second preselected helix angle along which at least some of the chip flutes of the cutting tip extend is between 10° and 45°. In other embodiments, the first preselected helix angle is between 10° and 20°, and the second preselected helix angle is between 15° and 30°. Other embodiments may utilize other helix angles. In some embodiments, the first preselected helix angle differs from the preselected helix angle along which the second chip flutes of the cutting tip extend.

[0014] In a third aspect, the chip removal grooves of the cutting tip portion can be arranged along the circumference or periphery of the cutting tip portion, such that the first chip removal groove of the cutting tip portion is located between the second chip removal groove and the fourth chip removal groove of the cutting tip portion, and the third chip removal groove of the cutting tip portion is located between the second chip removal groove and the fourth chip removal groove of the cutting tip portion.

[0015] Fourthly, the chip removal grooves in the shank portion have a larger clearance than the chip removal grooves in the cutting tip portion. The clearance of each chip removal groove in the shank portion can be the size of the groove opening, and the clearance of each chip removal groove in the cutting tip portion can be the size of the groove opening. The clearance of each chip removal groove in the shank portion can be larger than the clearance of the chip removal grooves in the cutting tip portion.

[0016] In the fifth aspect, the cutting tip portion can be removably attached to the shank portion via one or more fasteners. Examples of fasteners that can be used include at least one screw or at least one bolt.

[0017] In a sixth aspect, the cutting tip portion has at least one cutting element located at the first end. For example, the cutting tip portion may include a first cutting element positioned in a recess defined adjacent to the first end in a first chip groove, a second cutting element positioned in a recess defined adjacent to the first end in a second chip groove, a third cutting element positioned in a recess defined adjacent to the first end in a third chip groove, and a fourth cutting element positioned in a recess defined adjacent to the first end in a fourth chip groove. In some embodiments, each cutting element may be made of a material harder than the material of the cutting tip portion and / or the shank portion.

[0018] In the seventh aspect, each chip removal groove of the cutting tip portion has a recess at the first end of the adjacent body for retaining the cutting element. Each recess can be sized and shaped to facilitate the positioning and attachment of the cutting element.

[0019] In the eighth aspect, the body can be a cutting insert used for cutting tools.

[0020] In a ninth aspect, the cutting device may include other elements. For example, the cutting device may include an actuator operatively coupled to a body to rotate the body to cut material from a workpiece. In some embodiments, the actuator may also be configured to linearly move the body in addition to rotating it. The actuator may be configured to move the body relative to the workpiece, and the body may be configured to cut one or more holes in the workpiece.

[0021] In the tenth aspect, the length of the cutting tip portion is 0.5 to 5 times the diameter of the body.

[0022] In the eleventh aspect, the cutting device of the first aspect may include one or more features of the second, third, fourth, fifth, sixth, seventh, eighth, ninth, and / or tenth aspects. Embodiments may also utilize other features or elements. Examples of other features or elements can be understood from the exemplary embodiments discussed herein.

[0023] In a twelfth aspect, a cutting device may include a body having a first end portion, a second end portion opposite to the first end portion, and an intermediate portion between the first end portion and the second end portion. The body may have a length extending from a first end of the first end portion to a second end of the second end portion. The first end portion may be removably connected to a first end of the intermediate portion. The body may also have a plurality of chip removal grooves defined on the outer surface of the body. The chip removal grooves may include a first chip removal groove, a second chip removal groove, a third chip removal groove, and a fourth chip removal groove. A first chip removal groove extends along the outer surface of the body from a first end portion to at least the middle portion of the body at a first preselected helical angle. A second chip removal groove extends along the outer surface of the body from a first end portion to at least the middle portion of the body at a first preselected helical angle. A third chip removal groove extends from the first end portion to a first interface between the third chip removal groove and the first chip removal groove, such that the third chip removal groove is in fluid communication with the first chip removal groove via the first interface to facilitate the flow of debris from the third chip removal groove to the first chip removal groove, and that debris can be transferred from the third chip removal groove to the first chip removal groove via the first interface to be transferred along the first chip removal groove thereby removing debris from the first end portion. A fourth chip removal groove extends from the first end portion to a second interface between the fourth chip removal groove and the second chip removal groove, such that the fourth chip removal groove is in fluid communication with the second chip removal groove via the second interface to facilitate the flow of debris from the fourth chip removal groove to the second chip removal groove, and that debris can be transferred from the fourth chip removal groove to the second chip removal groove via the second interface to be transferred along the second chip removal groove thereby removing debris from the first end portion. A third chip removal groove extends from the first end portion to the first interface along the length of the first end portion at a second pre-selected helix angle. A fourth chip removal groove extends from the first end portion to the second interface along the length of the first end portion at a second pre-selected helix angle. The first pre-selected helix angle may be the same as or different from the second pre-selected helix angle. The gap of the first chip removal groove adjacent to the first end portion is smaller than the gap size of the first chip removal groove at the middle portion, and the gap of the second chip removal groove adjacent to the first end portion is smaller than the gap size of the second chip removal groove at the middle portion.

[0024] In the thirteenth aspect, the first preselected helix angle is between 10° and 45°, and the second preselected helix angle is between 10° and 45°. In some embodiments, the first preselected helix angle and the second preselected helix angle are the same. In other embodiments, the first preselected helix angle and the second preselected helix angle are different.

[0025] In the fourteenth aspect, the first end portion may be removably attached to the first end of the intermediate portion via one or more fasteners (e.g., one or more bolts or one or more screws).

[0026] In a fifteenth aspect, at least one cutting element may be positioned on a first end of the first end portion. For example, each cutting element may be positioned in a corresponding recess defined by an adjacent corresponding chip removal groove. For example, each chip removal groove may have a recess in which the first end of the body of the adjacent first end portion holds the cutting element.

[0027] In some embodiments, there may be a first cutting element positioned in a recess defined at a first end adjacent to a first end portion in a first chip removal groove, a second cutting element positioned in a recess defined at a first end adjacent to a first end portion in a second chip removal groove, a third cutting element positioned in a recess defined at a first end adjacent to a first end portion in a third chip removal groove, and a fourth cutting element positioned in a recess defined at a first end adjacent to a first end portion in a fourth chip removal groove.

[0028] In the sixteenth aspect, the cutting device of the twelfth aspect may include one or more features or elements of the thirteenth, fourteenth, and / or fifteenth aspects. Other embodiments may also include other features or elements. Examples of other features or elements that may be included in the cutting device can be understood from the exemplary embodiments discussed herein, for example.

[0029] These and other embodiments will be described in more detail herein and in the accompanying drawings illustrating exemplary embodiments. Therefore, further details, objects, and advantages will become apparent as some of the presently preferred embodiments of the invention and some of its presently preferred practices are described below. Attached Figure Description

[0030] Exemplary embodiments of the cutting apparatus and methods for manufacturing and using the cutting apparatus are shown in the accompanying drawings. It should be understood that similar reference numerals used in the drawings may identify similar components:

[0031] Figure 1 This is a block diagram of an exemplary embodiment of the cutting device 1.

[0032] Figure 2 This is a side view of an exemplary embodiment of the cutting body 3 of the cutting blade 2 used in the cutting device 1.

[0033] Figure 3 This is a cross-sectional view of the first end portion 3t of an exemplary embodiment of the cutting body 3.

[0034] Figure 4 This is a cross-sectional view of the middle portion 3m of an exemplary embodiment of the cutting body 3.

[0035] Figure 5 This is a schematic diagram showing... Figures 2-4 How the cross sections of the first end portion 3t and the middle portion 3m of the exemplary embodiment of the cutting body 3 shown overlap each other.

[0036] Figure 6 This is a partial perspective view of the first end portion 3t of an exemplary embodiment of the cutting body 3.

[0037] Figure 7 This is an end view of the first end portion 3t of an exemplary embodiment of the cutting body 3.

[0038] Figure 8 This is an enlarged partial perspective view of the first end portion 3t of an exemplary embodiment of the cutting body 3.

[0039] Figure 9 This is another enlarged partial perspective view of the first end portion 3t of an exemplary embodiment of the cutting body 3.

[0040] Figure 10 This is a perspective view of the cutting body 3 of the first exemplary embodiment.

[0041] The reference numerals used in the accompanying drawings include:

[0042] 1. Cutting device

[0043] 2 Cutting inserts

[0044] 3 cutting body

[0045] 3a Cutting the first end of the body

[0046] 3b The second end of the cutting body

[0047] 3F Cross-section of the first end portion 3t

[0048] 3i Interface

[0049] 3m cutting body 3 middle part

[0050] 3n defines a recess in the sidewall of the chip removal groove FL for receiving the cutting element CE.

[0051] 3p Cutting the second end portion of body 3

[0052] 3s Cutting the outer surface of body 3

[0053] 3t Cutting the first end portion of the body 3

[0054] 4 First chip removal groove

[0055] 4a Part 1

[0056] 4b Part Two

[0057] 4F Cross-section of the middle portion 3m of the adjacent interface 3i

[0058] 5 Actuators

[0059] 6 Second chip removal groove

[0060] The gap between the 6g interface and the 3i

[0061] 9. Groove clearance dimension of the first part 4a of the first chip removal groove 4a

[0062] 10. Groove clearance dimension of the second part 4b of the first chip removal groove 4a

[0063] 11. Gap size of the second chip removal groove 6

[0064] 12-axis section

[0065] 13 Cutting tip portion

[0066] CE cutting elements

[0067] D diameter

[0068] The distance between the innermost and outermost parts of the second part 4b of the first chip removal groove 4 of DG1

[0069] The distance between the innermost and outermost parts of the first part 4a of the first chip removal groove 4 of DG2

[0070] The distance between the innermost and outermost surfaces of each second chip removal groove in DG3

[0071] FC fluid conduit

[0072] FL chip conveyor

[0073] LB Body Length

[0074] The middle section of the LM is 3 meters long.

[0075] LP second end portion 3p length

[0076] LT First end portion 3t length

[0077] WP workpiece

[0078] W9 First chip removal groove 4 first part 4a groove opening gap dimension

[0079] The groove gap dimension of the second part 4b of the first chip removal groove 4 of W10

[0080] W11 Second chip removal groove 6 groove opening gap dimension Detailed Implementation

[0081] refer to Figures 1 to 10 The cutting device 1 may include a cutting tool comprising a cutting blade 2 having a cutting body 3 operably connected to an actuator 5 to cut into a workpiece WP to shape the workpiece WP. For example, the actuator 5 may be configured to rotate or otherwise move the cutting blade 2 such that the cutting edge of the cutting body 3 contacts the workpiece to form a hole (e.g., a hole, channel, opening, recess, groove, etc.) therein. For example, the cutting blade 2 may be rotated and also inserted or otherwise moved to form one or more holes in the workpiece WP. For example, the cutting blade 2 may be adapted to remove material from the workpiece to help shape the workpiece to form an apparatus or a component of an apparatus.

[0082] The body 3 of the cutting insert 2 may be composed of a suitable material. For example, the body 3 may be composed of a metal, alloy, ceramic material, composite material, carbide material, tungsten carbide, tool steel, or other suitable material. In some embodiments, the cutting point or cutting edge of the body 3 may include one or more cutting elements CE, which may be composed of a material harder than the body material (e.g., polycrystalline diamond (PCD), tungsten carbide, carbide, etc.). In other embodiments, the cutting body 3 of the cutting insert 2 may be integrally formed of the same type of material, such that the entire body 3 is made of the same material (e.g., tungsten carbide, tool steel, etc.), and no additional supplementary cutting elements are attached to the body 3.

[0083] The cutting body 3 can be sized and shaped to provide hole drilling by rotating the body along an axis extending along the length L of the body. The cutting body 3 can also be alternatively or additionally configured to provide end milling, reaming, or other types of cutting functions.

[0084] Actuator 5 may be configured to move cutting insert 2 (e.g., by linear motion, rotary motion, and / or other types of motion). For example, actuator 5 may be configured to rotate cutting insert 2 such that the cutting insert can perform a drilling operation to drill a hole in the workpiece. As another example, actuator 5 may be configured to move cutting insert 2 vertically and / or horizontally along and / or into workpiece WP to perform a cutting operation.

[0085] In some embodiments, the body 3 of the cutting insert may be shaped such that the body portion at the distal region of the first end portion 3t provides a cutting edge for direct contact with and cutting of the workpiece WP. In other embodiments, a recess 3n may be defined to hold a cutting element CE made of a material harder than the material of the body 3. When in use, such a cutting element CE may be fastened or otherwise attached to the first end portion 3t of the body. For example, in some embodiments where the body 3 is made of tool steel, high-speed steel, carbide material, or tungsten carbide material, a PCD cutting element may be attached within a recess 3n defined in the first end portion 3t of the body at the cutting edge of the cutting insert 2. In other embodiments, no cutting element CE may be used, and the cutting body may be formed as a single monolithic body made of the same material (e.g., carbide material, tungsten carbide, tool steel, suitable alloy, suitable type of metal, suitable type of ceramic material, or suitable type of composite material, etc.).

[0086] If possible Figures 2 to 10 Ideally, the cutting body 3 of the cutting insert 2 may have an arrangement of chip removal grooves FL that extend helically along at least a portion of the length LB of the body 3. For example, each chip removal groove FL may be defined on the outer surface 3s of the cutting body 3 to define a helically extending groove having an outer opening extending along the outer surface 3s of the body 3. In some embodiments, the cutting body 3 may also have one or more fluid conduits FC defined therein, such that coolant fluid or other types of fluid can be passed through the body 3 and discharged from one or more fluid outlets defined in the outer surface of the body.

[0087] The arrangement of chip removal grooves FL can be provided on the body 3 such that more chip removal grooves FL are defined in the first end portion 3t of the body 3 compared to the intermediate portion 3m which may be located between the first end portion 3t and the second end portion 3p opposite to the first end portion 3t. The second end portion 3p can be considered as the shank end of the cutting body 3, and the first end portion 3t can be considered as the cutting head or cutting tip end of the cutting body 3 in some embodiments.

[0088] In some embodiments, the diameter D of the body 3 may be in the range of 20 mm to 150 mm. Other embodiments may utilize another suitable range for the diameter size (e.g., 30 mm to 130 mm, 25 mm to 175 mm, etc.). The length of the body LB may be selected as a suitable size based on the selected diameter D of the body 3.

[0089] For example, the body 3 may be an elongated member having a length LB extending from a first end 3a to a second end 3b of the body 3. A first end portion 3t may extend from the first end 3a to a first end of an intermediate portion 3m. A second end portion 3p may extend from the second end 3b to a second end of the intermediate portion 3m, the second end being opposite the first end of the intermediate portion. The intermediate portion 3m may have a length LM, the first end portion 3t may have a length LT, and the second end portion 3p may have a length LP. The length LB of the body may be equal to the sum of these lengths (e.g., the length LB of the body may be equal to the length LM of the intermediate portion, the length LT of the first end portion 3t, and the length LP of the second end portion 3p). In some embodiments, the length LT of the first end portion may be 0.5 to 5 times the diameter D of the body 3 (e.g., between 15 mm and 150 mm for a body 3 with a diameter of 30 mm). For example, in some embodiments, for a body 3 with a diameter D of 5 mm, the length LT of the first end portion may be between 2.5 mm and 25 mm. In other embodiments, the length LT of the first end portion may be 1.0 to 3 times the diameter D of the body 3 (e.g., between 30 mm and 90 mm for a body 3 with a diameter D of 30 mm).

[0090] In some embodiments, the chip removal groove FL of the first end portion 3t may be considered to include a first chip removal groove 4 and a second chip removal groove 6. The first chip removal groove 4 may be considered as the main chip removal groove, which may be sized and shaped to have a larger surface area than the second chip removal groove 6. Each second chip removal groove 6 may be shaped and configured to extend from its distal end at a first end 3a at the distal end of the first end portion 3t to an interface 3i, where the terminal end of the second chip removal groove 6 opposite its distal end is in fluid communication with the corresponding first chip removal groove 4. In some embodiments, the interface 3i may be located at or adjacent to the first end of the intermediate portion 3m of the body 3. In other embodiments, the interface 3i may be located in the first end portion 3t or within the intermediate portion 3m between its first and second ends.

[0091] Each first chip removal groove 4 may have a first portion 4a extending from a first end 3a of a first end portion 3t to an interface 3i, and a second portion 4b extending from an interface 3i to a second end portion 3p. The first portion 4a of the first chip removal groove 4 may be formed with a slot having a gap of size 9. The gap size of the slot of the first portion 4a of the first chip removal groove 4 may be smaller than the gap size 10 of the slot of the second portion 4b of the first chip removal groove 4. These gaps may have pre-selected or predetermined sizes. For example, the gap size W9 of the slot of the first portion 4a of the first chip removal groove 4 may be a gap extending circumferentially between 60 degrees and 100 degrees on the first end 3a of the body 3, and the gap size W10 of the slot of the second portion 4b of the first chip removal groove 4 may be a gap extending circumferentially between 70 degrees and 110 degrees.

[0092] The dimensional differences between size 9 and size 10 can also be seen from Figure 3 , Figure 4 and Figure 5 The cross-sectional view of the first end portion 3t shown Figure 3 Cross-sectional view of F and the middle part 3m adjacent to interface 3i Figure 4 For understanding (where two cross-sectional views overlap to help illustrate the dimensional differences). In some embodiments, the dimensions of the chip removal groove FL can change continuously as it extends from the first end 3a to the intermediate portion 3m adjacent to the interface 3i. For example, the forming of each chip removal groove FL can be defined such that the curvature and shape of the chip removal groove FL change continuously as it extends from the adjacent first end 3a along a preselected helix angle to the interface 3i. For example, the initial shapes of the first and second chip removal grooves 4 and 6 can change as the chip removal groove FL extends toward the interface 3i.

[0093] Each second chip removal groove 6 may also have an opening. The gap dimension of the opening of the second chip removal groove 6 may be smaller than the gap dimension 9 (or dimension W9) of the opening of the first portion 4a of the first chip removal groove 4 (and therefore may also be smaller than the gap dimension 10 (or dimension W10) of the opening of the second portion 4b of the first chip removal groove 4). In some embodiments, the gap dimension W11 of the opening of the second chip removal groove 6 may be a circumferentially extending gap between 40 degrees and 80 degrees.

[0094] The chip removal groove FL can be defined such that an opening is formed in the cutting tip portion 13 to reduce the surface area of ​​the body of the cutting tip portion 13 (compared to the cutting tip portion 13 being entirely solid). The first and second chip removal grooves 4, 6 in the cutting tip portion can have a gap providing a ratio of the surface area of ​​the cutting tip portion to that of a solid cutting tip portion in the range of 0.50-0.60 (e.g., the cutting tip portion has a chip removal groove FL defined therein such that the surface area of ​​the cutting tip portion is 650 mm). 2 If the cutting tip is solid, it can have a diameter of 1200 mm. 2 The surface area of ​​the cutting tip portion is such that the ratio of its surface area to that of the solid cutting tip portion is 0.54 (650 / 1200). The chip removal groove FL (e.g., the first chip removal groove 4) defined in the shank portion 12 can be shaped and configured to extend from the interface 3i, such that the shank portion 12 has a ratio of its surface area to that of the solid shank portion in the range of 0.60-0.70 (e.g., a shank portion in which the chip removal groove FL is defined such that the surface area of ​​the shank portion is 760 mm). 2 If the cutting tip is solid, then the surface area of ​​the shank portion may be 1200 mm. 2The ratio of the surface area of ​​the handle portion to the surface area of ​​the solid handle portion is 0.63 (760 / 1200).

[0095] In some embodiments, each second chip removal groove 6 may be configured to have a larger gap 6g at the interface 3i where the second chip removal groove 6 is in fluid communication with the corresponding first portion 4a of the first chip removal groove 4. The size of this larger gap 6g may be larger than the gap size 11 of the groove opening of the second chip removal groove 6. The size of this larger gap 6g may be smaller than the gap size 10 of the groove opening of the second portion 4b of the first chip removal groove 4.

[0096] Interface 3i can be the region that feeds debris along the second chip removal groove into the first chip removal groove 4. The second chip removal groove 6 is in fluid communication with the first chip removal groove 4, which helps guide the debris away from the first end 3a and through the second portion 4b of the first chip removal groove 4 to the second end 3b. Each second chip removal groove 6 may have an interface 3i with the corresponding main chip removal groove 4. For example, in some embodiments, a total of three or four chip removal grooves FL may be defined in the first end portion 3t, and a total of two chip removal grooves FL may be defined only in the middle portion 3m. The reduction in the number of chip removal grooves FL may be a result of each second chip removal groove 6 being incorporated into the corresponding first chip removal groove 4 at interface 3i. Interface 3i may be defined such that the second chip removal groove 6 has a larger gap 6g at interface 3i to help facilitate the supply of debris (e.g., chips) from the second chip removal groove 6 to the first chip removal groove 4 via interface 3i. In some embodiments, the interface 3i may have a predetermined structure defined in the first end portion 3t to provide a larger gap 6g, which also helps to facilitate the flow of debris from the second chip discharge groove 6 to the first chip discharge groove 4.

[0097] Each second chip removal groove 6 may extend along the length LT of the first end portion 3t at a preselected helix angle. Each first chip removal groove 4 may have a first portion 4a extending along the length LT of the first end portion 3t at a preselected helix angle. The preselected helix angle of the first portion 4a may be between 10 degrees and 40 degrees, and the preselected helix angle of the second chip removal groove 6 may be between 15 degrees and 45 degrees. For example, each first portion 4a may extend at a helix angle between 10° and 30°, and each second chip removal groove 6 may extend at a helix angle between 10° and 20°, and also at an angle less than or greater than the helix angle of the first portion 4a.

[0098] The second portion 4b of the first chip removal groove 4 may extend at the same helix angle as the first portion 4a. In other embodiments, it is conceivable that the second portion 4b may transition to extending at a different helix angle compared to the first portion 4a.

[0099] In other embodiments, the first chip removal groove 4 and the second chip removal groove 6 may extend along the same preselected helix angle. For example, the helix angle of the first chip removal groove may be between 10° and 30°, and the second chip removal groove 6 may extend at the same helix angle (e.g., the first and second chip removal grooves 4 and 6 may each extend at helix angles of 10°, 15°, 20°, 25° or 30°, etc.).

[0100] In some embodiments, each of the second chip removal grooves 6 may have a gap that is sized to the gap size of the first chip removal groove 4. For example, each second chip removal groove 6 may have a gap that extends circumferentially between 60° and 100°, and each first chip removal groove 4 may have an opening that has a gap size that extends circumferentially between 60° and 100°.

[0101] In some implementations, each second chip removal groove 6 may have a gap size such that the opening of each second chip removal groove 6 may have a gap of, for example, 2 / 3 of the gap size of the opening of the first chip removal groove 4 to which the second chip removal groove 6 is interconnected at interface 3i.

[0102] In some embodiments, each second chip removal groove 6 may be sized such that the distance between the innermost and outermost surface portions of each second chip removal groove 6 is spaced apart by a distance DG3, which is 30% to 80% of the diameter D of the body 3. In such an embodiment, the first portion 4a of the first chip removal groove 4 may have a distance DG2 between its innermost and outermost surface portions, which is between 15% and 55% of the diameter D of the body 3, and the second portion 4b of the first chip removal groove 4 may have a distance DG1 between its innermost and outermost surface portions, which is between 20% and 60% of the diameter D of the body 3. Distances DG1, DG2, and DG3 may each be measured as distances extending linearly along a portion of the diameter D of the body 3.

[0103] In other embodiments, the chip removal groove FL of the first end portion 3t may include a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL, and a fourth chip removal groove FL. Some such embodiments may be provided to include four chip removal grooves FL near the first end 3a of the body and two chip removal grooves FL at the middle portion 3m of the body. Other embodiments may utilize more than four chip removal grooves FL (e.g., six chip removal grooves FL, etc.). In some embodiments, the first and second chip removal grooves FL may be considered as main chip removal grooves (or the first chip removal groove 4), which may be sized and shaped to have a larger surface area than the third and fourth chip removal grooves FL, which may be considered as secondary or second chip removal grooves. For example, the third chip removal groove FL may extend from the first end 3a to a first interface 3i between the first and third chip removal grooves FL, while the fourth chip removal groove FL may extend from the first end 3a to a second interface 3i between the second and fourth chip removal grooves FL. The third and fourth chip removal grooves FL can extend along the length LT of the first end portion 3t to their respective interfaces 3i, where the chip removal groove FL terminates at a preselected helix angle, which may be the same as or different from the preselected helix angle along which the first and second chip removal grooves FL can extend.

[0104] In other embodiments, the chip groove FL may be defined such that a first end portion 3t can be considered a cutting tip portion 13, which is modular and removably connected to a shank portion 12 via one or more fasteners and / or an interlocking profile located between a second end of the cutting tip portion 13 opposite to the distal first end 3a of the cutting tip portion 13 and a first end of the shank portion 12. The shank portion 12 may include a middle portion 3m and a second end portion 3p of the cutting tool insert, and the cutting tip portion 13 may be a removable first end portion 3t to facilitate removal and replacement of the cutting tip portion 13 after it has become sufficiently worn due to use, making it possible that only the cutting tip portion 13 needs to be replaced.

[0105] In such modular embodiments, the cutting tip portion 13 may include a plurality of chip removal grooves FL, wherein two or more chip removal grooves FL of the cutting tip portion 13 are fluidly connected to corresponding chip removal grooves FL of the shank portion 12. For example, the cutting tip portion 13 may have a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL, and a fourth chip removal groove FL. The first, second, third, and fourth chip removal grooves FL may each extend along a length LT of the first end portion 3t to its corresponding interface 3i, where the chip removal groove FL terminates at a preselected helix angle. The shank portion 12 may have a first chip removal groove FL, which may be positioned to extend from its interface 3i, which engages with the first and second chip removal grooves FL of the cutting tip portion 13, such that chips passing along the first and second chip removal grooves FL of the cutting tip portion 13 may be fed into the first chip removal groove FL of the shank portion 12. The first chip removal groove FL of the shank portion 12 may extend from the first end of the shank portion 12 (or the first end of the intermediate portion 3m) along a preselected helix angle to the second end of the shank portion 12, which is opposite to the end to which the cutting tip portion of the shank portion 12 is connected, or extend to the second end portion 12p connected to the second end of the intermediate portion 3m.

[0106] The shank portion 12 may also have a second chip removal groove FL, which may be positioned to extend from the interface 3i where it engages with the third and fourth chip removal grooves FL of the cutting tip portion 13, such that chips passing along the third and fourth chip removal grooves FL of the cutting tip portion 13 may be fed into the second chip removal groove FL of the shank portion 12. The second chip removal groove FL of the shank portion 12 may extend from a first end (or the first end of the intermediate portion 3m) of the shank portion 12 along a preselected helix angle to a second end of the shank portion 12, which is opposite to the end to which the cutting tip portion of the shank portion 12 is connected, or extend to a second end portion 12p connected to the second end of the intermediate portion 3m.

[0107] After the modular cutting tip portion 13 is connected to the first end of the shaft portion 12, the first and second chip removal grooves FL of the shank portion 12 can be considered as the second portion 4b of the first chip removal groove 4 in some embodiments, and the first and third chip removal grooves FL of the cutting tip portion can be considered as the first portion 4a of the first chip removal groove 4. In such embodiments, the second and fourth chip removal grooves FL of the cutting tip portion 13 can be considered as the second chip removal groove 6. In such embodiments, the first, second, third, and fourth chip removal grooves FL of the cutting tip portion 13 can be defined on the outer surface of the cutting tip portion 13 such that they are spaced apart from each other along the circumference or periphery of the cutting tip portion 13, such that the second chip removal groove FL is located between the first and third chip removal grooves FL of the cutting tip portion 13, the third chip removal groove FL is located between the second and fourth chip removal grooves FL of the cutting tip portion 13, and the fourth chip removal groove FL is located between the third and first chip removal grooves FL of the cutting tip portion 13.

[0108] The first end 3a of the cutting tip portion 13 or the first end portion 3t may have one or more cutting elements CE positioned at the center portion of the first end 3a. Such a configuration may, for example, be derived from... Figure 7 As best seen, such cutting elements can be positioned to help facilitate drilling into the workpiece, while other cutting elements CE positioned in the recesses 3n on the chip groove sidewalls adjacent to the first end 3a or at the first end 3a can be positioned to help remove material from adjacent sides extending from the first end 3a. The cutting elements CE positioned in the recesses 3n can be positioned such that they are located at different positions along the length LT of the first end portion 3t to help facilitate material removal from the workpiece WP, for example, when the body 3 is inserted into the workpiece WP while it is also rotating.

[0109] An embodiment of the cutting insert 2 can be used in a cutting tool that can be controlled via at least one actuator 5 to cut material from a workpiece WP. The cutting insert can facilitate drilling or other types of cutting operations. For example, when the workpiece WP is being cut, chips may initially exit the workpiece along a plurality of first and second chip evacuation grooves 4, 6, and chips subsequently passing along each second chip evacuation groove 6 may be fed into the corresponding first chip evacuation groove at the interface 3i between the second chip evacuation groove 6 and the corresponding first chip evacuation groove 4. As the chips travel from the workpiece WP toward the second end 3b of the body 3, the chips may then continue along the length LB of the body 3 along the second portion 4b of the first chip evacuation groove 4 downstream of the interface 3i. When the body 3 moves (e.g., rotates) to cut the workpiece WP, chips passing along the chip evacuation groove FL may also be guided away from the body 3 via the slot of the chip evacuation groove FL.

[0110] As can be understood from the above, the cutting device 1 may include a body 3 having a first end portion 3t, a second end portion 3p opposite to the first end portion 3t, and an intermediate portion 3m between the first end portion 3t and the second end portion 3p. The body 3 has a length LB extending from a first end 3a of the first end portion 3t to a second end 3b of the second end portion 3p. The body 3 also has a plurality of first chip removal grooves 4 and a plurality of second chip removal grooves 6 defined on an outer surface 3s, such that the first chip removal grooves 4 extend along the outer surface 3s of the body 3 from the first end portion 3t to at least the intermediate portion 3m of the body 3 along a first preselected helix angle. Each second chip removal groove 6 may extend from the first end portion 3t to the interface 3i between the second chip removal groove 6 and the corresponding first chip removal groove 4, such that the second chip removal groove 6 is in fluid communication with the first chip removal groove 4 via the interface 3i, to facilitate the flow of debris from the second chip removal groove 6 to the first chip removal groove 4, so that debris can be transferred from the second chip removal groove 6 to the first chip removal groove 4 via the interface 3i to be transferred along the first chip removal groove 4 thereby removing debris from the first end portion 3t. Each second chip removal groove 6 may extend from the first end portion 3t to the interface 3i along the length LT of the first end portion 3t at a second preselected helix angle.

[0111] Each interface 3i may have a gap 6g larger than the gap of the second chip removal groove 6. The gap of the second chip removal groove 6 may be smaller than the gap of the first portion 4a of the first chip removal groove 4 extending along the first end portion of the body 3t. The second portion 4b of the first chip removal groove 4 extending along the middle portion 3m of the body may also have a gap larger than the gap of the first portion 4a of the first chip removal groove 4.

[0112] The first end portion defines a first chip removal groove and a second chip removal groove, thereby defining different cutting points with different cutting heights and different cutting point angles. In some embodiments, the length LT of the first end portion 3t may be 10% to 30% of the length LB of the body 3.

[0113] Embodiments of such a cutting device 1 may include a cutting device 1 comprising a body 3 having a first end portion 3t, a second end portion 3p opposite to the first end portion 3t, and an intermediate portion 3m between the first end portion 3t and the second end portion 3p. The length LB of the body 3 may extend from a first end 3a of the first end portion 3t to a second end 3b of the second end portion 3p. The body 3 has a plurality of chip removal grooves FL defined on an outer surface 3s. The chip removal grooves FL may include a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL, and a fourth chip removal groove FL. The first chip removal groove FL may extend along the outer surface 3s of the body 3 from the first end portion 3t to at least the intermediate portion 3m of the body 3 along a first preselected helix angle. The second chip removal groove FL may also extend along the outer surface 3s of the body 3 from the first end portion 3t to at least the intermediate portion 3m of the body 3 along a first preselected helix angle. A third chip removal groove FL extends from the first end portion 3t to a first interface 3i between the third chip removal groove FL and the first chip removal groove FL, such that the third chip removal groove FL is in fluid communication with the first chip removal groove FL via the first interface 3i to facilitate the flow of debris from the third chip removal groove FL to the first chip removal groove FL, and allows debris to be transferred from the third chip removal groove FL to the first chip removal groove FL via the first interface 3i to be carried along the first chip removal groove FL, thereby removing debris from the first end portion 3t. A fourth chip removal groove FL extends from the first end portion 3t to a second interface 3i between the fourth chip removal groove FL and the second chip removal groove FL, such that the fourth chip removal groove FL is in fluid communication with the second chip removal groove FL via the second interface 3i to facilitate the flow of debris from the fourth chip removal groove FL to the second chip removal groove FL, and allows debris to be transferred from the fourth chip removal groove FL to the second chip removal groove FL via the second interface 3i to be carried along the second chip removal groove FL, thereby removing debris from the first end portion 3t. The third chip removal groove FL can extend from the first end portion 3t to the first interface 3i along the length LT of the first end portion 3t along the second preselected helix angle, and the fourth chip removal groove can extend from the first end portion 3t to the second interface 3i along the length LT of the first end portion 3t along the second preselected helix angle.

[0114] In some embodiments, the first preselected helix angle is between 10° and 45°, and the second preselected helix angle is between 10° and 45°. Other embodiments may utilize other suitable helix angles.

[0115] As can be understood from the above, some embodiments may be provided such that the first interface 3i has a gap 6g larger than the gap of the third chip removal groove FL, and the gap of the third chip removal groove FL may also be smaller than the gap of the first portion 4a of the first chip removal groove FL extending along the first end portion 3t of the body 3. The second interface 3i may also have a gap larger than the gap of the fourth chip removal groove FL, and the gap of the fourth chip removal groove FL may also be smaller than the gap of the first portion of the second chip removal groove FL extending along the first end portion 3t of the body 3.

[0116] The first chip removal groove FL may also have a second portion extending along the middle portion 3m of the body 3, wherein the second portion of the first chip removal groove FL may have a larger gap than the first portion of the first chip removal groove FL. Furthermore, the second chip removal groove may have a second portion extending along the middle portion 3m of the body 3, wherein the second portion of the second chip removal groove FL has a larger gap than the first portion of the second chip removal groove FL.

[0117] The first end portion of the body may define a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL and a fourth chip removal groove FL, such that different cutting points are defined thereon, which have different cutting heights and different cutting apex angles (e.g., defined on the first end portion 3t adjacent to and / or at the first end 3a).

[0118] As can be understood from the above, in some embodiments, the body 3 has a cutting tip portion 13 removably connected to the shank portion 12. The cutting tip portion 13 may define a first end 3a of the body 3, and the shank portion 12 may have an intermediate portion 13m of the body 3 between the cutting tip portion 13 and a second end portion 3p of the body 3 opposite to the cutting tip portion 13. The shank portion 12 may have a plurality of chip removal grooves FL defined on the outer surface of the intermediate portion 3m of the body 3. Each chip removal groove FL of the shank portion 12 may extend from the adjacent cutting tip portion 13 to the second end portion 3p along a first preselected helix angle. The chip removal grooves FL of the shank portion 12 include a first chip removal groove FL and a second chip removal groove FL of the shank portion 12.

[0119] The cutting tip portion 13 may also have a plurality of chip removal grooves FL extending from the first end 3a of the body 3 to the middle portion 3m of the body 3. The chip removal grooves FL of the cutting tip portion 13 may include a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL, and a fourth chip removal groove FL of the cutting tip portion 13. The first chip removal groove FL of the cutting tip portion 13 may extend from the first end 3a of the body 3 to an interface 3i, at which the first chip removal groove FL of the cutting tip portion 13 is fluidly connected to the first chip removal groove FL of the shank portion 12, such that chips passing along the first chip removal groove FL of the cutting tip portion 13 can be transferred to the first chip removal groove FL of the shank portion 12. The second chip removal groove FL of the cutting tip portion 13 extends from the first end 3a of the body 3 to the interface 3i, where it is fluidly connected to the first chip removal groove FL of the shank portion 12, such that chips passing along the second chip removal groove FL of the cutting tip portion 13 can be transferred to the first chip removal groove FL of the shank portion 12. The third chip removal groove FL of the cutting tip portion 13 extends from the first end 3a of the body 3 to the interface 3i, where it is fluidly connected to the second chip removal groove FL of the shank portion 12, such that chips passing along the third chip removal groove FL of the cutting tip portion 13 can be transferred to the second chip removal groove FL of the shank portion 12. The fourth chip removal groove FL of the cutting tip portion 13 extends from the first end 3a of the body 3 to the interface 3i, where the fourth chip removal groove FL of the cutting tip portion 13 is fluidly connected to the second chip removal groove FL of the shank portion 12, such that chips passing along the fourth chip removal groove FL of the cutting tip portion 13 can be transferred to the second chip removal groove FL of the shank portion 12.

[0120] The chip removal grooves of the cutting tip portion 13 can be arranged along the circumference or periphery of the cutting tip portion 13, such that the first chip removal groove FL of the cutting tip portion 13 is located between the second chip removal groove FL and the fourth chip removal groove FL of the cutting tip portion 13, and the third chip removal groove FL of the cutting tip portion 13 is located between the second chip removal groove FL and the fourth chip removal groove FL of the cutting tip portion 13.

[0121] The chip removal groove FL of the shank portion 12 may have a larger gap than the chip removal groove FL of the cutting tip portion 13.

[0122] In some embodiments, the cutting tip portion 13 may be removably attached to the shank portion via one or more fasteners, such as screws or bolts. The cutting tip portion 13 and the shank portion 12 may also have interlocking profiles to facilitate removable attachment via one or more fasteners. The removability of the cutting tip portion 13 allows for replacement of the cutting tip portion 13 upon wear without having to replace the shank portion 12, enabling faster replacement and reducing costs due to the potential wear of the cutting tip portion 13 after use. Modularity and ease of replacement also facilitate other types of maintenance (e.g., if the cutting tip portion 13 may break or fracture during use).

[0123] The cutting tip portion may also have at least one cutting element CE located on the first end 3a and / or a cutting element CE located near the first end 3a of the body 3. For example, the cutting tip portion 13 may include a first cutting element CE positioned in a recess 3n defined in a first chip groove FL adjacent to the first end 3a, a second cutting element CE positioned in a recess 3n defined in a second chip groove FL adjacent to the first end 3a, a third cutting element CE positioned in a recess 3n defined in a third chip groove FL adjacent to the first end 3a, and a fourth cutting element CE positioned in a recess 3n defined in a fourth chip groove FL adjacent to the first end 3a. The cutting element CE may be composed of a hard material (e.g., carbide material, PCD material, tungsten carbide material, etc.) and may have a preselected or predetermined shape (e.g., generally rectangular or cubic, generally polygonal, etc.). In some embodiments, the cutting element CE may be made of a material harder than the material of the cutting tip portion 13 and / or the shank portion 12 (e.g., the cutting element may be made of PCD material, and the cutting tip portion 13 may be made of carbide material or tool steel, etc.).

[0124] Other embodiments of the cutting device 1 may include a body 3 having a first end portion 3t, a second end portion 3p opposite to the first end portion 3t, and an intermediate portion 3m between the first end portion 3t and the second end portion 3p. The body may have a length LB extending from a first end 3a of the first end portion 3t to a second end 3b of the second end portion 3p. The first end portion 3t may be removably connected to the first end of the intermediate portion 3m. The body 3 may have a plurality of chip removal grooves FL defined on the outer surface 3s of the body 3. The chip removal grooves FL may include a first chip removal groove FL, a second chip removal groove FL, a third chip removal groove FL, and a fourth chip removal groove FL. The first chip removal groove FL may extend along the outer surface 3s of the body 3 from the first end portion 3t to at least the intermediate portion 3m of the body 3 along a first preselected helix angle, and the second chip removal groove FL may extend along the outer surface 3s of the body 3 from the first end portion 3t to at least the intermediate portion 3m of the body 3 along a first preselected helix angle. A third chip removal groove FL extends from the first end portion 3t to a first interface 3i between the third chip removal groove FL and the first chip removal groove FL, such that the third chip removal groove FL is in fluid communication with the first chip removal groove FL via the first interface 3i to facilitate the flow of debris from the third chip removal groove FL to the first chip removal groove FL, and allows debris to be transferred from the third chip removal groove FL to the first chip removal groove FL via the first interface 3i to be carried along the first chip removal groove FL, thereby removing debris from the first end portion. A fourth chip removal groove FL extends from the first end portion 3t to a second interface 3i between the fourth chip removal groove FL and the second chip removal groove FL, such that the fourth chip removal groove FL is in fluid communication with the second chip removal groove FL via the second interface 3i to facilitate the flow of debris from the fourth chip removal groove FL to the second chip removal groove FL, and allows debris to be transferred from the fourth chip removal groove FL to the second chip removal groove FL via the second interface 3i to be carried along the second chip removal groove FL, thereby removing debris from the first end portion. The third chip removal groove extends from the first end portion 3t to the first interface 3i along the length LT of the first end portion 3t at the second preselected helix angle, and the fourth chip removal groove FL extends from the first end portion 3t to the second interface 3i along the length LT of the first end portion 3t at the second preselected helix angle. The gap between the first chip removal groove FL and the adjacent first end portion 3t is smaller compared to the gap size of the second chip removal groove FL at the middle portion 3m, and the gap between the adjacent second chip removal groove FL and the adjacent first end portion 3t is smaller compared to the gap size of the second chip removal groove FL at the middle portion 3m.

[0125] The first end portion 3t may also have at least one cutting element CE located on the first end 3a and / or a cutting element CE located near the first end 3a of the body 3. For example, the cutting tip portion 13 may include a first cutting element CE positioned in a recess 3n adjacent to the first end 3a in a first chip groove FL, a second cutting element CE positioned in a recess 3n adjacent to the first end 3a in a second chip groove FL, a third cutting element CE positioned in a recess 3n adjacent to the first end 3a in a third chip groove FL, and a fourth cutting element CE positioned in a recess 3n adjacent to the first end 3a in a fourth chip groove FL. The cutting element CE may be composed of a hard material (e.g., carbide material, PCD material, tungsten carbide material, etc.) and may have a preselected or predetermined shape (e.g., generally rectangular or cubic, generally polygonal, etc.).

[0126] Embodiments of the cutting insert 2 can be sized and configured to allow for improved material removal while also providing improved ability to form straight holes. Embodiments can also be configured to facilitate a robust body between the shank of the body 3 and the first end portion 3t of the body 3. Embodiments can also provide more space for fluid conduits FC (e.g., coolant channels) in at least some portions of the cutting tool body 3. For example, the second end portion 3p and the intermediate portion 3m can define internal fluid conduits FC within the body, such that they are spaced further apart within the body, to contribute to improved strength and toughness, and to provide a desired flow path for fluid to pass through the body 3 during operation to aid in cooling the body 3, and to drain from the body 3 during operation to aid in cooling and debris removal.

[0127] Some embodiments can be configured such that the cutting tip of the cutting insert 2 has different apex angles at different heights to facilitate improved cutting operations, thereby allowing for higher throughput cutting of the workpiece. Different cutting apex angles and chip flute configurations can be provided to adjust the volume of chips (e.g., debris, workpiece material cut from the workpiece, etc.) that may be cut during the cutting operation, in order to facilitate improved material removal as the workpiece WP is cut. Utilizing multiple different cutting apex angles and chip flute configurations can also help provide improved straightness in holes or other cavities that may be formed in the workpiece WP.

[0128] 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 cutting body 3, the size and shape of the chip flute FL, and the type of material used for the body 3 can be any of a variety of different options. For example, the type of material used for the body 3 can be any of a variety of suitable materials (e.g., cubic boron nitride, ceramic materials, carbides, sintered carbides, tungsten carbide, steel, other types of hard materials, etc.). As another example, the shape, diameter, and / or width of the movable cutting insert 2 can be adjusted to meet a particular set of design criteria. Therefore, while certain currently preferred embodiments of the cutting device 1, the cutting insert 2, and embodiments for manufacturing and using the cutting device and cutting insert have been shown and described above, it should be clearly understood that the invention is not limited thereto, but can be embodied and practiced in various other ways within the scope of the following claims.

Claims

1. A cutting device, comprising: A body having a cutting tip portion having a shank portion defining a first end of the body, and the shank portion having an intermediate portion between the cutting tip portion and a second end portion of the body opposite to the cutting tip portion; The shank portion has a plurality of chip removal grooves defined on the outer surface of the middle portion of the body, each chip removal groove of the shank portion extending from the adjacent cutting tip portion to the second end portion along a first preselected helix angle, the chip removal grooves of the shank portion including a first chip removal groove of the shank portion and a second chip removal groove of the shank portion. The cutting tip portion has multiple chip removal grooves extending from the first end of the body to the middle portion of the body. The chip removal grooves of the cutting tip portion include a first chip removal groove, a second chip removal groove, a third chip removal groove, and a fourth chip removal groove of the cutting tip portion. The first chip removal groove of the cutting tip portion extends from the first end of the body to the interface, where the first chip removal groove of the cutting tip portion is fluidly connected to the first chip removal groove of the shank portion, such that chips passing along the first chip removal groove of the cutting tip portion can be transferred to the first chip removal groove of the shank portion. The second chip removal groove of the cutting tip portion extends from the first end of the body to the interface, where the second chip removal groove of the cutting tip portion is fluidly connected to the first chip removal groove of the shank portion, so that chips passing along the second chip removal groove of the cutting tip portion can be transferred to the first chip removal groove of the shank portion. The third chip removal groove of the cutting tip portion extends from the first end of the body to the interface, where the third chip removal groove of the cutting tip portion is fluidly connected to the second chip removal groove of the shank portion, so that chips passing along the third chip removal groove of the cutting tip portion can be transferred to the second chip removal groove of the shank portion. The fourth chip removal groove of the cutting tip portion extends from the first end of the body to the interface, where the fourth chip removal groove of the cutting tip portion is fluidly connected to the second chip removal groove of the shank portion, such that chips passing along the fourth chip removal groove of the cutting tip portion can be transferred to the second chip removal groove of the shank portion.

2. The cutting device according to claim 1, wherein the first preselected helix angle is between 5° and 30°, and the second preselected helix angle along which at least some of the chip removal grooves of the cutting portion extend is between 10° and 45°.

3. The cutting device according to claim 2, wherein the chip removal grooves of the cutting tip portion are arranged along the circumference or periphery of the cutting tip portion, such that the first chip removal groove of the cutting tip portion is located between the second chip removal groove and the fourth chip removal groove of the cutting tip portion, and the third chip removal groove of the cutting tip portion is located between the second chip removal groove and the fourth chip removal groove of the cutting tip portion.

4. The cutting device according to claim 1, wherein the first preselected helix angle is different from the preselected helix angle along which the second chip groove extends from the cutting tip portion.

5. The cutting device according to claim 1, wherein the chip removal groove of the shank portion has a larger gap than the chip removal groove of the cutting tip portion.

6. The cutting device of claim 5, wherein the cutting tip portion is removably attached to the shank portion via one or more fasteners.

7. The cutting device according to claim 1, wherein the cutting tip portion has at least one cutting element positioned on the first end.

8. The cutting device according to claim 7, wherein the cutting tip portion includes a first cutting element positioned in a recess defined adjacent to a first end in a first chip removal groove, a second cutting element positioned in a recess defined adjacent to a first end in a second chip removal groove, a third cutting element positioned in a recess defined adjacent to a first end in a third chip removal groove, and a fourth cutting element positioned in a recess defined adjacent to a first end in a fourth chip removal groove.

9. The cutting device according to claim 1, wherein each chip removal groove of the cutting tip portion has a recess for holding the cutting element at the first end of the adjacent body.

10. The cutting device according to claim 1, wherein the body is a cutting blade for a cutting tool.

11. The cutting device according to claim 1, comprising: An actuator that is operably coupled to the body to rotate the body in order to cut material from the workpiece.

12. The cutting device of claim 11, wherein the body is configured to cut one or more holes in a workpiece.

13. The cutting device according to claim 1, wherein the length of the cutting tip portion is 0.5 to 5 times the diameter of the body.

14. A cutting device, comprising: A body having a first end portion, a second end portion opposite to the first end portion, and an intermediate portion between the first end portion and the second end portion, the body having a length extending from a first end of the first end portion to a second end of the second end portion; The body has a plurality of chip removal grooves defined on the outer surface of the body, including a first chip removal groove, a second chip removal groove, a third chip removal groove and a fourth chip removal groove; The first chip removal groove extends along the outer surface of the body from the first end portion to at least the middle portion of the body along the first preselected helix angle; The second chip removal groove extends along the outer surface of the body from the first end portion to at least the middle portion of the body along the first preselected helix angle. The third chip removal groove extends from the first end portion to the first interface between the third chip removal groove and the first chip removal groove, such that the third chip removal groove is in fluid communication with the first chip removal groove via the first interface to facilitate the flow of debris from the third chip removal groove to the first chip removal groove, and such that debris can be transferred from the third chip removal groove to the first chip removal groove via the first interface to be transferred along the first chip removal groove thereby removing the debris from the first end portion. The fourth chip removal groove extends from the first end portion to the second interface between the fourth chip removal groove and the second chip removal groove, such that the fourth chip removal groove is in fluid communication with the second chip removal groove via the second interface to facilitate the flow of debris from the fourth chip removal groove to the second chip removal groove, and such that debris can be transferred from the fourth chip removal groove to the second chip removal groove via the second interface to be transferred along the second chip removal groove thereby removing the debris from the first end portion. The third chip removal groove extends from the first end portion to the first interface along the length of the first end portion and at the second pre-selected helical angle; The fourth chip removal groove extends from the first end portion to the second interface along the length of the first end portion and at the second preselected helix angle; The first pre-selected helix angle may be the same as or different from the second pre-selected helix angle; Compared to the gap size of the first chip removal groove in the middle portion, the gap of the first chip removal groove adjacent to the first end portion is smaller; and The gap of the second chip removal groove adjacent to the first end portion is smaller compared to the gap size of the second chip removal groove in the middle portion.

15. The cutting apparatus of claim 14, wherein the first preselected helix angle is between 10° and 45°, and the second preselected helix angle is between 10° and 45°.

16. The cutting device according to claim 15, wherein the first preselected helix angle is the same as the second preselected helix angle.

17. The cutting device of claim 14, wherein the first end portion is removably attached to the first end of the intermediate portion via one or more fasteners.

18. The cutting device according to claim 14, comprising at least one cutting element positioned on a first end of a first end portion.

19. The cutting apparatus according to claim 18, comprising: A first cutting element positioned in a recess defined at a first end of a first chip removal groove adjacent to a first end portion; a second cutting element positioned in a recess defined at a first end of a second chip removal groove adjacent to a first end portion; a third cutting element positioned in a recess defined at a first end of a third chip removal groove adjacent to a first end portion; and a fourth cutting element positioned in a recess defined at a first end of a fourth chip removal groove adjacent to a first end portion.

20. The cutting device of claim 14, wherein each chip removal groove has a recess for holding the cutting element at the first end of an adjacent first end portion.

21. The cutting apparatus of claim 14, wherein the chip removal grooves include only a first chip removal groove, a second chip removal groove, a third chip removal groove, and a fourth chip removal groove, such that there are four chip removal grooves in the first end portion, which are arranged such that the middle portion has only two chip removal grooves.

22. The cutting apparatus of claim 21, wherein the first interface is defined in a first end portion adjacent to a first end of the intermediate portion, and the second interface is defined in a first end portion adjacent to a first end of the intermediate portion.

23. The cutting device as claimed in claim 1, wherein the cutting tip portion has only four chip removal grooves, and the shank portion has only two chip removal grooves.

24. The cutting device according to claim 23, wherein: The interface between the first chip removal groove of the cutting tip portion and the first chip removal groove of the shank portion is defined as the middle portion adjacent to the shank portion. The interface between the second chip removal groove of the cutting tip portion and the first chip removal groove of the shank portion is defined as the middle portion adjacent to the shank portion. The interface between the third chip removal groove of the cutting tip portion and the second chip removal groove of the shank portion is defined as the middle portion adjacent to the shank portion. The interface between the fourth chip removal groove of the cutting tip portion and the second chip removal groove of the shank portion is defined as the middle portion adjacent to the shank portion.

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