Method for clamping a first cutting insert or adapter in a holder

Abstract

A method for clamping a first cutting insert or an adapter in a holder, the holder including two insert pockets configured for machining in two different orthogonal directions, or the holder including a single insert pocket configured to hold an adapter in two different orthogonal directions, the method including selecting one of the two orthogonal directions for machining and securing the first cutting insert in the appropriate one of the two pockets or the adapter in the adapter pocket for machining in the selected orthogonal direction.

Description

Technical Field

[0001]

[0001] The subject matter of the present invention generally relates to a holder configured for a machining process along the Y-axis feed direction. The holder has a pocket configured to hold either a cutting insert (hereinafter also referred to as an "insert") or an adapter configured to hold the insert. The present invention also relates to the holder and the cutting insert, or a tool assembly comprising the holder, the adapter, and the cutting insert held by the holder, and a method of attaching the cutting insert or the adapter to the holder, and / or a method of machining using the tool assembly.

[0002]

[0002] More specifically, the present invention relates to a preferred type of adapter that is a parting blade (hereinafter also referred to as a "blade" or a "parting adapter"), and in such a case, the parting adapter, the holder, and the tool assembly comprising the parting adapter and the holder are configured for parting and grooving along the Y-axis feed direction.

Background Art

[0003]

[0003] The present application relates to a tool assembly and a machining process in the so-called Y-axis feed direction.

[0004]

[0004] Such processes are disclosed, for example, in US Patent Application Publication No. 2020 / 0009757 directed to a Y-axis blade portion and US Patent Application Publication No. 2019 / 0358710 directed to a machining method for the same structure (hereinafter referred to as "the patent publication").

[0005]

[0005] Returning to the patent publication, it is described that there has been a desire to reduce vibration in conventional parting or deep grooving processes. Thus, in summary, an alternative blade portion has been proposed in which the blade portion extends substantially in the same direction as the main clearance surface of the cutting insert attached to the blade portion.

[0006]

[0006] The applicant also further discusses such tools in U.S. Patent Application Publication No. 2019 / 0240741, which was assigned to the applicant.

[0007]

[0007] The present invention relates to an improved Y-axis holder, a tool assembly including the Y-axis holder, and a machining method using the adapter. In a particularly advantageous embodiment, the improved Y-axis adapter is a parting blade.

Summary of the Invention

[0008]

[0008] It has been found that relatively few CNC machines are capable of machining operations in the Y-axis feed direction.

[0009]

[0009] Accordingly, Y-axis feed tools are in low demand and are therefore relatively expensive due to their low production volume.

[0010]

[0010] A secondary problem that has been pointed out is that the setup of the Y-axis tool assembly is more complex compared to a standard X-axis tool assembly and requires a large number of offsets before starting the machining operation.

[0011]

[0011] The present invention is the development of a single holder and a tool assembly including the holder configured for machining operations in both the Y-axis feed direction and the X-axis feed direction (hereinafter, for simplicity, this concept is referred to as "two orthogonal directions").

[0012]

[0012] The present invention also relates to a method of attaching a cutting insert or adapter to such a holder.

[0013] According to one advantageous embodiment, the holder is configured to fix the insert in the holder in two orthogonal directions. The holder can be configured, for example, according to a first aspect, by providing an X-axis insert pocket and a different Y-axis insert pocket in the same holder. In other words, the holder can be configured to have two pockets, and each pocket is configured to be machined in a different orthogonal direction.

[0014] The holder can be defined by orienting the X-axis insert pocket and the Y-axis insert pocket so that they are orthogonal to each other (by the method detailed below).

[0015] More precisely, a method of clamping a first cutting insert or adapter in the holder is provided, the holder comprising a first insert pocket and a second insert pocket each configured to machine a workpiece in one of two different orthogonal directions, or the holder comprising a single adapter pocket configured to hold the adapter in a first orientation and a second orientation each configured to machine a workpiece in one of two different orthogonal directions, the method comprising: selecting a first orthogonal direction; and fixing a first cutting insert in the first insert pocket or fixing the adapter in the first orientation in the adapter pocket, either for machining in the selected first orthogonal direction.

[0016] According to a second aspect of the present invention, there is provided a holder, the holder comprising: a shank portion having a shank central axis; and a head portion, the head portion comprising a first insert pocket and a second insert pocket; the first insert pocket comprising a base surface extending substantially perpendicular to the shank central axis and at least one flank wall extending in a longitudinal direction substantially parallel to the shank central axis; and the second insert pocket comprising a base surface extending in a longitudinal direction substantially parallel to the shank central axis and at least one flank wall extending in a direction substantially perpendicular to the shank central axis.

[0017] Alternatively defined, according to a third aspect of the present invention, there is provided a holder, the holder comprising: a shank portion having a shank central axis; and a head portion, the head portion comprising a first insert pocket and a second insert pocket; the first insert pocket comprising a threaded hole extending substantially perpendicular to the shank central axis; and the second insert pocket comprising a threaded hole extending substantially parallel to the shank central axis.

[0018] Further alternatively defined, according to a fourth aspect of the present invention, there is provided a holder, the holder comprising: a first insert pocket; and a second insert pocket; the first insert pocket being oriented to hold a cutting insert in a first orthogonal direction; and the second insert pocket being oriented to hold a cutting insert in a second orthogonal direction different from the first orthogonal direction. In other words, the first insert pocket is oriented to hold a cutting insert in a first direction, and the second insert pocket is oriented to hold a cutting insert in a second direction orthogonal to the first direction.

[0019]

[0019] According to any of the above aspects, the features may preferably include the following. The holder may comprise a head portion with external ribs formed thereon. The external ribs may be arranged adjacent to the shank portion. When two cutting inserts are attached to the holder, the rake face of the first cutting insert may be substantially parallel to the end face of the head portion, and the rake face of the second insert may be substantially parallel to the side face of the head portion.

[0020]

[0020] Alternatively, according to a further aspect, the holder may be defined as a tool assembly (i.e., an assembly comprising the holder and further including at least one cutting insert). The cutting insert comprises a leading cutting edge (when attached to the insert pocket) that serves to define the two orthogonal orientations of the two insert pockets.

[0021]

[0021] In a particular CNC machine, the holder can be held in one orientation (e.g., the X-axis feed orientation as illustrated in Figure 6B), and using the first insert in the X-axis insert pocket, a machining process can be carried out without removing the holder from the turret or tool post. It is understood that the holder can be re-oriented by the CNC machine and a machining process can be carried out using the second insert in the Y-axis insert pocket (as illustrated in Figure 6C). It is understood that the said process can be carried out in the reverse order.

[0022]

[0022] Alternatively, the holder (or tool assembly) can simply be used for machining in either the X-axis feed direction or the Y-axis feed direction. Thereby, the manufacturer can mass-produce dual-purpose tools. Further, the inventory that the user has to maintain can be reduced.

[0023]

[0023] The insert pockets according to a preferred embodiment may be the same (and thus configured to hold the same insert as illustrated in FIG. 6). Alternatively, according to other preferred embodiments, the insert pockets may be different (and thus configured to hold inserts of different shapes).

[0024]

[0024] The above-described tool is considered to be disadvantageous in that many users do not prefer a holder with the additional cost of the second insert pocket, and thus it is understood that they may prefer a standard holder. Nevertheless, at least some users may find the two functions of the Y-axis and the X-axis beneficial.

[0025]

[0025] Yet another advantage is that the integral holder on which the insert pocket is formed is structurally more rigid than the holder that holds the adapter on which the insert pocket is formed. In other words, stability is lost by having non-integral parts.

[0026]

[0026] The two insert pockets may preferably be spaced apart from each other (for example, the two insert pockets may be disposed at opposite corners of the head portion). However, even if the two insert pockets are on a common side of the holder or are arranged orthogonally to each other, it is possible to achieve that the insert pockets are open to each other.

[0027]

[0027] According to yet another aspect of the present invention, there is provided a holder configured to fix an adapter to the holder in two orthogonal directions.

[0028]

[0028] This is an advantageous embodiment, despite being less rigid than the above example (where optimal support cannot be achieved in two different predicted machining directions without using at least a compactly designed tool). However, since the adapter is usually considerably larger than the cutting insert, it is thought that such a drawback of optimal support is compensated by the advantage of a single holder that enables machining in two different orthogonal directions.

[0029]

[0029] The adapter comprises insert pockets. Preferably, the adapter is indexable and comprises a plurality of insert pockets.

[0030]

[0030] Preferably, the holder comprises a single adapter pocket configured to fix the adapter in both of two orthogonal directions.

[0031]

[0031] Since a single adapter pocket can be used in both of two orthogonal directions, such an embodiment can be more economical than two separate insert pockets.

[0032]

[0032] The above configuration of the single adapter pocket can be, for example, by providing additional holes in the adapter pocket (for each of the two orthogonal directions).

[0033]

[0033] In other words, the adapter pocket can be configured to have at least one clamping hole for one orientation and at least one clamping hole for the other orientation. In a preferred embodiment, at least one clamping hole is not used when clamped in one orientation.

[0034] Alternatively, the single adapter pocket may comprise an external clamp or wedge (of the type shown in FIG. 12A of US Patent Application Publication No. 2019 / 0240741) for holding the adapter in the adapter pocket. To configure the holder to hold the adapter in both orientations, the clamp is preferably configured to bias the adapter at the corners of the insert pocket. Alternatively, the clamp may be used on the side of the adapter pocket suitable for a particular orientation.

[0035]

[0035] The above-described embodiments allow the tool assembly to be moved in two orthogonal directions during the cutting process, but it was considered to position the adapter so that fewer offsets are required during setup.

[0036]

[0036] Specifically, when the adapter is attached to the holder, the holder and the adapter may be configured so that no offset is required in at least one of the two orientations along at least one axis. For example, if the holder is primarily configured for X-axis feed machining as shown in FIG. 1A and the adapter is fixed as shown in FIG. 1A, there is no need to enter an offset into the CNC machine. Also, when the same adapter is changed to the Y-axis feed machining direction as shown in FIG. 2, an offset needs to be provided in the X-axis direction rather than the Y-axis feed direction. In contrast, in the pocket shown in FIG. 5, which is a modified pocket basically the same as that shown in US Patent Application Publication No. 2019 / 0240741, two offsets are required for each orientation.

[0037]

[0037] More preferably, according to a particularly advantageous embodiment, when the adapter is attached to the holder, the holder and the adapter are configured such that no offset is required in both of two directions along at least one axis. Thus, for example, if the holder is mainly configured for X-axis feed machining as shown in FIG. 1A and the adapter is fixed as shown in FIG. 1A, there is no need to input an offset to the CNC machine at all. Also, in the Y-axis feed machining direction as shown in FIG. 2, only one offset in the X-axis direction needs to be provided. It is understood that the usability of the operation of such a holder and / or tool assembly is significantly improved thereby.

[0038]

[0038] In addition to the above development, it has been found that such an adapter can be incorrectly and inaccurately fixed to the holder by mistake (for example, the adapter can be fixed to the holder for X-axis feed operation and then operated in the Y-axis direction). To prevent such a situation, it has been considered to provide a mechanism for preventing incorrect assembly.

[0039]

[0039] One preferred embodiment is to provide a so-called "pocket protrusion" in the pocket of the holder, which protrudes into the pocket and prevents the adapter from being incorrectly (in the wrong orientation) inserted therein. In other words, the pocket protrusion is received in the recess of the adapter in one orthogonal orientation of the adapter, but not in the other.

[0040]

[0040] Preferably, the pocket protrusion is removable and reattachable so that the user can use another orientation as needed. In the illustrated example, the pocket protrusion is a removable pin having a basically cylindrical or cylindrical shape. However, it is understood that the pocket protrusion need not be cylindrical and other pin shapes are conceivable.

[0041]

[0041] Preferably, the recess of the adapter has a non-cylindrical shape so that the adapter can be easily placed in the adapter pocket.

[0042]

[0042] Preferably, the recess of the adapter is an unused insert pocket, and thus, there is no need to provide an additional recess in the adapter itself that could weaken or complicate its structure.

[0043]

[0043] While a particular advantageous embodiment for the parting process is shown, with necessary modifications, it is also possible for the adapter to hold the turning insert in two different orientations.

[0044]

[0044] To elaborate on the above offset, a standard X-axis feed parting blade (or "parting adapter") can be fixed to a holder (fixed to the machine interface), and the parting process can be started without the need to offset the position of the tool assembly (i.e., to adjust the setting of the non-zero position of the cutting edge, hereinafter referred to as "offset"). In a known Y-axis tool assembly, an offset is required along both the X-axis and the Y-axis.

[0045]

[0045] Thus, the present invention enables an adapter that is preferably not elongated and preferably ejectable to have fewer offsets than currently known.

[0046]

[0046] A machine capable of Y-axis feed machining can provide both of the above offsets, but it was considered to reduce the complexity of the setting by providing a single-offset tool assembly to reduce the complexity for the user. The setting is more complex than an X-axis feed tool assembly that does not require any offset, but it can still provide the advantage of Y-axis stability (reduction of vibration).

[0047]

[0047] According to a preferred embodiment, a tool assembly is provided, the tool assembly comprising: a parting adapter; a cutting insert fixed in an insert pocket of the parting adapter and having a leading cutting edge; and a holder having a holder shank portion with an uppermost holder shank surface and a holder shank cross-sectional shape, wherein the holder shank cross-sectional shape is square or rectangular and the leading cutting edge is aligned with the uppermost holder shank surface; or the holder shank cross-sectional shape is circular and the holder shank axis extends to the leading cutting edge.

[0048]

[0048] According to another aspect of the present invention, a holder is provided, the holder comprising: a shank portion having a shank central axis; and a head portion, wherein the head portion has an adapter pocket, and the adapter pocket comprises: a plurality of first holes for a first orientation; and a plurality of second holes for a second orientation, and the plurality of first holes and the plurality of second holes are positioned in mirror symmetry.

[0049]

[0049] According to another aspect of the present invention, a holder is provided, the holder comprising: a shank portion having a shank central axis; and a head portion, wherein the head portion has an adapter pocket, and the adapter pocket comprises: a plurality of first holes for a first orientation; and a plurality of second holes for a second orientation, wherein the spacing of the plurality of first holes is the same as the spacing of the plurality of second holes; and the plurality of first holes and the plurality of second holes are shifted relative to each other.

[0050]

[0050] According to another aspect of the present invention, a tool assembly is provided, the tool assembly comprising: a holder having an adapter pocket; and an adapter, wherein the holder and the adapter are configured such that the adapter can be attached to the adapter pocket in two different orthogonal directions.

[0051] [0051 The holder can be according to any of the described embodiments.

[0052]

[0052] The adapter can be configured to be attached to the adapter pocket at a first orthogonal position through at least one of the plurality of first holes, and can be configured to be attached to the adapter pocket at a different orthogonal position through at least one of the plurality of second holes.

[0053]

[0053] The adapter can be configured to be attached to the adapter pocket at a first orthogonal position only through the plurality of first holes, and can be configured to be attached to the adapter pocket at a different orthogonal position only through the plurality of second holes.

[0054]

[0054] The following may be possible as a method of attaching the adapter. The adapter can be fixed to the adapter pocket in a first orientation using a number less than all of the plurality of holes. Then, the adapter is removed and can be fixed to the adapter pocket in a second orientation using a number of holes less than all of the plurality of holes without using at least one of the plurality of holes used to fix the adapter in the first orientation.

[0055]

[0055] The adapter can be configured to be attached to the adapter pocket in a first orthogonal orientation, and is configured to be prevented by a pocket protrusion from being attached to the adapter pocket in a different orthogonal direction. If the pocket protrusion is removed, the adapter can be attached to the adapter pocket in a different orthogonal orientation.

[0056]

[0056] Preferably, the pocket protrusion is positioned in the first orthogonal orientation so that the pocket protrusion protrudes into the insert pocket of the adapter attached to the adapter pocket in the first orthogonal orientation.

[0057]

[0057] In particular, in the case of a square or rectangular holder shank (a standard shank type in the industry), for clarity, as is known in the art, the uppermost holder shank surface is typically aligned with the foremost cutting edge of a standard X-axis holder. However, in order to also be aligned with the cutting edge in the direction orthogonal to the Y-axis, a Y-axis tool assembly configured for the same holder shank surface (referred to as the "foremost holder shank surface" when considering only the Y-axis feed direction; in this specification, since the X-axis is the reference, the name, foremost holder shank surface, is used) is not known. Further, a tool assembly for holding an adapter in two different orthogonal directions is not known.

[0058]

[0058] With the above configuration, it is possible to align the foremost cutting edge with the uppermost holder shank surface, whereby the tool assembly only needs to be offset in the X-axis direction (i.e., a direction parallel to the extension direction of the holder shank portion) as required.

[0059]

[0059] The alternative cross-sectional shape referred to as "circular" is a simple way of defining a basically cylindrical or basically conical shank cross-section according to the types described in ISO standard 26623-1 or ISO12164-3. It is understood that this is also a standard shank type in the industry. In the case of such a shank type, the foremost cutting edge is aligned with the central holder shank axis, whereby, as required, the tool assembly only needs to be offset in one direction, i.e., the X-axis direction.

[0060]

[0060] The alternative option is the same concept and only describes the two main shank types used (i.e., the alignment position is at the center of the circular type shank or in front of the square / rectangular type shank). The term "circular" encompasses various shank types, but it is understood that essentially it means that the alignment position is along the center of the shank.

[0061]

[0061] According to another preferred embodiment, a tool assembly is provided, the tool assembly comprising: a parting adapter; a cutting insert; and a holder; the parting adapter comprising: opposite first and second side surfaces; and a periphery connecting the first and second side surfaces; the periphery comprising: opposite front and rear sub-peripheries; and an upper sub-periphery connecting the front and rear sub-peripheries; the first and second side surfaces defining a first transverse direction directed from the first side surface to the second side surface and a second transverse direction opposite the first transverse direction; the forward direction being defined perpendicular to both the first and second transverse directions and directed from the rear sub-periphery to the front sub-periphery, the rearward direction being opposite the forward direction; the upward direction being defined perpendicular to both the first and second transverse directions and to both the forward and rearward directions; the downward direction being defined opposite the upward direction; an insert pocket being formed at the intersection of the front sub-periphery and the upper sub-periphery; the insert pocket comprising: a base jaw having a foremost base jaw surface; a second jaw at least partially disposed above the base sheet jaw; and a slot end connecting the base jaw and the second jaw; the adapter shank portion comprising an adapter clamping device; the cutting insert being fixed in the insert pocket, and the cutting insert comprising: an insert base surface abutting the base jaw; an upwardly facing rake surface disposed above the insert base surface; an insert second surface adjacent to the second jaw; a foremost clearance surface extending downwardly from the rake surface; and a foremost cutting edge formed at the intersection of the rake surface and the foremost clearance surface; the holder comprising: a holder head portion; and a holder shank portion connected to the holder head portion; the holder head portion comprising an adapter pocket in which the adapter shank portion is fixed; the holder shank portion comprising: a holder shank axis extending through the center of the holder shank and extending parallel to the upward and downward directions; a holder shank cross-sectional shape extending perpendicular to the holder shank axis and being either (a) square or rectangular or (b) circular; and a topmost holder shank surface; a virtual line extending from the topmost holder shank surface; the holder shank cross-sectional shape being square or rectangular and the foremost cutting edge being aligned with the topmost holder shank surface;Alternatively, the holder shank has a circular cross-sectional shape, and the holder shank axis extends to the foremost cutting edge.;

[0062]

[0062] According to yet another aspect of the present invention, there is provided a method of machining a workpiece having a central rotation axis (AW) configured such that the workpiece rotates about it, using a cutting tool having a working cutting insert, the cutting tool being configured to be selectively moved in either a first cutting direction or a second cutting direction towards the central rotation axis (AW) relative to the workpiece, the first cutting direction and the second cutting direction being perpendicular to the central rotation axis (AW) and perpendicular to each other, the method comprising: providing a cutting tool comprising a tool holder having a shank portion and a head portion, the shank portion being held within a machine interface and the head portion having a working cutting insert mounted therein; and selectively moving the cutting tool relative to the workpiece to machine the workpiece in either the first cutting direction while the workpiece is rotating in a first rotational direction such that the cutting force received by the working cutting insert is directed laterally in a direction from the head portion towards the machine interface, or in the second cutting direction while the workpiece is rotating in a second rotational direction opposite to the first rotational direction such that the cutting force received by the working cutting insert is directed parallel to a direction from the head portion towards the machine interface.

[0063]

[0063] The head portion may comprise an end face, and a first insert pocket and a second insert pocket both opening towards the end face, the first insert pocket and the second insert pocket being identical, and a first cutting insert and a second cutting insert being seated therein respectively; when the cutting tool is moved in the first cutting direction, the first cutting insert is the working cutting insert; and when the cutting tool is moved in the second cutting direction, the second cutting insert is the working cutting insert.

[0064]

[0064] The adapter may comprise a first main adapter surface and a second main adapter surface, each surface being configured to face the pocket surface when the adapter is attached to the adapter pocket. The adapter further comprises a plurality of insert pockets, and at least one of the plurality of insert pockets holds a cutting insert therein.

[0065]

[0065] The method may selectively include either the step of fixing the adapter in a first orientation in the adapter pocket with a first main adapter surface facing the pocket surface before moving the cutting tool in a first cutting direction relative to the workpiece, or the step of fixing the adapter in a second orientation in the adapter pocket with a second main adapter surface facing the pocket surface before moving the cutting tool in a second cutting direction relative to the workpiece.

[0066]

[0066] According to yet another aspect of the present invention, there is provided a method of machining a workpiece having a central axis of rotation (AW) about which the workpiece is configured to rotate, using a cutting tool configured to be selectively moved towards the central axis of rotation (AW) in either a first cutting direction or a second cutting direction relative to the workpiece for machining the workpiece, the first and second cutting directions being perpendicular to the central axis of rotation (AW) and also perpendicular to each other, the method comprising: providing a cutting tool comprising a tool holder having a shank portion and a head portion, the shank portion being held by a machine interface and the head portion comprising an adapter pocket having a pocket face; providing an adapter comprising a first main adapter face and a second main adapter face, each face being configured to face the pocket face when the adapter is attached to the adapter pocket, the adapter further comprising a plurality of insert pockets, at least one of the plurality of insert pockets holding a cutting insert therein; selectively attaching the adapter into the adapter pocket with the first main adapter face facing the pocket face and then moving the cutting tool in a first cutting direction relative to the workpiece while the workpiece is rotating in a first rotational direction such that the cutting force received by the active cutting insert is directed laterally with respect to the direction from the head portion to the machine interface; or selectively attaching the adapter into the adapter pocket with the second main adapter face facing the pocket face and then moving the cutting tool in a second cutting direction relative to the workpiece while the workpiece is rotating in a second rotational direction opposite to the first rotational direction such that the cutting force received by the active cutting insert is directed parallel to the said direction from the head portion to the machine interface, either.

[0067]

[0067] According to yet another aspect of the present invention, there is provided a method of machining a workpiece having a central axis of rotation (AW) configured such that the workpiece rotates about it, using a cutting tool configured to be selectively moved towards the central axis of rotation (AW) in either a first cutting direction or a second cutting direction with respect to the workpiece, the first and second cutting directions being perpendicular to the central axis of rotation (AW) and also perpendicular to each other, the method comprising: providing a cutting tool comprising a tool holder having a shank portion and a head portion, the shank portion being held within a machine interface and the head portion comprising an end face and a first insert pocket and a second insert pocket both opening towards the end face, the first insert pocket and the second insert pocket seating a same first cutting insert and a second cutting insert therein, respectively; selectively moving the cutting tool relative to the workpiece to machine the workpiece in either the first cutting direction while the workpiece rotates in a first rotational direction such that only the first cutting insert is operative and the cutting force received by the first cutting insert is directed laterally with respect to the direction from the head portion to the machine interface; or in the second cutting direction while the workpiece rotates in a second rotational direction opposite to the first rotational direction such that only the second cutting insert is operative and the cutting force received by the second cutting insert is directed parallel to the said direction from the head portion to the machine interface.

[0068]

[0068] According to yet another aspect of the present invention, there is provided a method of clamping an insert or an adapter in a holder, the method comprising: selecting one of two orthogonal directions; and fixing the insert or the adapter in a suitable one of two pockets, or fixing the adapter in one of two possible orthogonal orientations with respect to an adapter pocket.

[0069]

[0069] A preferred further step is to relatively move the holder towards the workpiece in a selected one of two orthogonal directions.

[0070]

[0070] Preferred steps are to set an offset only in the X-axis direction defined as the direction parallel to the elongated shank of the holder; and, following step (b), to move the cutting adapter in the Y-axis direction defined as the direction perpendicular to the X-axis direction with respect to the rotating workpiece to machine or cut the workpiece.

[0071]

[0071] Preferred steps are to set an offset only in the Y-axis direction defined as the direction parallel to the elongated shank of the holder; and, following step (b), to move the cutting adapter in the X-axis direction defined as the direction perpendicular to the Y-axis direction with respect to the rotating workpiece to machine or cut the workpiece.

[0072]

[0072] In the most preferred embodiment, the adapter can provide only a single offset for one of two orientations.

[0073]

[0073] Preferred additional steps include removing the adapter (if it is the adapter of step b) and fixing the adapter in a second (different) orthogonal orientation. Yet another step includes relatively moving the holder towards the workpiece in a selected second orthogonal direction.

[0074]

[0074] The above examples / embodiments and methods are preferably carried out using an adapter configured for a cutting process (hereinafter referred to as a "cutting adapter") when the adapter is the object.

[0075]

[0075] It does not seem beneficial that a single offset is easier for the operator than two offsets (the offset needs to be input in any case, but the inventor believes that such an advantage may still be more preferable than a slight additional stability (which can be lost by misaligning the adapter or insert to a slightly suboptimal position to achieve the desired alignment advantage).

[0076]

[0076] Preferred additional steps (when it is the cutting insert of step b) are the step of fixing the second cutting insert to the second pocket of the two pockets, and the step of moving the tool assembly along the first axis to machine the workpiece with the first cutting insert, and then the tool assembly is moved along a second axis orthogonal to the first axis to machine the workpiece with the second cutting insert. Preferably, this further includes the step of rotating the workpiece in a first direction during the machining by the first cutting insert, and the step of rotating the workpiece in the opposite direction during the machining by the second cutting insert.

[0077]

[0077] Preferably, the second jaw of the insert pocket is entirely disposed behind the base jaw. Alternatively or additionally, the second jaw of the insert pocket and the base jaw extend adjacent to each other in a direction parallel to the upward and downward directions.

[0078]

[0078] The adapter according to the present invention preferably comprises a plurality of insert pockets.

[0079]

[0079] The insert pocket of the present invention is preferably of the illustrated elastic type (i.e., without screws).

[0080]

[0080] The various features described above are explained using words such as "frontmost". Such words are understood to mean that the feature is in a more forward direction (i.e., closer to the workpiece) with respect to the remaining part of the component (e.g., the adapter or the cutting edge). It is also understood that all given directions are not in an absolute sense with respect to the ground, but are for the purpose of the reference of features relative to each other. Similarly, the directions can be optionally selected as defined for a particular component such as a parting adapter, but it is understood that they can be similarly defined for the holder or the tool assembly.

[0081]

[0081] As is well known in the art, the rake face is a surface intended for the machined chips to flow thereon, and the clearance face is usually designed to recede from the cutting edge.

[0082]

[0082] Preferably, the bearing surface of the adapter is mirror symmetric with respect to a bisecting turning line extending through two orthogonal positions.

[0083]

[0083] The bisecting line can extend through the frontmost cutting edge of the insert.

[0084]

[0084] Preferably, the bearing surface of the adapter is straight in side view.

[0085]

[0085] Preferably, the adapter has a quadrilateral shape, preferably a square shape, most preferably a square shape in side view.

[0086]

[0086] It is understood that the present invention refers to tool assemblies and holders configured only for different orthogonal orientations. Specifically, the present invention is not related to tool designs configured to enable fine adjustment of positions that may involve repositioning of the insert or the adapter by 90° (or more).

[0087] According to any aspect, for machining a workpiece, the holder can be moved in a first orthogonal direction or a second orthogonal direction (or repositioned from one direction to another).

[0088]

[0088] When the adapter is reattached to the adapter pocket in a different orientation, the same insert pocket can be used for machining, or a different insert pocket can be used.

[0089]

[0089] To better understand the subject matter of the present application and to show how the subject matter of the present application is actually implemented, reference is now made to the accompanying drawings.

Brief Description of the Drawings

[0090]

Figure 1A

Figure 1B

Figure 2

Figure 3

Figure 4A

Figure 4B

Figure 4C

Figure 5

Figure 6A

Figure 6B

Figure 6C

Figure 6D

Figure 6E

DETAILED DESCRIPTION OF THE INVENTION

[0091]

[0090] Referring to FIGS. 1A and 1B, a tool assembly 10 is shown. The tool assembly 10 includes a holder 12, a parting adapter 14 (substantially the same as the parting blade shown in FIGS. 18A - 18C of U.S. Patent Application Publication No. 2019 / 0240741, at least with respect to the shape of the parting blade, a flat bearing surface), at least one insert pocket (in this example, a first insert pocket 15A, a second insert pocket 15B, a third insert pocket 15C, and a fourth insert pocket 15D), and a working cutting insert 16 fixed to the parting adapter 14.

[0092]

[0091] The content of U.S. Patent Application Publication No. 2019 / 0240741, particularly FIGS. 18, 19, and 20, is incorporated herein by reference.

[0093]

[0092] Referring particularly to FIG. 1A, the holder 12 is positioned adjacent to a generally cylindrical rotating workpiece 20. The workpiece 20 has a central workpiece axis AW and is rotated in the counterclockwise direction DCC as shown in this figure during machining.

[0094]

[0093] For the description and the reference system, the figure shows the forward direction DF, the rearward direction DR, the upward direction DU, the downward direction DD, the first lateral direction DS1, and the second lateral direction DS2.

[0095]

[0094] The forward direction DF constitutes the X-axis feed direction in which the tool assembly 10 is moved to machine the workpiece 20.

[0096]

[0095] The cutting insert 16 includes a rake face 22, an opposite insert base face 24, a foremost clearance face 26A that extends downward (and slightly inward, i.e., in the downward direction DD and slightly in the rearward direction DR) from the rake face 22, an opposite insert rear face 28, and a foremost cutting edge 30A formed at the intersection of the rake face 22 and the foremost clearance face 26A.

[0097]

[0096] Preferably, the rake face 22 is provided with a chip forming device (not shown).

[0098]

[0097] Each of the first insert pocket 15A, the second insert pocket 15B, the third insert pocket 15C, and the fourth insert pocket 15D of the adapter is identical and is circumferentially arranged at equal intervals about the indexing axis center AI (shown in FIG. 3) about which the adapter 14 has four-way rotational symmetry. As can be seen from FIG. 1A, it can be seen that the second insert pocket 15B includes a base jaw 17A, a second jaw 17B, and a slot end 17C. It is understood that the remaining pockets 15A, 15C, and 15D have a similar structure.

[0099]

[0098] Returning to the first insert pocket 15A, adjacent to each of the insert pockets 15, outside the insert adapter 14, adjacent to the base jaw 17A, there is an external pocket clearance face 17D, and adjacent to the second jaw 17B, there is an external pocket rake face 17E.

[0100]

[0099] Referring briefly to FIG. 3, the parting adapter 14 further includes a first main adapter surface 19A and a second main adapter surface 19B. The first peripheral adapter bearing surface 54A, the second peripheral adapter bearing surface 54B, the third peripheral adapter bearing surface 54C and the fourth peripheral adapter bearing surface 54D connect the first main adapter surface 19A and the second main adapter surface 19B.

[0101]

[0100] The holder 12 includes a holder head portion 32 and a holder shank portion 34.

[0102]

[0101] The holder shank portion 34 is fixed to a machine interface 18, which can be a tool post or a turret, etc.

[0103]

[0102] The holder head portion 32 includes an adapter pocket 36.

[0104]

[0103] The holder head portion 32 includes a holder concave front surface 44, which is useful for structural strength when the holder 12 is used with a standard parting adapter.

[0105]

[0104] The adapter pocket 36 includes an adapter pocket side surface 46 and a pocket protruding edge 48 extending along the adapter pocket side surface 46.

[0106]

[0105] In this preferred but non-limiting example, the pocket protruding edge 48 can include a pocket lower adjacent surface 48A facing the forward direction DF, a pocket rear abutting surface 48B facing the upward direction DU, and preferably a pocket relief recess 48C connecting the pocket lower abutting surface 48A and the pocket rear abutting surface 48B.

[0107]

[0106] The holder shank portion 34 further has a holder shank axis As, which is shown for understanding the position when the cross-sectional shape of the holder shank is circular.

[0108]

[0107] The foremost virtual line L1 extends in the X-axis direction (the forward direction DF in the illustrated reference direction) from the uppermost holder shank surface 52A to the foremost cutting edge 30A.

[0109]

[0108] In this example, the term "uppermost holder shank surface" refers to the foremost surface of the shank in the Y-axis direction (the upward direction DU in the illustrated reference direction), and the term is arbitrarily referenced with respect to the X-axis direction in this specification, that is, the holder shank surface that is in the uppermost direction DU in FIG. 1A; the term "uppermost" is merely a name, and in the case of a square or rectangular shank, the surface shown as 52A is understood to be a relevant reference surface known in the art. In the case of a cylindrical or other circular type of shank, the foremost surface is a thin linear portion of the shank parallel to the holder shank axis AS and is the foremost portion of the shank in the Y-axis direction.

[0110]

[0109] Since the position of the holder shank portion 34 is set from the connection portion with the machine interface 18, the position of the foremost cutting edge 30A is calibrated to zero on the CNC machine and does not require any offset input.

[0111]

[0110] As shown in the side view of FIG. 1A, it is understood that the foremost cutting edge 30A is directly in the forward direction DF from the uppermost holder shank surface 52A even without the useful explanatory aid of the foremost virtual line L1.

[0112]

[0111] As will be described in more detail below, a pocket projection 53 in the form of a pin 53A fixed to the pin hole 53B is formed in the adapter pocket 36 (shown better in FIG. 4C).

[0113]

[0112] Referring now to FIG. 2, to reach the position illustrated in FIG. 1A, the punching adapter 14 is removed from the holder 12, and a two-step sequence including, for example, one rotation and one inversion may be performed. For example, after removal, the punching adapter 14 may first be rotated clockwise (90°) about the indexing axis AI of the punching blade, and then inverted from right to left and inserted again. In another sequence, the transition from FIG. 1A to FIG. 2 may be achieved by first inverting the punching adapter 14 from left to right and then rotating it 90° counterclockwise and inserting it again. With respect to FIG. 3, further sequences will be described below. In any of these sequences, for machining the workpiece 20, the punching adapter 14 is oriented in a second orthogonal direction. In any of these sequences, the punching adapter 14 is effectively pivoted about the leading cutting edge 30A so as to be oriented in the second orthogonal direction for machining the workpiece 20.

[0114]

[0113] Further, after the punching adapter 14 is removed and before it is reattached to the holder 12, the pin 53A shown in FIG. 1A is first removed from the pin hole 53B, and then the punching adapter 14 is attached to the adapter pocket 36.

[0115]

[0114] More specifically, in the reconfigured tool, the upward DU is also, here, the Y-axis feed direction, which is the direction in which the tool assembly 10 is moved relative to the workpiece 20 for machining the workpiece 20 (rotated here in the clockwise direction DC).

[0116]

[0115] The leading cutting edge 30A at both positions (i.e., both in FIGS. 1A and 2) is aligned with the so-called uppermost holder shank surface 52A, and the only necessary calibration in the orientation of FIG. 2 is such that, as schematically shown by a second virtual line L2 extending perpendicularly in the forward direction DF and the rearward direction DR from the center point WC to the leading cutting edge 30A, the leading cutting edge 30A is aligned with the central workpiece axis AW, which is the forward direction DF and the rearward direction DR.

[0117]

[0116] The diagonal plane P (FIG. 2) can extend through the leading cutting edge 30A and through the opposing jaws of the insert pocket.

[0118]

[0117] The terms "indexing" and "reversing" are known in the art, but the terms for changing the orientation of a particular tool or cutting insert from the X-axis orientation to the Y-axis orientation (i.e., changing between said "two different orthogonal directions") are not known to the applicant.

[0119]

[0118] One way is to define that the rake face and the relief face of the insert pocket are swiveled relative to each other (the current-shaped adapter can be swiveled at an angle of 180°).

[0120]

[0119] Alternatively defined, the working cutting insert 16 and the plunge adapter 14 to which the working cutting insert 16 is attached can be inverted about the diagonal plane P (FIG. 2) (i.e., rotated 180°). At least the insert pocket is mirror-symmetrical with respect to the first orientation with respect to the second orientation achieved after the plunge adapter 14 is inverted about the diagonal plane P.

[0121]

[0120] Further alternatively defined, the insert pocket can be rotated 180° about a bisector line LB extending through the centers of two orthogonal positions. The bisector line LB can be defined as extending through a predetermined cutting edge position (the position occupied by the cutting edge 30A) defined by the insert pocket, as is known in the art. More precisely, the bisector line LB extends through the center of the piercing adapter 14 (not necessarily through the indexing axis center AI, depending on the shape of the piercing adapter 14, but rather it means that it is equidistant from the first main adapter surface 19A and the second main adapter surface 19B).

[0122]

[0121] Further alternatively defined, with respect to the working cutting insert 16, the foremost cutting edge 30A can be held in a single position, and the insert (and any component parts such as the adapter to which the insert is attached) is rotated 180° about the front cutting edge. In other words, the end portion on the opposite side of the cutting edge 30A (visible from FIGS. 1A and 2 as extending into the sheet) is turned over.

[0123]

[0122] To ensure understanding, referring now to FIG. 3, a schematic illustration is provided of how such a change in position is achieved (it is difficult to understand in a 2D drawing for a symmetric object, and instead of simply showing the rotated adapter as shown in FIGS. 1A - 2, a more detailed explanation that can be shown is exemplified here for understanding, and such an exact sequence of movements is not actually required).

[0124]

[0123] The same adapter 14 as described above is shown in a first (initial) position 14A, a second (intermediate) position 14B, and a third (final) position 14C with respect to the forward direction DF.

[0125]

[0124] In the top figure, the first position 14A of the adapter may correspond to, for example, the orientation shown in FIG. 1A (in this example, the direction shown in FIG. 1A is used for illustrative purposes only; alternatively, it may be the orientation of FIG. 2, in which case the forward direction DF shown in the first position 14 is replaced with the upward direction DU with the necessary modifications, and the same applies hereinafter).

[0126]

[0125] From its initial position, the adapter 14 (or insert) at the initial position 14A is rotated 90° in the counterclockwise direction DCC, while the leading cutting edge 30A is maintained in the same position (i.e., it does not undergo translational movement but only rotational movement; for ease of understanding, the adapter 14 at the translated position 14B is depicted at a different translated position, but it can be imagined that the leading cutting edge 30A is adjacent to the first position 14A in a state where it has not undergone the same translational movement; as a result, the rake face 22 of the adapter 14 at the intermediate position 14B is perpendicular to the first position 14A here).

[0127]

[0126] While maintaining the rake face 22 (and the leading cutting edge 30A) in the same position (i.e., without undergoing translational movement), the adapter 14B is inverted from right to left as indicated by the arrow 56.

[0128]

[0127] As a result, the adapter 14 at the final position 14C is in the second orthogonal direction, which is the Y-axis feed direction or the upward direction DU (a non-limiting relative direction is used in this example).

[0129]

[0128] Referring now to FIGS. 4A - 4C, if the pin 53A is not removed from the pin hole 53B, the adapter 14 could not be attached to the adapter pocket 36 in the orientation shown in FIG. 2. In the illustrated example, when attempting to attach the adapter 14 to the holder 12 in the same orientation as FIG. 2, the external pocket relief surface 17D abuts against the pin 53A. Thus, if one of the specific orientations is to be repeatedly used for machining, the pocket protrusion prevents incorrect attachment of the adapter 14.

[0130]

[0129] The position of the pocket protrusion is, although non-limiting, particularly useful at the insert pocket position when the insert pocket is asymmetric (i.e., the location where the insert pocket is disposed on the adapter pocket 36). This is because when the adapter 14 is correctly attached, the user does not need to perform any special operations for attachment and does not even need to notice or pay attention to the pocket protrusion.

[0131]

[0130] The above examples were not related to a specific way in which the cutting adapter 14 is attached (i.e., fixed) to the holder 12, but FIG. 5 details one exemplary way.

[0132]

[0131] Referring to FIG. 5 of the present application, it should be noted that FIG. 19A of U.S. Patent Application Publication No. 2019 / 0240741 has a tool holder 404 and an adapter pocket that is similar to but not identical to the adapter pocket 400 of FIG. 5.

[0133]

[0132] The same reference numerals are assigned to corresponding features in FIG. 19A of U.S. Patent Application Publication No. 2019 / 0240741 and current FIG. 5. Specifically, both adapter pockets include: a first threaded tool hole 432, a tool holder outlet opening 434 for transmitting coolant to the cutting adapter 14; a biasing hole 436 for providing a biasing element 438 (FIG. 20A of U.S. Patent Application Publication No. 2019 / 0240741); and a pocket surface 444 having a plurality of peripheral threaded tool holes 450A, 450C (note that in this preferred embodiment, it has been found that two peripheral threaded tool holes are required instead of three as shown in U.S. Patent Application Publication No. 2019 / 0240741).

[0134]

[0133] Referring only to FIG. 5 of the present application, additional elements are added to configure the adapter pocket 400 in two different orthogonal directions, and an apostrophe (') is added to the end of the corresponding elements.

[0135]

[0134] Accordingly, an additional first threaded tool hole 432', an additional tool holder exit opening 434', and two additional peripheral threaded tool holes 450A', 450C' are added. As can be seen from the plan view of FIG. 5, the adapter pocket 400 has a pocket bisecting plane P1, about which the first threaded tool holes 432, 432', the exit openings 434, 434', and the peripheral threaded tool holes 450A, 450A, 450C, 450C' are mirror symmetric.

[0136]

[0135] In this example, the biasing hole 436 and the biasing element 438 are provided only for a single orientation. However, it is understood that additional biasing holes (not shown) can be provided as needed, and the biasing element 438 can be attached to the additional biasing holes. In such a case, the entire pocket surface 444 has mirror symmetry with respect to the pocket bisecting plane P1.

[0137]

[0136] It is understood that FIG. 5 shows only one possible modification out of many modifications that can enable the two different orthogonal orientations.

[0138]

[0137] It is understood that the adapter should have a contact surface (or outer surface) to enable two or more orthogonal orientations. These contact surfaces can be attached to the same pocket surface to maintain the same cutting edge position.

[0139]

[0138] Finally, referring to FIGS. 6A - 6C, an example of a tool assembly 100 configured for two different orthogonal orientations is shown.

[0140]

[0139] The tool assembly 100 includes, for purposes of explanation, a holder 102 and at least one (and two in the illustrated example) cutting inserts 104, 106 that are identical but are referred to herein as an X - axis cutting insert 104 and a Y - axis cutting insert 106.

[0141]

[0140] The X-axis cutting insert 104 is fixed to the X-axis insert pocket 105 (FIG. 6C), and the Y-axis cutting insert 106 is fixed to the Y-axis insert pocket 107 (FIG. 6C).

[0142]

[0141] Preferably, the holder comprises a shank portion 108 and a head portion 110. Both the X-axis pocket 105 and the Y-axis pocket 107 are formed on the head portion 110 and both open to the end face 120 of the head portion 110. However, the X-axis pocket seating surface 105A and the Y-axis pocket seating surface 107A face in different orthogonal directions.

[0143]

[0142] The external rib 112 preferably extends perpendicular to the longitudinal axis AL of the shank portion 108 and provides a stopper function between the head portion 110 and the shank portion 108.

[0144]

[0143] In FIG. 6B, the X-axis cutting insert 104 is oriented to machine the workpiece 114 in the designated “X” direction. In this cutting configuration, the resulting first cutting force FX experienced by the actuated X-axis cutting insert 104 (i.e., most of the tangential cutting force component with respect to the workpiece 114, note that the overall cutting force is directed a little more towards the shank portion 108) is directed transverse to the interface direction D1 (the direction D1 is basically the direction from the head portion 110 towards the machine interface where the shank portion 108 is held). As can be seen from FIG. 6A, the interface direction D1 extends substantially along the length of the shank portion 108.

[0145]

[0144] In FIG. 6C, the Y-axis cutting insert 106 is oriented to machine the workpiece 116 in the designated “Y” direction. In this cutting configuration, the resulting second cutting force FY (i.e., the majority of the tangential cutting force component with respect to the workpiece 114) experienced by the actuated Y-axis cutting insert 106 is directed parallel to the direction D1 from the head portion toward the machine interface where the shank portion 108 is held. And again, as can be seen from FIG. 6C, the direction D1 extends substantially along the length of the shank portion 108. In certain embodiments, D1 can extend in the rearward direction DR.

[0146]

[0145] The X-axis insert pocket 105 and the Y-axis insert pocket 107 are positioned apart from each other and, in this preferred example, are at opposite corners of the head portion 110 so that they can be simultaneously attached to the holder 102 and the workpieces 114, 116 can be machined at any time, even if only one of the two inserts is actuated.

[0147]

[0146] If it is not necessary to machine in both orientations in a single attachment, the holder 102 can optionally have only one cutting insert attached thereto, as shown in FIGS. 6D and 6E.

Claims

1. A method of clamping an adapter to a holder, the holder comprising a single adapter pocket configured to hold the adapter in a first orientation configured to machine a workpiece in a first orthogonal direction of two different first and second orthogonal directions, and in a second orientation configured to machine the workpiece in the second orthogonal direction, the method comprising: (a) first selecting the first orthogonal direction; (b) fixing the adapter in the first orientation in the adapter pocket for machining in the selected first orthogonal direction; (c) machining the workpiece in a first machining step without providing an offset in the first orthogonal direction and the second orthogonal direction to a CNC machine operably connected to the holder; (d) removing the adapter; and then (e) fixing the adapter in the second orientation for further machining the workpiece in a second machining step without providing an offset in the first orthogonal direction to the CNC machine; or (f) first selecting the second orthogonal direction; (g) fixing the adapter in the second orientation in the adapter pocket for machining in the selected second orthogonal direction; (h) machining the workpiece in a first machining step without providing an offset in the first orthogonal direction to a CNC machine operably connected to the holder; (i) removing the adapter; and then (j) fixing the adapter in the first orientation for further machining the workpiece in a second machining step without providing an offset in the first orthogonal direction and the second orthogonal direction to the CNC machine.

2. The adapter comprises an insert pocket and a cutting insert attached to the insert pocket, the method further comprising moving the holder in the first orthogonal direction for machining the workpiece with the adapter via the cutting insert during step (c).

3. The adapter includes an insert pocket and a cutting insert attached to the insert pocket, and the method further includes, after the step (e), moving the holder in the second orthogonal direction to machine the workpiece with the adapter via the cutting insert, the method according to claim 1.

4. The machining in the first orthogonal direction and the second orthogonal direction is performed by using the same cutting insert, the method according to claim 3.

5. After the step of removing the adapter from the adapter pocket, but before fixing the adapter in the second orientation to the adapter pocket, a two-step sequence including one rotation and one reversal of the adapter is performed, the method according to claim 3.

6. After the step of removing the adapter from the adapter pocket, but before fixing the adapter in the second orientation to the adapter pocket, the leading cutting edge of the cutting insert is held in a single position, and the insert and the adapter to which the insert is attached are rotated 180° about the leading cutting edge, the method according to claim 3.

7. The method according to claim 3, including rotating the workpiece in a first rotational direction when machining with the adapter in the first orientation and rotating the workpiece in an opposite second direction when machining with the adapter in the second orientation.

8. The adapter is fixed to the adapter pocket, the adapter pocket includes a plurality of holes, and the method includes fixing the adapter in the first orientation to the adapter pocket using fewer holes than all of the plurality of holes, the method according to claim 1.

9. After the step of fixing the adapter to the adapter pocket in the first orientation, the adapter is removed and fixed to the adapter pocket in the second orientation using at least one of the plurality of holes that is not used to fix the adapter in the first orientation using fewer holes than all of the plurality of holes, the method according to claim 8.

10. The adapter is fixed to the adapter pocket, the adapter includes an adapter recess, the adapter pocket includes a pocket protrusion for preventing attachment of the adapter to the adapter pocket in the second orientation, and the method includes fixing the adapter to the adapter pocket with the pocket protrusion protruding into the adapter recess, the method according to claim 1.

11. The method according to claim 10, wherein the adapter recess is an insert pocket of the adapter.

12. The adapter includes a plurality of insert pockets, and the method further includes performing machining in at least one of the first orthogonal direction and the second orthogonal direction by using two or more of the plurality of insert pockets, the method according to claim 1.

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