Insert fitter and turning tool equipped with insert fitter

Abstract

To provide a new and improved insert fitter. An insert fitter (32) is configured to securely fasten an insert (16b, FIG. 1) within an insert pocket (14, FIG. 1). The insert fitter (32) is configured to be positioned between the insert (16b) and the insert pocket (14) and includes at least one magnetic surface (48) configured to apply a magnetic force to the insert pocket (14) or a shim (50b, FIG. 47). The magnetic surface (48) may be formed with a magnet (54) that fits within a recess (52, FIG. 8).

Description

[Technical field]

[0001] The subject matter of this application relates to an insert fitter configured for insertion into an insert pocket of a cutting tool. In particular, the subject matter of this application relates to an insert fitter configured to fit a pocket of a standard cutting tool into a pocket configured to hold a smaller insert. [Background technology]

[0002] According to current technology and standards, the insert pocket is typically designed to secure a cutting insert of a single shape and size. In particular, the term "insert" in this specification and claims is a shortened name for a cutting insert, typically made of cemented carbide, for machining. Similarly, the term "insert adaptor" is a adaptor configured for use with a cutting insert in the cutting insert pocket.

[0003] Although the standard insert pocket is designed for a single shape and size insert, there are of course exceptions, at least in US 8,807,884, which discloses an insert pocket designed to accommodate two different insert shapes.

[0004] The present invention differs substantially from US 8,807,884 in that the present invention is directed to an insert adaptor designed to be inserted within an insert pocket between an insert and said insert pocket, rather than an insert pocket which is integrally formed with the tool's insert holder itself.

[0005] US 4,722,642 discloses a spacing adaptor adapted to separate an insert from a wall of an insert pocket of a turning tool. The portion of the spacing adaptor separating the insert from the pocket wall is connected by a weakened portion which may be a break or a reduction in size. The adaptor is manufactured flush with the weakened portion, which connects the adapted portion separating the insert from a recessed wall, the recessed wall being provided such that the adaptor is adaptable to various insert configurations. The portion of the adaptor separating the insert face from the recessed wall has a thickness equal to the amount of material removed from the insert face in one or more regrind operations.

[0006] The present invention differs substantially from US 4,722,642 in that the present invention is not directed to ultra-thin insert adaptors designed to provide very small size differences through a regrinding operation. In particular, regrinding of turning inserts is no longer commonplace in the modern high-precision machining industry, and is perhaps even outdated. The present invention is directed to components of the high-precision industry, and not to what may be called a basic bendable metal spacer of the kind disclosed in US 4,722,642.

[0007] US 4,600,341 discloses an insert adaptor for a standard (ANSI) insert holder. The insert adaptor is configured so that a standard insert pocket can accommodate smaller inserts of the same or different shapes. US 4,600,341 further discloses special clamping assemblies for inserts of various sizes.

[0008] The present invention relates to an improved insert adaptor that was originally developed for a purpose similar to that described in US 4,600,341, namely, to allow smaller inserts to be secured in standard insert pockets of standard insert holders (ANSI, ISO, etc.), however, it will become apparent that some of the advantageous design features are advantageous regardless of this original design purpose. Summary of the Invention

[0009] It is an object of the present application to provide a new and improved insert fitter.

[0010] Smaller, and therefore less expensive, inserts (typically made of a material much more expensive than steel, e.g., cemented carbide) are naturally purchased when it is believed that the desired machining application can be accomplished. Typically, an appropriately sized insert holder (i.e., with an appropriately sized insert pocket) for the selected insert is purchased for a variety of reasons.

[0011] The first reason is that in modern mass production manufacturing, especially in the international metal machining competition for standard inserts and standard tools that every manufacturer can produce, it is self-evident that an insert holder optimized for a specific insert is expected to perform better than an insert holder designed for a general purpose.

[0012] The second reason is that additional components such as the insert adaptor represent a significant added cost.

[0013] A third reason is that machining is typically performed in space-constrained environments, which means that many turrets cannot accommodate insert holders larger than a certain size.

[0014] A fourth reason is that as the number of components in a tool increases, the user friendliness of the tool decreases, since there is a strong possibility that small components will be dropped during assembly or disassembly (known in the art as "dropping parts").

[0015] Finally, as a general rule, additional components will typically reduce the tightness with which the insert is secured to the insert holder, reducing the stability of the machining process and therefore reducing the quality of the finish of the machined product.

[0016] Additive manufacturing techniques have advanced significantly in recent years, enabling the practical production of components that were previously difficult or expensive to manufacture.

[0017] The cost of additively manufactured components still does not reach the precision of standard subtractive machining and is relatively expensive, but such costs decrease as the components are made significantly smaller.

[0018] Here, the hypothesis was made that if an insert adaptor allows a standard turning tool to accommodate a smaller insert (which is more economically efficient if suitable for a given machining application), the cost would be offset by the choice of a standard product, which would simply be the purchase of an additional insert holder for the appropriate size insert.

[0019] However, the "dropping parts" problem mentioned above still needed to be overcome and it was decided to magnetize the insert fitter to ensure that the component would stay in the pocket even when the insert was not secured in the pocket. This also overcame the problem of modifying the existing insert holder.

[0020] While it is known to use magnets to hold components together, it has not previously been known to use them adjacent to cutting inserts typically used in metal workpieces because of problems that can occur when metal chips magnetically stick to a magnetic insert or tool and cause inconvenience or even damage if the chip becomes wedged between the components.

[0021] Thus according to a first aspect of the present invention there is provided an insert fitter for an insert pocket comprising an insert fitter having opposing fitter top and bottom surfaces, and an outer circumferential fitter surface comprising opposing insert abutment surfaces and pocket abutment surfaces, the outer circumferential fitter surface comprising a fitter outer circumferential surface connecting the top and bottom surfaces and an imaginary mid-plane bisecting the top and bottom surfaces, wherein one of the insert abutment surfaces, pocket abutment surfaces and fitter bottom surface comprises a first magnetic surface configured to apply a magnetic force.

[0022] For example, the word "first" as in the paragraph above reciting a "first magnetic surface" should be understood not to require that a "second magnetic surface" must likewise, unless expressly indicated. Such language is used hereinafter for convenience to distinguish elements (e.g., in dependent claims).

[0023] Preferably, the insert abutment surface comprises at least one abutment minor surface protrusion, which may allow a high level of insert stability that modern machining requirements generally require. Even more preferably, for the same reason, the insert fitter comprises a first leg, which in a top view of the insert fitter is straight, and said at least one abutment minor surface protrusion is at least two abutment minor surface protrusions spaced apart by abutment relief recesses.

[0024] Preferably, the insert fitter with the first leg described above can be equipped with a second leg, in which in a top view of the insert fitter, the second leg is straight and non-parallel to the first leg, said second leg being equipped with at least two abutment minor surface protrusions spaced apart by an abutment relief recess. In particular, this provides the insert with contact with the insert fitter in four different locations (i.e. two abutment minor surface protrusions on the first leg and two abutment minor surface protrusions on the second leg). This design was intended to make the insert fitter interchangeable for a right or left insert fitter. However, this design also provided a generally unnecessary phenomenon (also called "over-constraint") of four intentional contact points instead of the traditional three contact points. In fact, during testing, it was discovered that a hard high-precision insert can contact four points. This is because the relatively small insert fitter is resilient, but not plastically deformable like the bendable insert fitter of US 4,722,642, seemingly allowing for more contact, which could theoretically be assisted by an insert clamping method that pulls the insert into the insert fitter via an upper clamp or lever.

[0025] In a plan view of the top surface of the fitter, the first straight leg and the second straight leg may meet at a corner of the insert fitter. This corner may be configured for a desired insert. For example, the corner may be a right angle corner.

[0026] Preferably, at least one abutment secondary surface protrusion extends on both sides of the mid-plane, whereby the insert adaptor is interchangeable and thus suitable for a right or left insert holder, as the case may be.

[0027] Preferably, the first magnetic surface is configured to provide said magnetic force by forming with a first magnet recess, the insert fitter further comprising a first magnet occupying the recess.

[0028] It will be appreciated that the first magnetic surface may be accomplished in other ways, such as by magnetizing the insert adaptor itself, attaching an external magnet to the desired portion of the insert adaptor, etc. The recess feature described above is preferred because the magnet that is surrounded (by the insert adaptor and the surfaces that the first magnetic surface contacts, e.g., shim or insert pocket surfaces) helps to keep the tip from being attracted to the first magnetic surface.

[0029] For similar reasons, the first magnet is preferably fully recessed within the insert fitter such that the outermost surface of the first magnet is either flush with the first magnetic surface or recessed from the first magnetic surface to the inside of the fitter, It will be appreciated that if the magnet protrudes from the insert holder it may prevent proper seating of the insert fitter or create a space in which the tip may become lodged.

[0030] Preferably, the magnet is securely secured within the magnet recess.

[0031] Preferably, the magnet has a basic cylindrical shape.

[0032] Preferably, the insert fitter further comprises a second magnet recess and a second magnet occupying the second magnet recess. It will be appreciated that while a single magnet may be of sufficient magnetic strength to hold the insert fitter to the desired adjacent shim or insert pocket, two spaced apart magnets are believed to be preferred over a single magnet in order to maintain sufficient space for other features of the insert fitter (such as abutment surfaces, note that magnets are generally fragile) and for purposes of proper orientation.

[0033] It should further be pointed out that prior art insert adaptors do not have any magnetic surface since they use an insert clamping mechanism to simultaneously hold the insert adaptor in the insert holder. While one very small magnet is sufficient to hold the insert holder in the insert pocket, the use of multiple magnets still allows for sufficient strength to hold the insert adaptor in the insert pocket even when the insert has been removed and while the insert pocket is being cleaned using pressurized air. At present, there are no known insert adaptors configured to be held in a standard insert pocket even during the application of said pressurized air (i.e., not modified for mechanical fastening, e.g., not provided with a threaded hole for the insert adaptor).

[0034] For similar reasons, it is preferred that the insert fitter comprises a first leg, in a top view of the insert fitter, the first leg is straight and both the first magnet recess and the second magnet recess can be located within the first leg, which in turn provides additional strength during, for example, the application of said pressurized air.

[0035] Preferably, the first magnet recess can be located closer to the bottom surface than the top surface, which can help keep the fragile magnet out of the area where relatively high forces compress the insert adaptor against the insert pocket and / or allow for a thinner / smaller insert adaptor by spacing the magnet away from the abutment portion of the insert adaptor.

[0036] Preferably, one of the insert abutment surface, pocket abutment surface and fitter bottom surface, different from the surface comprising the first magnetic surface, comprises a second magnetic surface configured to apply a magnetic force. For example, the first magnetic surface may be for holding the insert fitter in the insert pocket and the second magnetic surface may be for holding the insert fitter to the shim. One preferred option is for the fitter bottom surface to comprise a second magnetic surface that holds the insert fitter to either the pocket base surface or the shim.

[0037] The second magnetic surface may be configured to provide said magnetic force by being formed with a magnet recess, the insert fitter further comprising a magnet occupying the recess.

[0038] The insert adaptor is preferably metallic. Other materials may be used, but metal may help ensure that magnetic forces do not reach metal tips near the insert pocket.

[0039] The insert adaptor may be preferably configured to be elastic but not plastically deformable. In particular, the prior art inserts of US 4,722,642 are plastically deformable. However, for precision manufacturing, a rigid, pre-defined shape is preferred. It will be appreciated, however, that such thin components may be elastically deformable to some extent.

[0040] According to another aspect, a tool includes an insert, an insert holder, and an insert fitter. The insert fitter may have any of the features described above.

[0041] More precisely, the tool may comprise an insert holder, the insert holder comprising a shank portion and a cutting portion extending from the shank portion. The cutting portion is formed with an insert pocket. The insert pocket comprises a pocket base surface and at least one pocket support surface extending from the pocket base surface. The instrument further comprises an insert fitter according to claim 1 and an insert seated in the insert pocket. The insert abuts against an insert abutment surface of the insert fitter, and the pocket abutment surface of the insert fitter abuts against the insert pocket.

[0042] In one preferred embodiment, the pocket abutment surface comprises a first magnetic surface and the insert fitter is configured to self-secure to the insert pocket by the first magnetic surface.

[0043] In particular, the main envisaged use is for fastening the insert adaptor to a pocket support surface, as shown. Thus, the first magnetic surface is preferably configured to be fastened to the pocket support surface of the insert pocket, or more preferably to two or more pocket surfaces. However, the same benefit may be considered for what is conventionally called a "shim", i.e. a component that is inserted between the insert and the pocket base surface. For the purposes of the specification and claims, unless specified by further features (e.g. the claimed insert adaptor is located between the "shim" and the "pocket abutment surface"), the "insert adaptor" may also refer to what is conventionally called a "shim", i.e. a component that is interposed between the insert and the pocket base surface. However, it will be understood that according to any combination of the claimed features or embodiments, the invention may be defined to exclude the function of a shim. For example, the insert adaptor may be further defined as a so-called lateral insert adaptor, which is configured to be located only between the insert and at least one pocket support surface. In other words, the lateral insert adaptor has no part configured to be located between the insert and the pocket base surface or between them. Alternatively, the present invention may be defined to explicitly include the function of a shim by defining a shim as a shim-insert fitment configured to be positioned at least between the insert and the pocket base surface.

[0044] Additionally, in another method, the insert adaptor may be further defined as a so-called lateral insert adaptor by having an elongated shape, with a height dimension measured perpendicular to the midplane being greater than a width dimension measured along the length of the lateral insert adaptor perpendicular to the height dimension, such dimension being an average dimension in the defined direction.

[0045] The first magnetic surface can be a pocket abutment surface, thereby configuring the insert fitter to be insert-pocket self-locking.

[0046] According to some embodiments, the tool may further include a shim positioned between the insert and the pocket base surface.

[0047] The first magnetic surface may be an insert abutment surface adjacent the shim, thereby configuring the insert fitter to be self-locking to the shim.

[0048] The first magnetic surface can be the fitter bottom surface, thereby configuring the insert fitter to be self-attaching to either the insert pocket or the shim. It will be appreciated that if the fitter bottom surface is adjacent to the pocket, the fitter bottom surface is attached to the pocket, and if the shim is interposed between the fitter bottom surface and the pocket, the first magnetic surface is attached to the shim.

[0049] According to some embodiments, the tool includes a lever that extends through the pocket base surface to hold the insert in the insert pocket. An advantage of such a system is that it allows better chip flow than using the top fastener shown in US 4,600,341, although a completely different lever is required for use when the insert adaptor is not in the pocket. Moreover, such a lever is preferable to the complex top fastener designed for various positions according to the preferred embodiment of US 4,600,341. It is also pointed out that while a conventional simple screw can fasten the insert without impeding chip flow, using an insert adaptor in a standard pocket means that a new screw hole (in a different position) is required for the smaller insert (assuming the hole in the insert is centered).

[0050] According to some embodiments, the tool further comprises a shim in addition to the insert fitter. The shim is located between the insert and the pocket base surface. Preferably, the insert fitter is made of metal and the shim is made of cemented carbide. This allows the insert fitter to include the magnetic forces described above, and the shim can be made of a material that is favorable for protecting the tool from machining damage. Preferably, the metal is steel.

[0051] For a better understanding of the subject matter of the present application, and to show how it may be carried out in practice, reference will now be made to the accompanying drawings, in which: [Brief description of the drawings]

[0052] [Figure 1] FIG. 1 is an isometric view of a standard turning tool having an insert holder, a standard insert with a standard negative abutment shape, a shim, a screw, and a standard lever. [Diagram 2] FIG. 2 is an isometric exploded view of the tool of FIG. [Diagram 3] FIG. 2 is an isometric view of a tool that includes the same insert holder and screw, special insert, and special lever as the tool of FIG. 1, and further includes an insert adaptor with a single bend (i.e., with two straight legs). [Figure 4] FIG. 4 is an isometric exploded view of the tool of FIG. [Diagram 5] FIG. 1 is an isometric view of a turning tool having an insert holder, an insert adaptor with a single bend, a special upper clamp, and a negative special insert with a standard negative abutment shape. [Figure 6] FIG. 6 is an isometric exploded view of the tool of FIG. [Figure 7] FIG. 6 is an isometric view of the insert fitter of FIG. 5 . [Figure 8] FIG. 6 is an isometric exploded view of the insert fitter of FIG. [Figure 9] FIG. 6 is a top view of the insert fitter of FIG. 5 showing hidden lines. [Figure 10]FIG. 6 is a rear view of the insert fitter of FIG. 5 showing the pocket abutment surface. [Figure 11] FIG. 10 is a cross-sectional view taken along line XI-XI of FIG. 9. [Figure 12] FIG. 6 is a front view of the insert fitter of FIG. 5 showing the insert abutment surface. [Figure 13] FIG. 1 is an isometric view of a turning tool having an insert holder, an insert adaptor with a single bend, a special lever, and a special insert, the special insert having a positive cutting feature and a non-standard positive relief abutment feature. [Figure 14] FIG. 14 is an isometric exploded view of the turning tool of FIG. [Figure 15] FIG. 14 is an isometric view of the insert fitter of FIG. 13. [Figure 16] FIG. 14 is an isometric exploded view of the insert fitter of FIG. [Figure 17] FIG. 14 is a top view of the insert fitter of FIG. 13 showing hidden lines. [Figure 18] FIG. 18 is a cross-sectional view taken along line XVIII-XVIII in FIG. 17. [Figure 19] FIG. 19 is a cross-sectional view taken along line XIX-XIX of FIG. 17. [Figure 20] FIG. 1 is an isometric view of a turning tool having an insert holder, an insert adaptor without a bend, a special lever, and a negative special insert with a standard negative abutment shape. [Figure 21] FIG. 21 is an isometric exploded view of the turning tool of FIG. [Figure 22] FIG. 21 is an isometric view of the insert fitter of FIG. 20. [Figure 23] FIG. 21 is an isometric exploded view of the insert fitter of FIG. 20. [Figure 24] FIG. 21 is a top view of the insert fitter of FIG. 20 showing hidden lines. [Diagram 25] FIG. 21 is a rear view of the insert fitter of FIG. 20 showing the fitter abutment surface. [Figure 26] FIG. 26 is a cross-sectional view taken along line XXVI-XXVI in FIG. 24. [Figure 27]FIG. 21 is a front view of the insert fitter of FIG. 20 showing the fitter interior surface. [Figure 28] FIG. 1 is an isometric view of a turning tool having an insert holder, an insert adaptor with a single bend, a special lever, and a negative special insert with a standard negative abutment shape. [Figure 29] FIG. 29 is an isometric exploded view of the turning tool of FIG. [Diagram 30] FIG. 29 is an isometric view of the insert fitter of FIG. 28. [Diagram 31] FIG. 29 is an isometric exploded view of the insert fitter of FIG. 28. [Diagram 32] FIG. 29 is a top view of the insert fitter of FIG. 28 showing hidden lines. [Diagram 33] FIG. 29 is a rear view of the insert fitter of FIG. 28 showing the fitter exterior. [Diagram 34] FIG. 34 is a cross-sectional view taken along line XXXIV-XXXIV in FIG. 32. [Diagram 35] FIG. 33 is a cross-sectional view taken along line XXXV-XXXV of FIG. 32. [Diagram 36] FIG. 29 is a front view of the insert fitter of FIG. 28 showing the fitter interior surface. [Figure 37] FIG. 1 is an isometric view of a turning tool with an insert holder, an insert adaptor with two bends, a special lever, and a negative special insert with a standard negative abutment shape. [Figure 38] FIG. 38 is an isometric exploded view of the turning tool of FIG. [Figure 39] FIG. 38 is an isometric view of the insert fitter of FIG. 37. [Diagram 40] FIG. 38 is an isometric exploded view of the insert fitter of FIG. 37. [Diagram 41] FIG. 38 is a top view of the insert fitter of FIG. 37 showing hidden lines. [Diagram 42] FIG. 42 is a cross-sectional view taken along line XLII-XLII in FIG. 41. [Diagram 43] FIG. 43 is a cross-sectional view taken along line XLIII-XLIII in FIG. 41. [Diagram 44]FIG. 29 is a rear view of the insert fitter of FIG. 28 showing the fitter exterior. [Diagram 45] FIG. 38 is a front view of the insert fitter of FIG. 37 showing the fitter interior surface. [Figure 46] Isometric view of a turning tool with an insert holder, an insert adaptor with a single bend, a special lever, and a negative special insert with an outwardly tapered non-standard abutment shape. [Figure 47] FIG. 47 is an isometric exploded view of the turning tool of FIG. [Figure 48] FIG. 47 is an isometric rear view of the insert fitter of FIG. 46. [Figure 49] FIG. 47 is an isometric exploded rear view of the insert fitter of FIG. 46. [Figure 50] FIG. 47 is an isometric front view of the insert fitter of FIG. 46. [Figure 51] FIG. 47 is an isometric exploded front view of the insert fitter of FIG. 46. [Figure 52] FIG. 47 is a rear view of the insert fitter of FIG. 46 showing the fitter exterior surface. [Figure 53] FIG. 53 is a cross-sectional view taken along line LIII-LIII in FIG. 52. [Figure 54] FIG. 47 is a top view of the insert fitter of FIG. 46 showing hidden lines. [Figure 55] FIG. 53 is a cross-sectional view taken along line LV-LV of FIG. 52. [Figure 56] FIG. 47 is a front view of the insert fitter of FIG. 46 showing the fitter inner surface and the shim abutment surface. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0053] Reference characters may be repeated among the figures to indicate corresponding or analogous elements.

[0054] Attention is directed to Figures 1 and 2. Turning tool 10 includes an insert holder 12 having a pocket 14 configured to secure a single insert 16 of a particular shape and size. The illustrated insert 16 is a standard insert 16a (i.e., the size of standard insert 16a matches the size of pocket 14) and includes an insert top surface 17a, an insert bottom surface 17b, and an insert outer periphery surface 17c extending between insert top surface 17a and insert bottom surface 17b. Insert outer periphery surface 17c includes four lateral abutment surfaces 17d.

[0055] This application generally refers to the insert generally designated "16." For ease of understanding, an insert sized for a particular insert holder 12 will be referred to as a "standard insert" and designated as "16a." Alternatively, a smaller insert (described below) used with the insert adaptor 32 of the present invention will be referred to as a "special insert" and designated as "16b." Both the standard insert and the special insert will generally be referred to by the name and designation "insert 16," with it being understood that this suffixing is merely for convenience and applies to some, but not all, components described below, such as levers, top fasteners, shims, etc., as will be apparent from the context (any suffixes are not generic, with the addition of an "a" suffix referring to components as per the prior art and the addition of a "b" suffix referring to specialized components of the present invention).

[0056] The term "standard" is used herein to indicate that the insert shape, pocket or abutment shape is designed according to a generally accepted standard, such as an ISO or ANSI standard.

[0057] Alternatively, the word "special" is used herein to indicate components that are modified, i.e., different from standard components.

[0058] The insert holder 12 has a cutting portion 18 extending from a shank portion 20. The shank portion 20 is configured to be mounted to and secured by a computer numerically controlled (CNC) machine.

[0059] The insert holder 12, more precisely the cutting part 18, comprises the insert pocket 14 and a fastening mechanism 22 (in this example a standard fastening mechanism 22a), and the standard insert 16a is fixed in the pocket 14 via the standard fastening mechanisms 22, 22a.

[0060] The standardized tightening mechanism 22 according to this exemplary embodiment comprises a tightening member 23, in this case a lever 24 (in this example a standardized lever 24a), and a corresponding lever screw 26 (see Figs. 1-2), which is screwed into the cut-out portion 18 of the insert holder. According to other embodiments of the invention, the standardized tightening mechanism 22 can alternatively comprise a tightening member 23, which is a special upper tightener 28b (Fig. 6), together with a corresponding tightening screw 30.

[0061] Attention is directed to Figures 3-4. Tool 10 may further include an insert fitter 32 that is configured to allow a variety of inserts to be secured within the same insert pocket 14, as will be described further below.

[0062] 2 is configured to secure a standard insert 16a of a first shape and size. In various scenarios, an operator may replace the standard insert 16a with a special insert 16b of a smaller size and possibly a different shape (in this example, the shape is the same). Thus, the standard fastening mechanism 22a described above is no longer suitable for securing the special insert 16b in the same insert pocket 14.

[0063] According to some embodiments, the standard insert 16a is a negative insert having a negative lateral abutment surface 17d. In the context of the present invention, the term negative insert means that the lateral abutment surface 17d is perpendicular to both the insert top surface 17a and the insert bottom surface 17b.

[0064] It will be appreciated that while the special insert 16b may be identical to the standard insert 16a, except for a smaller size, the insert fitter 32 may be configured to abut a smaller insert of the same shape as the standard insert 16a, or a smaller insert having a different shape (not shown). More precisely, the insert fitter 32 comprises what is referred to as an insert abutment surface (FIG. 9), which, as the name suggests, is configured to abut an insert, and the insert abutment surface 38 may be configured for a different insert shape, if desired.

[0065] As illustrated in Figures 3 and 4, the illustrated special insert 16b has the same shape as the larger standard insert 16a and is therefore also a negative insert having a negative lateral abutment surface 17d, as shown, for example, in Figures 1-6, 20-21, 28-29 and 37-38.

[0066] Alternatively, as illustrated in Figures 13 and 14, a different special insert 16b intended for the same insert holder 12 shown in Figures 1 and 2 can have not only a smaller size but also a different abutment shape, which in this case is a positive cutting abutment shape. Another example, i.e., the special insert 16b shown in Figures 46-47, has a negative cutting shape but has a convex abutment protrusion with an outwardly tapered lateral abutment surface 17d. This abutment shape is sometimes referred to as a "dovetail" abutment shape.

[0067] It will be appreciated that the insert fitter 32, or more precisely the insert abutment surface 38 of the insert fitter 32, may be designed to fit the abutment shape as required.

[0068] 3 and 4, as described above, now a different insert 16b is secured to the insert pocket 14 and the standard clamping mechanism 22a is no longer suitable. It will be appreciated that the special insert is smaller than the standard insert and the center of the insert clamping hole 68 is located in a different location relative to the center of the standard insert clamping hole, therefore a different lever is required. Thus, the tool 10 is fitted with the special lever 24b.

[0069] 5 and 6, the cutting portion 18 of the holder may alternatively be of the type that uses an upper fastener. Illustrated is a special upper fastener 28b (FIGS. 5-6) sized for use with an insert fitter 32.

[0070] Rather than the previous suffix system, each insert adaptor 32 is appended with a different suffix (ie, all insert adaptors are not standard components).

[0071] With reference to FIGS. 4-12, the insert adaptor 32a will now be described along with the basic features of all insert adaptors 32 according to the present invention, with any differences noted below for the different embodiments.

[0072] The insert adaptor 32a has a rigid body, or in other words, it is elastic because, although it is made of metal, it is not plastically deformable, or in other words, it is not designed to bend into other shapes.

[0073] The insert fitter 32 a includes opposed fitter top and bottom surfaces 42 and 44 that are connected by the fitter outer periphery 37 .

[0074] An imaginary mid-plane M (FIG. 12) bisects the top surface 42 and the bottom surface 44. The insert fitter 32a may preferably be symmetrical on either side of the mid-plane M, as illustrated here. In other embodiments, such as the embodiment illustrated in FIG. 56, there may be a preference that the insert fitter is not symmetrical on either side of the mid-plane M, as described below.

[0075] The fitter outer periphery 37 includes an insert abutment surface 38 configured to abut the insert and a pocket abutment surface 40 configured to abut the insert pocket 14 .

[0076] The insert fitter 32a is a lateral insert fitter having an elongated shape and a height dimension HD (FIG. 12) measured perpendicular to the midplane that is greater than a width dimension WD (FIG. 9) measured along the length of the lateral insert fitter perpendicular to the height dimension.

[0077] The insert abutment surface 38 may preferably include at least one abutment secondary surface protrusion 43, which is configured to engage with the special insert 16b. More preferably, the insert abutment surface 38 may include two abutment secondary surface protrusions 43 spaced apart by an abutment relief recess 47 (FIG. 7).

[0078] In the illustrated example, the insert adaptor 32a has two legs (i.e., a first leg 36a and a second leg 36b), both of which have the same features (i.e., two abutment minor surface protrusions 43 spaced apart by an abutment escape recess 47).

[0079] The insert adaptor 32, or more precisely the adaptor body 36 of the insert adaptor 32, is preferably made of steel and has a unitary, integral construction. The adaptor body 36 is preferably made by additive manufacturing.

[0080] The fitter body 36 can have an imaginary mid-plane configuration P (FIGS. 9, 17, 26, 35 and 41) passing halfway between the insert abutment surface 38 and the pocket abutment surface 40. According to some embodiments, such as FIG. 24, in top view, the mid-plane configuration P extends in a straight line. According to other embodiments, such as the example shown in FIG. 9, the mid-plane configuration P includes only a single bend 46. This bend 46 divides the mid-plane configuration P into two straight portions (or straight legs) forming a fitter acute angle a1 therebetween. According to further embodiments, such as the one shown in FIG. 41, the mid-plane configuration P includes more than two bends, in particular two bends as shown.

[0081] The insert fitter 32a has a first magnetic surface 48. In the example shown in FIG.

[0082] The first magnetic surface 48 can be configured to provide a magnetic force formed by the first magnet recess 52, and the insert fitter 32 further includes a first magnet 54 occupying the first magnet recess 52.

[0083] It will be appreciated that, alternatively, the entire insert fitter 32 or a portion of the insert fitter 32 may be magnetic. In embodiments in which an actual magnet is used, the insert fitter 32 includes both the fitter body 36 and a magnet 54 secured to the fitter body 36. In this and other examples shown, the attachment is via a magnet recess 52.

[0084] When the first magnet 54 is used as shown, the magnetic force direction provided more precisely by the exposed surface of the magnet (in this example, the magnet end 55 designated in FIG. 10 ) can therefore be controlled in a direction in which the first magnet 54 is not surrounded by the adaptor body 36.

[0085] The first magnet 54 may have a magnetic outer periphery 56 extending between magnetic ends 55. Preferably, the magnet 54 used may have an essentially cylindrical shape. The first magnet 54 may be securely secured within the magnetic recess 52 of the adaptor body 36, preferably via an adhesive.

[0086] For example, as shown in Figures 9 and 11, the first magnet 54 is fully embedded within the insert fitter such that the outermost surface of the first magnet 54 (in this case magnet end 55) is essentially flush with the first magnetic surface 48 or is slightly recessed from the first magnetic surface 48 to the inside of the fitter, as can be better seen in Figure 9. It will be appreciated that magnetic forces are also applied to adjacent surfaces, even if not in contact, as long as the separation distance is slight.

[0087] According to some embodiments, the insert abutment surface 38 may include a first magnetic surface 48 .

[0088] For example, one alternative shown in Figures 46-56 may be such that the insert fitter 32f includes two or more magnetic surfaces. Thus, as shown, the pocket abutment surface 40 may include a first magnetic surface 48 (which may be one or more magnets 54 in the recess 52 as shown) and the insert abutment surface 38 may include a second magnetic surface 48s (which may be one or more magnets 54s in the recess 52 as shown).

[0089] In this example, the second magnetic surface 48s is configured to secure the insert fitter 32f to a shim 50 (which in this example is a special shim 50b).

[0090] Returning to FIG. 4, certain common pocket 14 features are typically a pocket base surface 58, a pocket support surface 60, and fastening holes 62 that open into the pocket base surface 58 and in this example accommodate both the standard lever 24 and the special levers 24a, 24b. The pocket support surfaces 60 extend away from the pocket base surface 58. Each pocket support surface 60 may have one or two separate abutment areas 64 that are configured to abut the insert 16b or to abut the insert fitter 32 when the insert fitter 32 is inserted into the pocket 14. The abutment areas 64 are flat and typically perpendicular or substantially perpendicular (e.g., with a tolerance of up to 1 degree) to the pocket base surface 58.

[0091] The lever screw 26 is configured, when tightened, to force the standard lever 24a or special lever 24b forward to secure the respective standard insert 16a or special insert 16b against the respective abutment area 64 or abutment surface 38 of the insert fitter.

[0092] Please direct your attention to Figures 5-6. The special upper fastener 28b may include an abutment protrusion 66 configured to press against an insert fastener hole 68 rather than a lever.

[0093] In many cases, the pocket 14 may include a shim 50 that sits below the cutting insert 16 on a pocket base surface 58 and separates the two, the pocket base surface 58 and the cutting insert 162. The shim 50 is typically intended to protect at least the pocket base surface 58 from wear resulting from possible insert breakage, but also to protect the workpiece. In some cases, a special shim 50b may be configured to seat or accommodate a special insert 16b in the same pocket 14. The special shim 50b may be configured to accommodate an insert fitter 32.

[0094] The special shim 50b is typically made of a cemented carbide, which is harder than steel, so that the special shim 50b may melt and not damage the workpiece or pocket 14 in the event that the insert breaks.

[0095] Returning to Figs. 3 to 12, according to the first embodiment, the insert fitter 32a has exactly two fitter support surfaces 45 and exactly four abutment subsurface projections 43. The fitter abutment subsurface projections 43 and the support surfaces 45 are parallel or substantially parallel (with a maximum tolerance of 1 degree). This shape is suitable for fixing a negative special insert 16b in a negative pocket 14 originally designed for fixing a negative standard insert 16a. The insert fitter 32a has exactly two magnets 54. Each pocket attracting member 54 is located on the fitter support surface 45. The mid-plane configuration P has exactly one bend 46, so that the fitter 32a is considered to have two legs 36a, 36b. The fitter angle a1 is preferably acute.

[0096] Please direct your attention to Figures 13 to 19. According to the second embodiment, the insert fitter 32a still has two legs 36a, 36b, exactly two fitter support surfaces 45 and four abutment secondary surface projections 43. The abutment secondary surface projections 43 and fitter support surface 45 (Figure 18) on a given leg (leg 36a in Figure 18) can be non-parallel and converge towards the fitter bottom surface 44 (as seen in cross section in Figure 18). This shape is suitable for fixing a special insert 16b with tapered lateral abutment surfaces 17d in a negative pocket 14 that is suitable for fixing a negative standard insert 16a. The insert fitter 32b has exactly four magnets (Figure 16), namely two first magnets 54 on the first leg 36a and two second magnets 54b on the second leg 36b. The mid-plane configuration P has only a single bend 46, which is located in the area where the two legs 36a, 36b join together. The fitter has an internally located fitter angle a1, which is measured on either side of the bend 46. The fitter angle a1 is an acute angle.

[0097] Please direct your attention to Figures 20 to 27. According to the third embodiment, the insert fitter 32c has only one fitter support surface 45 and exactly two abutment secondary surface projections 43. The abutment secondary surface projections 43 and the support surface 45 are parallel or substantially parallel (with a maximum tolerance of 1 degree). This shape is suitable for fixing a negative special insert 16b in a negative pocket 14 that is suitable for fixing a negative standard insert 16a. The mid-plane configuration P has no bends, i.e. a single straight leg, and the fitter 32c appears straight or substantially straight in the top view of the fitter 32c (Figure 24). The fitter angle a1 is equal to 180 degrees. Furthermore, the pocket abutment surface 40 is flat.

[0098] Please direct your attention to Figures 28 to 36. According to the fourth embodiment, the insert fitter 32d has two legs 36a, 36b, exactly two fitter support surfaces 45 and four abutment sub-surface projections 43. The abutment sub-surface projections 43 and fitter support surfaces 45 (Figure 34) on a given leg (leg 36a shown in Figure 34) are parallel or substantially parallel (with a maximum tolerance of 1 degree). This shape is suitable for fixing a negative special insert 16b in a negative pocket 14 that is suitable for fixing a negative standard insert 16a. The insert fitter 32d has exactly two magnets (i.e., the first magnet 54 and the second magnet 54b), i.e., only one magnet on each leg 36a, 36b. The mid-plane configuration P has exactly one bend 46. The fitter angle a1 is an acute angle and is preferably equal to less than 65 degrees.

[0099] Please direct your attention to Figures 37-45. According to the fifth embodiment, the insert fitter 32e has three legs 36a, 36b, 36c, exactly two fitter support surfaces 45, and exactly three abutment secondary surface projections 43. The first leg 36a is between the second leg 36b and the third leg 36c. The first leg 36a forms a first angle with the second leg 36b and a second angle with the third leg 36c. The third leg 36c is at least shorter than the first leg 36a. The abutment secondary surface projections 43 and the fitter support surface 45 (Figure 43) on a given leg 36a, 36b form an angle with respect to each other. This shape is suitable for example for fixing a triangular negative special insert 16b (shown in Figs. 37-38) in the negative pocket 14 which is suitable for fixing a negative standard insert 16a. The mid-plane configuration P has exactly two bends 46. In this example, the first adaptor angle a1 is obtuse and the second adaptor angle a2 is also obtuse (Fig. 41).

[0100] Please direct your attention to Figures 46 to 56. According to the sixth embodiment, the insert fitter 32f has an upper body part 36d adjacent to and comprising the fitter upper surface 42, and a lower body part 36e adjacent to and comprising the fitter bottom surface 44. The fitter 32f has two legs 36a, 36b, exactly two fitter support surfaces 45 (one on each leg), and exactly four abutment secondary surface projections 43 (two on each leg). The abutment secondary surface projections 43 and the fitter support surfaces 45 are not parallel, but can converge towards the fitter bottom surface 44. This shape is suitable for fixing a special insert 16b whose lateral abutment surfaces 17d converge outwards. The sixth embodiment of the fitter 32e is configured to be installed in a negative pocket 14 that is suitable for fixing a negative standard insert 16a. The fitter inner surface 38 has two shim abutment surfaces 70 on its lower portion 36e that are configured to abut the special shim 50b.

[0101] According to the sixth embodiment, the fitter further includes six magnets 54s located on the fitter lower body portion 36e at the insert abutment surface 38. The magnets 54s are configured to hold / attract the shim 50b in the event that the shim 50b is not engaged within the pocket via other means.

[0102] Please direct your attention to Figures 3, 5, 13, 20, 28 and 37. In the clamped or working position of the insert adaptor 32 and the special insert 16b, the special upper clamp 28b or the special lever 24b abuts against the insert fastening hole 68 of the special insert 16b and forces the insert fastening hole 68 against the shim 50, which abuts against the pocket base surface 58. The special insert 16b is also forced against the insert adaptor 32. In particular, the lateral abutment surface 17d abuts against the respective abutment secondary surface projection 43. The adaptor support surface 45 in turn abuts against the respective abutment area 64 located on the pocket support surface 60 of the pocket 14.

[0103] Further, according to the sixth embodiment, the outer peripheral surface of the shim 50b engages a shim abutment surface 70 of the insert fitter 32, as shown in FIG.

[0104] It is also shown that for added strength, the magnets 54 may be arranged in rows, one above the other.

Claims

1. An insert adaptor for an insert pocket, comprising: The insert adaptor includes: Opposing top and bottom adaptor surfaces; a fitter outer periphery having opposing insert abutment and pocket abutment surfaces, said fitter outer periphery connecting said top surface and said bottom surface; an imaginary mid-plane that bisects the top surface and the bottom surface; one of the insert abutment surface, the pocket abutment surface, and the fitter bottom surface includes a first magnetic surface configured to apply a magnetic force; the first magnetic surface is configured to provide the magnetic force by being formed with a first magnet recess; the insert fitter further comprises a first magnet occupying the first magnet recess; the insert abutment surface includes at least one abutment minor surface protrusion; The insert fitter includes a first leg; In a top view of the insert fitter, the first leg is straight; The at least one abutment minor surface protrusion is at least two abutment minor surface protrusions spaced apart by an abutment relief recess.

2. Further comprising a second leg portion, in a top view of the insert fitter, the second leg is straight and non-parallel to the first leg; The insert fitter of claim 1 , wherein the second leg includes at least two abutment minor surface projections spaced apart by an abutment relief recess.

3. the first magnetic surface is further formed with a second magnet recess; The insert fitter of claim 1 , further comprising a second magnet occupying the second magnet recess.

4. The insert adaptor has a first leg, In a top view of the insert fitter, the first leg is straight; The insert fitter of claim 3 , wherein both the first magnet recess and the second magnet recess are located in the first leg.

5. 5. An insert adaptor as claimed in any one of claims 1 to 4, wherein the first magnet is completely embedded within the insert adaptor such that an outermost surface of the first magnet is flush with the first magnetic surface or recessed from the first magnetic surface to the inside of the adaptor.

6. The insert adaptor of any one of claims 1 to 5, wherein the first magnet recess is closer to the bottom surface than to the top surface.

7. An insert fitter as described in any one of claims 1 to 6, wherein one of the insert abutment surface, the pocket abutment surface and the fitter bottom surface, which is different from the surface comprising the first magnetic surface, comprises a second magnetic surface configured to apply a magnetic force.

8. The insert adaptor according to any one of claims 1 to 7, wherein the insert adaptor is made of metal.

9. An insert fitter according to any one of claims 1 to 8, wherein the insert fitter is configured to be elastic but not plastically deformable.

10. The insert adaptor further comprises a lateral insert adaptor having an elongated shape; The insert adaptor of any one of claims 1 to 9, wherein a height dimension measured perpendicular to the midplane is greater than a width dimension measured along a length direction perpendicular to the height dimension of the lateral insert adaptor.

11. A tool, the tool comprising: an insert holder comprising a shank portion and a cutting portion extending from the shank portion; The cutout portion is formed with an insert pocket; the insert pocket comprises a pocket base surface and at least one pocket side support surface extending from the pocket base surface; The tool further comprises an insert adaptor according to any one of claims 1 to 10 and an insert seated in the insert pocket; The insert abuts against the insert abutment surface of the insert adaptor; The pocket abutment surface of the insert fitter abuts the insert pocket.

12. the pocket abutment surface comprises the first magnetic surface; The tool of claim 11 , wherein the insert adaptor is configured to self-secure to the insert pocket by the first magnetic surface.

13. the insert abutment surface or the bottom surface of the adaptor includes a second magnetic surface; 13. The tool of claim 11 or 12, wherein the second magnetic surface is configured to apply a magnetic force such that the insert adaptor self-secures to the insert pocket.

14. a shim positioned between the insert and the pocket base surface; The tool of claim 11 , wherein the first magnetic surface is the insert abutment surface adjacent the shim, and the insert fitter is configured to self-lock to the shim.

15. the first magnetic surface is a bottom surface of the adaptor; The insert adaptor is configured to be secured to either the pocket base surface or the shim; The tool of claim 11 , wherein the shim is included with the tool, and when the insert fitter secures to the shim, the shim is located between the insert fitter and the pocket base surface.

16. a lever extending through the pocket base surface; A tool according to any one of claims 11 to 15, wherein the lever is configured to secure the insert in the insert pocket.

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