A cutting tool insert for machining internal surfaces

Abstract

ABSTRACT A CUTTING TOOL INSERT FOR MACHINING INTERNAL SURFACES The present invention provides a tool insert 100 is defined by the shape of the parallelogram having a curvature 26 on at least one of the flank surface 14. The curvature 26 is provided near to a cutting tip 12 with a desired nose radius 16 and within desired portion of flank surface in accordance 10 with the contour or shape of the profile required for the component. The tool insert 100 is configured with a mounting hole 10 to receive a fastener thereon for mounting the insert 100 with the tool holder.

Description

FIELD OF THE INVENTION-The present invention relates to a cutting tool. More particularly, the present invention pertains to a cutting insert used in metal cutting or machining processes.BACKGROUND OF THE INVENTION:The following background discussion includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.Generally, there is many cutting inserts available for machining internal surfaces of a component. These cutting inserts are removably secured in an insert receiving pocket of a tool holder. Typically, a tungsten steel or a carbide based tool inserts are used for machining a through-hole or for generation of internal profiles in the component. However, with conventional tool insert, the generation of the intricate profile or complex internal geometry for ex. for generating internal contour surface is difficult to achieve, which results in tool fouling and insert gets stuck.Further, due to the straight-flank surface of the conventional tool inserts, the required internal profile of desired dimension is difficult to obtain, which results in increase in wastage or rejection of the machined components as well as increases the machining and tooling cost.There is, therefore, felt a need of a tool insert for the generation of internal profiles on a component and that alleviates the aforementioned drawbacks.OBJECTIVE OF THE INVENTION:The primary object of the present invention is to overcome the drawback associated with prior art.An object of the present disclosure is to provide a cutting tool insert for machining internal surfaces.Still another object of the present disclosure is to provide a provide a cutting tool insert which can generate a desired internal profile while machining.Yet another object of the present disclosure is to provide a cost effective and environment friendly method for determining the amount of ingredients present in a composition.Yet another object of the present disclosure is to provide a cutting tool insert which can minimize the wearing of the tool inserts.Yet another object of the present disclosure is to provide a cutting tool insert which can avoid tool fouling and tool stuck.Still another object of the present disclosure is to provide a cutting tool insert which can improve the productivity of the machining process.Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.SUMMARY OF THE INVENTION:In an aspect of the invention there is provided a cutting tool insert (100) comprises:a. a flank surface (14);b. a curvature (26), wherein the curvature (26) is situated over the flank surface (14)c. a cutting tip (12), wherein the cutting tip (12) has a predetermined nose radius (16) forms contour shape on the portion of the flank surface (14)wherein the curvature (26), the cutting tip (12) and the contour shape with predetermined nose radius (16) on the flank surface (14) together forms shape of a parallelogram or a rhombus for easy movement cutting for generation of internal profiles in the component.In an embodiment, the cutting tool insert (100) comprises a mounting hole (10), wherein the mounting hole (10) is configured to receive fastener for mou8nting the tool insert (100) with the tool holder.In an embodiment, the radius of the curvature formed on the flank surface (14) is 4.25mm.In an embodiment, the length of the desired portion of the flank surface (14) to which the curvature is formed is 4mm.In an embodiment, a wedge angle (20) provided on the tool insert is 55°.In an embodiment, the radius of curvature provided on the cutting tool tip (12) is 0.4mm.In an embodiment, the side clearance angle 18 provided on the tool insert is 7°.In an embodiment, the cutting tool (100) insert is manufactured by the following's steps:a. grinding rough profile of the flank surface of the insert up to a radius of 02mm;b. grinding rough profile grinding up to a radius of 04.20mm; andc. grinding profile to generate a curvature up to a radius of 4.25mm.In an aspect of the invention there is provided a method of operation of cutting tool insert (100), comprising steps of:a. forming a curvature (26) over the flank surface (14);b. forming a cutting tip (12) with a predetermined nose radius (16) and forming contour shape on the portion of the flank surface (14)wherein jointly forming shape of a parallelogram or a rhombus curvature (26) by combining the cutting tip (12) and the contour shape on the flank surface together for easy movement cutting for generation of internal profiles in the component.DETAIL DESCRIPTION OF THE DRAWINGS:To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings in which:Figure 1: illustrates conventional tool insert (prior art) with a straight flank surface;Figure 2: illustrates a perspective view of a cutting tool insert in accordance with an embodiment of the present invention;Figure 3: illustrates a perspective view of a cutting tool insert in accordance with an exemplary embodiment of the present invention; andFigure 4A and Figure 4B: illustrates internal profile generation on a component (before and after encircled) by means of the tool insert in accordance with an embodiment of the present invention.LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING100 Present tool insert50 conventional tool insert10 cutter mounting hole12 Cutting tool tip14 Flank surface16 Nose radius18 side clearance angle20 wedge angle22 component24 Internal profile26 curvatureDETAILED DESCRIPTION:For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.In an aspect of the invention there is provided a cutting tool insert (100) comprises:a. a flank surface (14);b. a curvature (26), wherein the curvature (26) is situated over the flank surface (14)c. a cutting tip (12), wherein the cutting tip (12) has a predetermined nose radius (16) forms contour shape on the portion of the flank surface (14)wherein the curvature (26), the cutting tip (12) and the contour shape with predetermined nose radius (16) on the flank surface (14) together forms shape of a parallelogram or a rhombus for easy movement cutting for generation of internal profiles in the component.In an embodiment, the cutting tool insert (100) comprises a mounting hole (10), wherein the mounting hole (10) is configured to receive fastener for mou8nting the tool insert (100) with the tool holder.In an embodiment, the radius of the curvature formed on the flank surface (14) is 4.25mm.In an embodiment, the length of the desired portion of the flank surface (14) to which the curvature is formed is 4mm.In an embodiment, a wedge angle (20) provided on the tool insert is 55°.In an embodiment, the radius of curvature provided on the cutting tool tip (12) is 0.4mm.In an embodiment, the side clearance angle 18 provided on the tool insert is 7°.In an embodiment, the cutting tool (100) insert is manufactured by the following's steps:a. grinding rough profile of the flank surface of the insert up to a radius of 02mm;b. grinding rough profile grinding up to a radius of 04.20mm; andc. grinding profile to generate a curvature up to a radius of 4.25mm.In an aspect of the invention there is provided a method of operation of cutting tool insert (100), comprising steps of:a. forming a curvature (26) over the flank surface (14);b. forming a cutting tip (12) with a predetermined nose radius (16) and forming contour shape on the portion of the flank surface (14)wherein jointly forming shape of a parallelogram or a rhombus curvature (26) by combining the cutting tip (12) and the contour shape on the flank surface together for easy movement cutting for generation of internal profiles in the component.Typically, a tungsten steel or a carbide based tool inserts are used for machining a through-hole or for generation of internal profiles in the component. However, with conventional tool insert 50, the generation of the intricate profile or complex internal geometry for ex. generating internal contour surface is difficult to achieve, which results in tool fouling and insert gets stuck. Further, due to the straight-flank surface 14 of the conventional tool insert 50, the required internal profile of desired dimension is difficult to obtain, which results in increase in wastage or rejection of the machined components as well as increases the machining and tooling cost. Figure 1 illustrates a conventional tool insert (prior art) with a straight flank surface.The figure 1 shows the conventional tool insert 50 with a straight flank surface 14 near to a cutting tool tip 12. Due to the straight flank surface 14 in the conventional tool inserts 50, it is difficult to generate different internal profiles since the straight flank surface creates obstruction and does not provide any recess for the tool movement.Therefore, the present disclosure envisages a cutting tool insert ((hereinafter referred to as "tool insert 100") for internal machining. Figure 2 illustrates a perspective view of a cutting tool insert in accordance with an embodiment of the present invention.The cutting tool insert 100 as shown in the figure 2 is a composed of a suitable hard cutting material, such as tungsten carbide. The tool insert 100 is shaped in such a way that a crosssection of the insert 100, as shown in the figure. 2, is substantially in the shape of a parallelogram or a rhombus, when viewed from any of the ends of the insert 100. As shown in the figure 2, the tool insert 100 is defined by the shape of the parallelogram having a curvature 26 on at least one of the flank surface 14. The curvature 26 is provided near to a cutting tip 12 with a desired nose radius 16 and within desired portion of flank surface in accordance with the contour or shape of the profile required for the component. The tool insert 100 is configured with a mounting hole 10 to receive a fastener thereon for mounting the insert 100 with the tool holder.In one embodiment, the insert 100 is provided with a desired side clearance angle to avoid rubbing of the tool insert 100 with the component, as shown in the figure 2.In another embodiment, the insert 100 is configured with a desired wedge angle to provide proper strength to the cutting tool tip.Further, Figure 3 illustrates a perspective view of a cutting tool insert 100 in accordance with a preferred embodiment of the present disclosure.In an embodiment, the radius of the curvature formed on the flank surface 14 is 4.25mm.In another embodiment, the length of the desired portion of the flank surface 14 to which the curvature is formed is 4mm.In another embodiment, the wedge angle 20 provided on the tool insert is 55°.In another embodiment, the radius of curvature provided on the cutting tool tip 12 is 0.4mm.In another embodiment, the side clearance angle 18 provided on the tool insert is 7°.Further, the present cutting tool insert is manufactured by a list of machining operation as follows:• first Rough profile grinding of the flank surface of the insert up to a radius of 02mm;• secondly Rough profile grinding up to a radius of 04.20mm;• Finally, Finish profile grinding to generate a curvature up to a radius of 10 4.25mm.Other machining processes to achieved abovementioned geometries are also included in the scope of present invention.In an embodiment, a curvature of radius 06mm can be achieved by following the above mentioned machining operations.Advantageously, since the tool insert 100 is provided with the curved flank surface, therefore it provides proper recess for the tool insert 100 during generation of internal profile as shown in Figure 4. The Figure 4A and Figure 4B illustrates internal profile generation on a component (before and after encircled) by means of the tool insert in accordance with an embodiment of the present disclosure.TECHNICAL ADVANCEMENTS AND ECONOMICAL SIGNIFICANCEThe present disclosure described herein above has several technical advantages including, but not limited to, the realization of a cutting tool insert for machining internal surfaces, that:• generate a desired internal profile while machining;• minimize the wearing of the tool inserts;• improves the surface roughness of the internal machined component;• avoid tool fouling and tool stuck; and• improves the productivity of the machined component.Throughout this specification the word "comprise", or variations such as "comprises" or "comprising, will be understood to imply the inclusion of a stated element, integer or step," or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

1. A cutting tool insert (100) comprises: a. a flank surface (14); b. a curvature (26), wherein the curvature (26) is situated over the flank surface (14) c. a cutting tip (12), wherein the cutting tip (12) has a predetermined nose radius (16) forms contour shape on the portion of the flank surface (14) wherein the curvature (26), the cutting tip (12) and the contour shape with predetermined nose radius (16) on the flank surface (14) together forms shape of a parallelogram or a rhombus for easy movement cutting for generation of internal profiles in the component.

2. The cutting tool insert (100) as claimed in claim 1, wherein cutting tool insert (100) comprises a mounting hole (10), wherein the mounting hole (10) is configured to receive fastener for mou8nting the tool insert (100) with the tool holder.

3. The cutting tool insert (100) as claimed in claim 1, wherein the radius of the curvature formed on the flank surface (14) is 4.25mm.

4. The cutting tool insert (100) as claimed in claim 1, wherein the length of the desired portion of the flank surface (14) to which the curvature is formed is 4mm.

5. The cutting tool insert (100) as claimed in claim 1, wherein a wedge angle (20) provided on the tool insert is 55°.

6. The cutting tool insert (100) as claimed in claim 1, wherein the radius of curvature provided on the cutting tool tip (12) is 0.4mm.

7. The cutting tool insert (100) as claimed in claim 1, wherein the side clearance angle 18 provided on the tool insert is 7°.

8. The cutting tool insert (100) as claimed in claim 1, wherein the cutting tool (100) insert is manufactured by the following's steps: d. grinding rough profile of the flank surface of the insert up to a radius of 02mm; e. grinding rough profile grinding up to a radius of 04.20mm; and f. grinding profile to generate a curvature up to a radius of 4.25mm.

9. A method of operation of cutting tool insert (100) as claimed in claim 1, comprising steps of: a. forming a curvature (26) over the flank surface (14); b. forming a cutting tip (12) with a predetermined nose radius (16) and forming contour shape on the portion of the flank surface (14) wherein jointly forming shape of a parallelogram or a rhombus curvature (26) by combining the cutting tip (12) and the contour shape on the flank surface together for easy movement cutting for generation of internal profiles in the component.