Method for manufacturing a tool part and such a tool part

Abstract

The present disclosure relates to a method for manufacturing a metal cutting tool component, the method including the steps of manufacturing a front module (70) having a body (57) and a front module interface (63) at a rear end thereof, the steps including providing an intermediate element (58) including the steps of providing the front module interface (63) at a rear end thereof and a build surface (52) at a front end thereof, and building the body (57) on the build surface (52) of the intermediate element (58) using an additive manufacturing process. The method further includes the steps of providing a rear module (68) including providing a coupling piece (66) at a rear end and a rear module interface (65) at a front end, and after manufacturing the front module and providing the rear module (68), attaching a front module (70) to the rear module (68) by rigidly connecting the front module interface (63) and the rear module interface (65), and after the front module (70) is attached to the rear module (68), machining at least one surface of the body (57) and heat treating the intermediate element (58) having the constructed body (57), whereby at least the body (57) is hardened. The present disclosure also relates to a metal cutting tool component.

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a metal cutting tool component and to such a metal cutting tool component. [Background technology]

[0002] Conventionally, cutting tool components, such as cutting tool bodies for holding cutting inserts, are typically manufactured from a suitable steel, aluminum or titanium blank. The blank is machined to its final shape within desired tolerances by suitable milling, turning, drilling and / or grinding operations. These operations can be time consuming, and to avoid the need to remove more material than necessary, often only certain types of blanks are used for certain types of tool bodies. If it is intended to manufacture only a small number of tool bodies of the type in question, creating and manufacturing a suitable blank can be costly and laborious. Similarly, extending a machining operation due to the use of a less suitable blank can be costly and laborious.

[0003] It is therefore desirable to be able to use additive manufacturing processes for tool bodies that are manufactured in limited numbers. In some cases, the tool body comprises a standardized rear coupling part for connection with a complementary coupling part of another component or machine, and a front cutting head. Such a tool body can be manufactured by building both the coupling part and the cutting head in an additive manufacturing process. Another option is to manufacture the coupling part separately by conventional manufacturing, including machining a coupling part blank, and then build the cutting head on the coupling part. Usually, after the tool body or its cutting head is built in an additive manufacturing process, the tool body must be heat treated to provide sufficient mechanical strength and wear resistance. The problem with this is that the heat treatment process can affect the dimensional tolerances of the coupling parts. Summary of the Invention

[0004] The object of the present invention is to at least partially avoid the above-mentioned problems. This object is achieved according to the invention by a method according to claim 1 and a tool component according to claim 13.

[0005] According to a first aspect of the present invention there is provided a method of manufacturing a metal cutting tool component comprising the steps of: - manufacturing a front module comprising a body and a front module interface at a rear end, - providing an intermediate element comprising a front module interface at its rear end and a build surface at its front end; - building a body on a build surface of the intermediate element using an additive manufacturing process; and - providing a rear module, the rear module comprising a coupling element at a rear end and a rear module interface at a front end; - manufacturing the front module and, after providing the rear module, attaching the front module to the rear module by rigidly connecting the front module interface and the rear module interface; - machining at least one surface of the body after the front module has been attached to the rear module; - heat treating the intermediate element having the constructed body, in which at least the body is hardened; The present invention provides a method of manufacturing the same.

[0006] The method therefore includes providing an intermediate element by means of which it is possible to provide a metal cutting tool component in the form of a connectable module. The interface between the front module and the rear module does not have to comply with tight tolerances. Instead, it is sufficient that the interface provides a reliable connection so that the modules can be immovably fixed relative to each other. This allows the body to be built on the build surface of the intermediate element to form the front module. After the front module is manufactured, it is attached to the rear module by connecting the front and rear module interfaces. In particular, the interfaces of the modules are arranged to immovably connect the modules. At least one surface on the body is then machined. Thus, the surface is machined to the desired dimensions and alignment only after the modules are connected. This is also advantageous in that the rear module can be used to transport the front module to a machining station where at least one surface of the front module is machined.

[0007] Furthermore, since the front module is heat treated separately from the rear module, the rear module, which may have parts that are sensitive to the heat treatment process, such as coupling parts, does not need to be subjected to heat treatment. During the heat treatment of the front module, at least the body is hardened.

[0008] According to a second aspect of the present invention, a front module including a body manufactured and hardened by an additive manufacturing process and a front module interface at a rear end thereof; a rear module having a coupling part at a rear end and a rear module interface at a front end; Including, the front module and the rear module are fixedly connected at a front module interface and a rear module interface; - Providing a metal cutting tool component, the body of which is provided with at least one machined surface.

[0009] Thanks to the cutting tool component comprising two modules, it is possible to manufacture them separately, connect them and machine at least one surface of the body according to the method of the invention. Furthermore, the front module can be heat treated to harden the body when separated from the rear module, without affecting the dimensions of the rear module by the heat treatment. This results in a tool that can be fitted to tight tolerances and is cost-effective to manufacture even when produced in limited numbers.

[0010] The tool component manufactured by the method of the invention may be the front part of a cutting tool, such as comprising a cutting head, including a cutting edge or seat for a cutting insert. The tool component may be a holder, or part of a holder, for example for holding a cutting head. The tool component may be an extension or an adapter, or may itself constitute a metal cutting tool. Thus, a metal cutting tool component is a component used in a configuration for cutting metals. This configuration is suitable for cutting metals, but can also be used for cutting other materials, such as composites.

[0011] The method steps for manufacturing the front module can be performed in any suitable order, unless otherwise stated in the claims. Thus, the intermediate element can be provided as a complete component with a front module interface and a build surface, or the intermediate element can be provided as a blank, after which the front module interface and / or the build surface are manufactured. For example, the build surface can be machined after the intermediate element is provided, and the front module interface can be manufactured before or after the body is built, and / or before or after curing, e.g., by conventional machining. In an embodiment, both the intermediate element and the body are built using an additive manufacturing process, e.g., in separate processes or in a single continuous process.

[0012] Similarly, the rear module may be provided as a complete component with the rear module interface and coupling components, or the rear module may be provided as a blank, after which the rear module interface and coupling components are manufactured. For example, the rear module may be provided as a blank including the coupling components, and the interface is then manufactured, for example, by conventional machining. However, once the coupling components are manufactured, the method of the present invention advantageously does not require the rear module to be subjected to hardening or other operations that may affect the dimensions of the coupling components.

[0013] The rear module may be of any suitable material, such as a metal, for example steel.

[0014] The coupling part may be one of a coupling including two complementary parts, such as a Capto® coupling (conical or open), a screw coupling, or one of the rounded triangular coupling parts known as a dovetail coupling. However, other components may also be required to complete the coupling, such as, for example, a lock in the form of a screw or a clamp.

[0015] The front module is attached to the rear module by a permanent connection between the front module interface and the rear module interface. The connection at the interface can be removable, or a semi-permanent or permanent connection.

[0016] Machining at least one surface and / or any other features of the front or rear module may include, for example, milling, turning, drilling, grinding or boring. Preferably, the machining includes machining to precise tolerances.

[0017] In an embodiment, the surface, and possibly other parts or parts of the metal cutting tool component, may be subjected to one or more post-processing steps, which may include turning, milling, drilling, blasting, grinding, finishing, coating, EDM, cladding and / or measurement operations.

[0018] Preferably, the step of building the body comprises using an additive manufacturing process in the form of powder bed fusion of a printable and hardenable steel powder. Such a method advantageously allows the use of an intermediate element of steel, which can be conventionally machined, and the body to be printed on the build surface. Preferably, the body and the intermediate element comprise the same printable steel. In another preferred method, the powder is deposited on the surface with directed energy deposition (DED). A laser is used to fuse the steel powder with the build surface and the underlying powder. However, an electron beam can also be used.

[0019] In additive manufacturing methods in the form of binder jet printing, the object cannot be directly connected to the build surface during printing. This must be done, for example, by sintering or mechanical bonding after the object has been built. Such methods, while still possible, are less preferred.

[0020] The hardening step can be carried out by any suitable hardening process that achieves the desired properties of the material in question. The hardening process is heating. The desired material properties can be a particular mechanical strength and / or wear resistance.

[0021] The powder can be any powder material suitable for cutting tool components, capable of being used in additive manufacturing processes, and hardenable. Preferably, the powder is a printable steel powder, such as a maraging steel powder. For powder bed fusion, the nominal powder size is typically between 10 μm and 70 μm. For electron beam fusion, the nominal powder size is typically between 45 μm and 110 μm. For DED processes, the nominal powder size is typically between 50 μm and 110 μm.

[0022] Due to the method of the present invention involving manufacturing two connectable modules, the front module may include printable material that is not compatible with being printed on top of the rear module having coupling components.

[0023] Preferably, the hardening step involves heating to 450°C to 600°C. Heating can be performed for any suitable time. Typically, the hardening heat treatment lasts from a few minutes to a few hours, depending on the temperature. This achieves good mechanical strength for the preferred powder of printable and hardenable maraging steel.

[0024] Preferably, the step of machining at least one surface of the body is carried out after the step of curing the intermediate element with the built body, which is advantageous in that any dimensional deviations or inconsistencies caused by the additive manufacturing method and / or curing can be taken into account.

[0025] In other embodiments, for example, if the front module is feasibly connected to the rear module at an interface, the front module may be connected to the rear module before being cured. At least one surface of the body is then machined. The front module is then cut off and cured separately from the rear module. The front module can then be connected to the same or another rear module. These embodiments are advantageous because the machining of the at least one surface is performed in the softer state of the body. The embodiments are most suitable for body materials that do not deform much during curing, or for applications that do not require tight tolerances.

[0026] According to an embodiment, providing the coupling part on the rear module includes providing a coupling part having a reference axis, and the machining step includes machining at least one surface to a precise position and extent relative to the reference axis. This advantageously ensures that the surface is precisely positioned and aligned with other surfaces or parts that are also positioned with respect to the reference axis. Preferably, when the rear module is coupled with a complementary coupling part, the reference axis coincides with or is in a known relationship to the reference axis of the complementary coupling part. The at least one surface can then be machined to be precisely positioned and aligned with other surfaces or parts of the component that have complementary coupling parts positioned with respect to their reference axes.

[0027] The reference axis is typically perpendicular to the parting plane between the metal cutting tool component and the component to which it is coupled. Typically, the reference axis is also perpendicular to the parting plane between the front and rear modules at the interface. The reference axis can be the axis on which the active face of the coupling part is located and aligned to the reference. For example, in a threaded coupling or a conical rounded triangular coupling known as a Capto® coupling, the reference axis is the central axis of the thread or the Capto® cone / opening. In a dovetail coupling, the reference axis is an axis perpendicular to the parting plane. In embodiments in which the body and intermediate element are centered about a common longitudinal axis, the common longitudinal axis and the reference axis typically coincide. In other embodiments, the reference axis of the coupling part can extend at an angle relative to the longitudinal axis of the intermediate element and / or the body. In an embodiment, the intermediate element can have a substantial extension laterally relative to the longitudinal axis of the body. In such an embodiment, the reference axis of the coupling part can extend, for example, parallel to the longitudinal axis of the body.

[0028] In this application, the term axis of an object is not limited to the length of the object, but instead may require the axis to continue to coincide with or form an angle with another axis.

[0029] In an embodiment, the body is constructed in the form of a cutting head, and machining the surface comprises machining a support surface for a cutting insert. A corresponding inventive tool component comprises such a cutting head. The cutting head can be, for example, a cutting head of a milling tool, a drilling tool, a boring tool or a turning tool. The method is advantageous when it is desired to have a metal cutting tool component with a cutting head specially designed for a specific purpose. Thanks to these method steps, such a tool component can be manufactured in a time- and cost-efficient manner with the same tolerances of coupling parts and cutting edge positions as conventional machined tool components.

[0030] However, in other embodiments, machining at least one surface may include, for example, machining a component surface or a guide surface of the front coupling component.

[0031] According to an embodiment, the step of providing the coupling part on the rear module comprises providing the coupling part in the form of a part of a removable machine tool coupling. Thus, the metal cutting tool component may be part of a tool that is connected to a machine tool, such as a machine, e.g. a CNC machine, for milling, turning, drilling and / or grinding, e.g., a metal or composite workpiece.

[0032] Preferably, the coupling part is part of a removable machine tool coupling and at least one surface has a dimensional deviation of less than ±50 μm, preferably less than ±20 μm, more preferably less than ±5 μm.

[0033] Examples of couplings of some forms of removable machine tool couplings are Capto® couplings, HSK couplings, steep taper couplings, Big Plus couplings, or conical rounded triangular couplings known as ISO cone couplings. This advantageously allows at least one machined surface on the body to be machined to close to or match a desired tolerance with respect to the location of the machine interface. Thus, in an embodiment where the body is a cutting head, the insert seat can be machined to be aligned and positioned with respect to the reference axis of the removable machine tool coupling part, and therefore also with respect to the machine. In other embodiments, the rear module coupling part can also be used to couple metal tool components to other parts other than the machine, such as extensions or adapters. Also, in such embodiments, it may be important that the surface of the body is carefully aligned and positioned with respect to the component that contains the complementary coupling part.

[0034] According to an embodiment, the step of providing the intermediate element comprises providing an intermediate element having a flat building surface with a central building surface normal, which may be aligned with, angled or parallel to a reference axis of the coupling part of the rear module.

[0035] According to an exemplary embodiment, when the central construction surface normal extends at an angle to the reference axis, building the body on the construction surface includes vertically positioning an intermediate element having the central construction surface normal and then building the body on the construction surface.

[0036] By using such an intermediate element and arranging it according to the method steps, it is possible to manufacture the body in the vertical direction, even if the body extends at an angle to the reference axis of the coupling part and possibly also to the central longitudinal axis of the intermediate element. For example, the central construction surface normal can extend at an angle of 45° to 90° to the reference axis. Thus, if the reference axis coincides with the longitudinal axis of the intermediate element, the body can be manufactured in the vertical direction, despite extending at such a large angle to the longitudinal axis of the intermediate element. By providing such an intermediate element, advantageously, a body with parts extending at an angle of 45° to 90° to each other can be manufactured by additive manufacturing. In general, it is difficult to build a body with an angle of more than 45° to the vertical without a support structure, which makes the manufacturing more complicated. It is therefore considered difficult to manufacture a body with parts with an angle of more than 45° to each other by additive manufacturing.

[0037] In an exemplary embodiment of the cutting tool component, the body has a front portion with a central front longitudinal axis, and the coupling piece has a reference axis, with the central front longitudinal axis extending at an angle to the reference axis or parallel to the side of the reference axis. For example, the central front longitudinal axis can extend at an angle of 45° to 90° to the reference axis. These are desired shapes that can be achieved in a cost-effective manner by the manufacturing method of the present invention.

[0038] However, the present invention is also beneficial for conventional configurations in which the central front longitudinal axis is aligned with the reference axis.

[0039] According to an embodiment, the front module interface at the intermediate element can be located at a rear surface having a rear surface normal. In an embodiment, the rear surface normal of the intermediate element can coincide with a reference axis of the coupling part of the rear module. In an embodiment, the construction surface normal and the rear surface normal can be aligned or extend at an angle to each other or parallel to each other.

[0040] According to an embodiment, the step of providing an intermediate element includes the steps of providing an intermediate element blank of maraging steel and machining the intermediate element blank to form the front module interface and the build surface. Thus, according to this embodiment, the intermediate element is manufactured separately using a conventional subtractive machining operation on the steel blank. For an intermediate element comprising maraging steel, the intermediate element is suitable for use in the manufacturing method of the present invention, which includes building a body by a layering method using the same type of material and then hardening. The material of the intermediate element provides an intermediate element suitable for building a body on the build surface by powder bed fusion using printable maraging steel powder, as the steel of the build surface melts and fuses together with the powder so that the front module forms an integral unit. Then, when the latter step intermediate element hardens together with the built body, the intermediate element and the body react, similar to the hardening process.

[0041] Another advantage of this embodiment is that the intermediate element can act as a support for printing the body, thereby eliminating the need for a removal step common in the prior art to remove the printed object from the build platform. Moreover, the intermediate element can advantageously also act as a support for transporting the body from the printing station to the curing station.

[0042] The front module interface and the rear module interface can be of any kind that eliminates movement between the front and rear modules when connected to each other. In an embodiment, the interface is removable so that the front and rear modules can be separated. The interface can be self-locking or prevent relative movement of the modules by additional means such as screws or clamps. In some applications, the tolerance that can be achieved by the interface is sufficient for at least one surface to be machined when the front module is attached to the first rear module. The front module is then disconnected and cured. The front module can then be transferred to the second rear module for use therewith. In other embodiments, the front and rear modules are permanently and immovably connected to each other at the interface. The modules can be permanently or semi-permanently connected by fixed screws, welding, soldering, adhesives, etc.

[0043] According to an exemplary embodiment, the step of providing the intermediate element with a front module interface includes providing the front module interface in the form of saw teeth on the rearward facing rear surface, and the step of providing the rear module with a rear module interface includes providing the rear module interface in the form of saw teeth on the forward facing front surface, the saw teeth being complementary to the saw teeth of the front module interface. Moreover, a preferred embodiment of a metal cutting tool mars such an interface. This is a reliable and simple interface that can provide sufficient tolerances for most applications of the invention. Preferably, the modules are held immovably together at the interface by screws that press a set of saw teeth on the rear end of the front module into a complementary set of saw teeth on the front end of the rear module. Such an interface can be released by unlocking the screws so that the modules can be separated again. However, it is also possible to use permanent fixing screws that cannot be unscrewed.

[0044] In an embodiment of a metal cutting tool component produced by the method of the present invention, the front module comprises 3D printed hardened maraging steel and the rear module comprises conventionally produced steel.

[0045] Exemplary embodiments will now be described in more detail with reference to the accompanying drawings. [Brief description of the drawings]

[0046] [Figure 1] 1 is a schematic diagram of an embodiment of a manufacturing method for producing a metal cutting tool component in the form of a cutting tool comprising a cutting head; [Diagram 2] 2 is a flow chart of the embodiment shown generally in FIG. 1; [Diagram 3] 4 is a flow chart of a second exemplary embodiment of a method for manufacturing a metal cutting tool component. [Figure 4] FIG. 1 is a schematic diagram of an embodiment of a metal cutting tool component in the form of a turning tool including a cutting head. [Diagram 5] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; [Figure 6] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; [Figure 7] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; [Figure 8] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; [Figure 9] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; [Figure 10] FIG. 2 is a schematic diagram of an embodiment of a metal cutting tool component manufactured by a method according to the first or second embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] All figures are schematic, not necessarily to scale, and generally show only those parts necessary to elucidate the respective embodiment, while other parts may be omitted or merely suggested. Unless otherwise indicated, like reference signs refer to like parts in different figures.

[0048] 1 and 2, a first exemplary embodiment of a method for manufacturing a metal cutting tool component comprising a front module 70 and a rear module 68 will now be described.

[0049] In step 1, an intermediate element blank 51 is provided. The blank 51 comprises printable maraging steel and is a solid cylindrical element. However, the intermediate element blank 51 can have any suitable shape, such as a square or rectangular cylinder, and can have a cavity.

[0050] In step 2, the intermediate element blank 51 is machined. A milling tool 53 is used to form the build surface 52 at the front end and the front module interface 63 in the form of sawtooth at the rear end. The sawtooth forms sets of alternating elongated ridges and grooves. The sets in the exemplary embodiment include a plurality of linear ridges extending across the rear end. A drill 61 is used to drill two through holes 62 through the intermediate element blank 51. These machining operations provide the intermediate element 58.

[0051] The intermediate element 58 has an axis which in the exemplary embodiment coincides with the central longitudinal axis 76 of the intermediate element. The sawtooth forming the forward module interface 63 is formed in the flat rear end face. The plane of the rear end face is parallel to the parting plane between the modules at the interface when the forward module 70 is connected to the rear module 68. The plane of the rear end face has a central rear end face normal 69 which in the exemplary embodiment coincides with the central longitudinal axis 76 of the intermediate element 58. The build face is flat and machined to extend at an angle to the plane of the rear end face. The central build face normal 55 extends at an angle α of 50° to the central rear end face normal 69. The two through holes 62 extend approximately parallel to the central longitudinal axis 76 from the build face 52 at the forward end to the forward module interface 63 at the rear end.

[0052] In step 3, an intermediate element 58 is placed in a setup for powder bed fusion of printable and hardenable steel powder, and a body 57 is printed onto the build surface 52. The intermediate element 58 is positioned such that the build surface normal 55 extends vertically. The printing setup includes a support device 56 for holding the intermediate element 58 firmly in this position.

[0053] The printing method includes spreading powder on the build surface layer by layer. A laser 59 with a laser beam 60 is positioned to move over each layer and fuse the powder to the build surface 52 or, for successive layers, to the layer below. In an exemplary embodiment, the powder used to build the body 57 is the same material as the intermediate element 58 comprises. In an exemplary embodiment, the body 57 is built in the form of a cutting head for a turning tool in the printing method.

[0054] Once the step of constructing the body 57 is finished, in step 4, the intermediate element 58 with the constructed body 57 is placed in an apparatus 60 for hardening. During hardening, the intermediate element 58 with the constructed body 57 is heated to 500°C. This achieves good mechanical strength of the body, which comprises the preferred printable and hardenable maraging steel. The features that are most stressed during use are often the insert seats or through holes. Therefore, the intermediate element 58 with the constructed body must be hardened to a level that guarantees sufficient strength of the most sensible features.

[0055] Through steps 1 to 4, the front module 70 is manufactured.

[0056] In step 5, a rear module blank is provided. The blank comprises a steel, such as 25CrMo4 (SS 2225), 16MnCrS5 (20MnCrS5) (SS 2127), 34CrNiMo6 (SS 2541), or X40CrMoV5-1 (SS 2242) ER chuck. Typically, the rear module blank is a solid cylindrical element. However, the rear module blank can have any suitable shape, such as a square or rectangular cylinder, and can have a cavity.

[0057] In step 6, the rear module blank is machined. A milling tool 53 is used to form the rear module interface 65 in the form of sawtooth at the front end face and the coupling piece 66 at the rear end. The sawtooth forms sets of alternating elongated ridges and grooves. The sets in the exemplary embodiment include a number of linear ridges extending across the front end face.

[0058] A drill 61 is used to drill two holes 73 in the rear module blank 64, which are threaded with a thread cutting tool 67. These machining operations provide the rear module 68.

[0059] The coupling part includes a reference axis 54, which in the exemplary embodiment coincides with a central longitudinal axis 71 of the rear coupling part 66. In the exemplary embodiment, the coupling part is part of a Capto® coupling, i.e., a Capto® cone. The sawtooth forming the rear module interface 65 is formed in a flat front end face. The flat front end face has a central front end face normal 72, which in the exemplary embodiment coincides with the reference axis 54 and the central longitudinal axis 71 of the rear coupling part 66. Two screw holes 73 extend rearwardly from the rear module interface 65 approximately parallel to the reference axis 54 and at the front end face. The screw holes 73 are positioned relative to the sawtooth of the rear module interface 65 so as to be aligned with the through holes 62 of the front module 70 when the modules 68, 70 are connected at their interfaces 63, 65.

[0060] After the front module 70 and the rear module 68 are manufactured, in step 7, the front module 70 and the rear module 68 are assembled. The front module 70 and the rear module 68 are positioned with their interfaces 63, 65 facing each other. The reference axes 54 of the modules 68, 70 are aligned and the modules 68, 70 are placed in a mutual angular position to allow the front module interface 63 and the complementary rear module interface 65 to engage. The front module 70 and the rear module 68 are then pressed together and the sawtooth of their interfaces 63, 65 mesh together. In it, the centering mechanism engages. Two screws 74 are inserted into one through hole 62 respectively and tightened into the respective screw holes 73. Thanks to the interface, which includes sawtooth in the form of elongated ridges and grooves, and thanks to the pressure provided by the tightened screws, any slight deviation in the tolerance of some single ridge or groove does not affect the mutual position of the front module and the rear module. Furthermore, the serrations of the interfaces 63, 65 and the tightened screws 74 ensure that the front module 70 and the rear module 68 are positively positioned and immovably, i.e. immovably connected to one another. A parting plane 75 between the front module 70 and the rear module 68 can be defined at the interface. The parting plane 75 has a median normal coinciding with the reference axis 54, a median longitudinal axis 76 of the intermediate element 58, a median rear end surface normal 69 of the flat rear end surface having at its rear end the serrations of the front module interface 63, and a median front end surface normal 72 of the flat front end surface having at its front end the serrations of the rear module interface 65.

[0061] In step 8, at least one surface of the front module 70 is machined. A milling tool 53 is used to form the support surface of the insert seat 77 for the cutting insert. The support surface is carefully machined to have a position and extent within the required tolerances relative to the reference axis 54.

[0062] These method steps provide a metal cutting tool component in the form of a turning tool with a cutting head and a Capto® coupling part at its rear end. If necessary, the screws 74 can be removed and the front module 70 can be attached to another rear module 68. However, the other rear module 68 must correspond closely to the original actual module in order for the support surfaces of the insert seats 77 to maintain their tolerances relative to the reference axis 54.

[0063] With reference to FIG. 3, a second exemplary embodiment of a method for manufacturing a metal cutting tool component comprising a front module 70 and a rear module 68 will now be described.

[0064] In step 9, the intermediate element 58 is printed by a powder bed fusion setup that includes a build platform. The printing method includes spreading a powder of printable and hardenable steel powder layer by layer on the build platform surface. A laser with a laser beam is positioned to move over each layer and fuse the powder to the build platform or, for successive layers, to the layer below. This forms the intermediate element 58, which includes a front module interface 63 in the form of sawtooth on its rear end face and a front end build surface 52. In this embodiment, the build surface 52 constitutes the last printed layer of the intermediate element.

[0065] Then, in step 10, the body 57 is printed on the build surface 52. Step 10 essentially corresponds to step 3 according to the first embodiment of the method. However, the intermediate element 58 in this second embodiment is already in place in the configuration for powder bed fusion, so that to build the body 57, a continuous layer-by-layer printing process takes place without interruption after the intermediate element 58 is built. Alternatively, the intermediate element 58 is tilted so that the build surface normal 55 extends vertically before starting the printing of the body 57. The same powder is used for the body 57 as for the intermediate element 58.

[0066] Alternatively, the intermediate element is manufactured separately from the main body in an additive manufacturing process, in which the intermediate element can be printed in different configurations, or the same configuration in different settings, and / or with different powders. In other embodiments, the intermediate element 58 including the build surface is printed, but the front module interface in the form of sawtooth on the rear end face is subsequently machined.

[0067] In step 11, the intermediate element 58 with the built body 57 is removed from the build platform. This is done by electrical discharge machining (EDM).

[0068] Thereafter, steps 4 to 8 are carried out in the same manner as in the first embodiment of the method for producing a metal cutting tool component described above.

[0069] In a further alternative embodiment, intermediate element 58, instead of being provided as a blank 51 or printed, is provided as a finished element manufactured by any suitable method.

[0070] In figure 4 an embodiment of a metal cutting tool component in the form of a turning tool with a cutting head according to the invention is shown. The turning tool comprises a front module 70 and a rear module 68. The front module 70 has an intermediate element 58 at its rear end and a body 57 at its front end. The intermediate element 58 is machined from a blank 51, the body 57 being printed by an additive manufacturing process and hardened as described above in relation to the first or second embodiment of the method.

[0071] Intermediate element 58 has an interface 63 in the form of sawtooth formed in its rearwardly facing planar trailing surface. The sawtooth forms a set of alternating elongated ridges and grooves that are linear and extend across the trailing surface. Intermediate element 58 includes a planar build surface 52 having a central build surface normal 55.

[0072] Body 57 extends forwardly from build surface 52. At its forward most end, body 57 is provided with an insert seat 77.

[0073] The rear module 68 has a rear module interface 65 in the form of sawtooth formed in its forward-facing planar front end face. The sawtooth forms a set of alternating elongated ridges and grooves that are linear and extend across the front end face.

[0074] The rear module 68 further comprises a coupling piece 66 at its rear end. In the exemplary embodiment, the coupling piece is part of a Capto® coupling, i.e., a Capto® cone. The coupling piece 66 includes a reference axis 54 which in the exemplary embodiment coincides with a central longitudinal axis 71 of the rear coupling piece 66, which is also the central longitudinal axis of the rear module 68.

[0075] The support surface of the insert seat 77 on the body 57 is carefully machined to have a location and extent within the required tolerances relative to the reference axis 54 .

[0076] The two holes extend longitudinally parallel to the reference axis 54 of the cutting tool component. Each of the two holes includes an unthreaded portion 62 extending through the body 57 and the intermediate element 58 and a threaded portion 73 extending rearwardly from the forward-facing front surface having sawtooth into the rear module 68. Two screws 74 are inserted into one hole. Each screw 74 extends through the unthreaded portion 62 and is tightened with the threaded portion 73. The front module 70 and the rear module 68 are rigidly connected to each other because the complementary sawtooth of the interface 63, 65 are pressed into mesh with each other by the tightened screw 74. In other embodiments, another number of screws and corresponding holes are used, for example three or four.

[0077] A parting plane 75 between the front module 70 and the rear module 68 can be defined at the interface 63, 65. The reference axis 54 coincides with a median normal to the parting plane 75, a median longitudinal axis 76 of the intermediate element 58, a median rear end face normal 69 of the toothed flat rear end face of the front module interface 63, a median longitudinal axis 71 of the rear coupling part 66, and a median front end face normal 72 of the toothed flat front end face of the rear module interface 65. In this embodiment, the median building plane normal 55 forms an angle α of 45° with the reference axis 54.

[0078] A second parting surface 78 may be defined in the rear coupling piece 66, which is a plane that separates the metal cutting tool component from the component to which it is intended to be joined when the metal cutting tool component is joined to it.

[0079] 5-10 show an embodiment of a metal cutting tool component manufactured by the method described above.

[0080] 5-9 show different embodiments of a metal cutting tool component in the form of a turning tool having a coupling part 66 in the form of a removable machine tool coupling including a Capto® coupling cone. However, in other non-illustrated embodiments, the tool component may be a different type of cutting tool, such as a milling tool or a drill. Furthermore, other non-illustrated embodiments may have other coupling parts 66 than a Capto® coupling cone, such as, for example, an HSK coupling.

[0081] 5-9 differ primarily by their various designs, and so the following description will focus on the description of intermediate element 58. In all embodiments, the rear end face of front module interface 63 and the front end face of rear module interface 65 are parallel to parting plane 75, such that all three faces have a common normal direction 79.

[0082] The turning tools shown in Figures 5 and 6 differ from the turning tool described with reference to Figure 4 in that they both have an intermediate element 58 whose build surface 52 and parting surface 75 are parallel. The coupling part 66 has a reference axis 54 which is the central axis of the Capto® coupling cone and extends in a common normal direction 79. The build surface normal 55 is aligned (coincides) with the reference axis 54. The rear module 68 and the front module 70 have the reference axis 54 as a common longitudinal axis. Figures 5 and 6 differ only in that in Figure 5 the intermediate element 58 is a thin disk and in Figure 6 the intermediate element 58 is an elongated cylinder that contributes to the length of the turning tool.

[0083] The turning tool of Fig. 7 has an intermediate element 58 having the shape of a circular oblique cylinder. The build surface 52 and the parting surface 75 are parallel. The coupling part 66 has a reference axis 54 which is the central axis of the Capto® coupling cone and extends in a common normal direction 79. The central build surface normal 55 extends parallel to and transverse to the reference axis 54. The central longitudinal axis 76 of the intermediate element 58 extends at an angle β of 45° to the reference axis 54.

[0084] The turning tool shown in FIG. 8 is similar to the tool described with reference to FIGS. 1-3 and 4 in connection with the first and second embodiments of the manufacturing method. The intermediate element 58 has the shape of a cylinder obliquely capped at its end, the building surface 52 being formed at its end. The building surface 52 extends at an angle to the parting surface 75. The coupling part 66 has a reference axis 54 which is the central axis of the Capto® coupling cone and extends in a common normal direction 79. The longitudinal axis 76 of the intermediate element 58 also extends in the common normal direction 79. The central building surface normal 55 extends at an angle α of 50° to the reference axis 54. Furthermore, the central longitudinal axis 82 of the body, i.e. the central front longitudinal axis 82, coincides with the central building surface normal 55 and therefore has the same angle α to the reference axis 54.

[0085] The turning tool shown in Fig. 9 differs from that shown in Fig. 8 in that the intermediate element 58 has the shape of a cylinder obliquely capped at its end, and the interface 63 is formed at its end. The coupling parts 66 have a reference axis 54 which is the central axis of the Capto® coupling cone and extends in a common normal direction 79. The central construction surface normal 55 extends at an angle α of 50° to the reference axis 54. The longitudinal axis 76 of the intermediate element 58 coincides with the central construction surface normal 55 and therefore extends at the same angle α to the reference axis 54.

[0086] In FIG. 10, a metal cutting tool component in the form of a holder for holding a separate unit 80 in the form of a cutting head is shown. The intermediate element 58 and the rear module 68 are similar to the intermediate element 58 described with reference to the turning tool of FIGS. 4 and 8. The body 57 has the shape of two cylinders connected at right angles, the first cylinder having a first central longitudinal axis 81 and the second cylinder having a second central longitudinal axis 82, i.e. the central front longitudinal axis 82. However, the longitudinal axes of both cylinders extend at an angle α of 45° to the building surface normal 55. Thanks to the fact that the body can be printed on the horizontal building surface 52, both parts can be printed without additional supports, despite extending at 90° to each other.

Claims

1. 1. A method of manufacturing a metal cutting tool component, comprising the steps of: - manufacturing a front module (70), said front module (70) comprising a body (57) and a front module interface (63) at a rear end of said front module (70); - providing an intermediate element (58) including providing at its rear end the front module interface (63) and at its front end the building surface (52); - building said body (57) on said build surface (52) of said intermediate element (58) using an additive manufacturing process; and - providing a rear module (68) including a coupling part (66) at its rear end and a rear module interface (65) at its front end; - after manufacturing said front module (70) and providing said rear module (68), attaching said front module (70) to said rear module (68) by immovably connecting said front module interface (63) and said rear module interface (65); - machining at least one surface of said body (57) after said front module (70) has been attached to said rear module (68); - heat treating said intermediate element (58) with said constructed body (57), in which at least said body (57) is hardened; A manufacturing method comprising:

2. 2. The method of claim 1, wherein the step of building the body (57) includes using an additive manufacturing process in the form of powder bed fusion of a printable and hardenable steel powder.

3. The method of claim 2, wherein the step of heat treating comprises heating to between 450°C and 600°C.

4. 4. The method according to claim 1, wherein the step of machining at least one surface of the body (57) is carried out after the step of heat treating the intermediate element (58) having the constructed body (57).

5. - providing said coupling part (66) on said rear module (68) comprises providing said coupling part (66) with a reference axis (54); - said machining step comprises machining said at least one surface to a precise position and extent relative to said reference axis (54); 5. The method according to any one of claims 1 to 4.

6. - said step of constructing said body (57) comprises the step of constructing said body (57) in the form of a cutting head, - said step of machining at least one surface comprises machining at least one support surface for a cutting insert; The method according to claim 5.

7. 7. The method of claim 5 or 6, wherein the step of providing the coupling part (66) on the rear module (68) includes providing the coupling part (66) in the form of a portion of a removable machine tool coupling.

8. 8. The method of claim 7, wherein the step of providing the coupling part (66) in the form of a part of a removable machine tool coupling comprises providing at least one surface of the removable machine tool coupling part (66) with a dimensional deviation of less than ±50 μm.

9. - the step of providing the intermediate element (58) comprises the step of providing the intermediate element (58) having a flat construction surface (52) with a central construction surface normal (55), the central construction surface normal (55) extending at an angle to the reference axis (54), - the step of building said body (57) on said building surface (52) comprises positioning said intermediate element (58) having said central building surface normal (55) perpendicularly from said building surface (52) and then building said body (57) on said building surface (52); 9. The method according to any one of claims 5 to 8.

10. 10. The method of claim 9, wherein the step of providing the intermediate element (58) comprises the step of providing the intermediate element (58) wherein the central construction surface normal (55) extends at an angle of between 45° and 90° relative to the reference axis (54).

11. The step of providing the intermediate element (58) comprises: - providing an intermediate element blank (51) of maraging steel; - machining said intermediate element blank (51) to form said front module interface (63) and said building surface (52); The method of any one of claims 1 to 10, comprising:

12. - the step of providing said front module interface (63) on said intermediate element (58) comprises providing said front module interface (63) in the form of sawtooth on a rearward facing rear surface; - the step of providing the rear module interface (65) on the rear module (68) comprises providing the rear module interface (65) on its forward-facing front surface in the form of sawtooth, the sawtooth being complementary to the sawtooth of the front module interface (63); 12. The method according to any one of claims 1 to 11.

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