Y-axis plunge cutting adapter for cutting tools

Abstract

A cutting tool assembly having a longitudinal axis that establishes an upward and downward direction includes a Y-axis parting adapter mounted to a holder. The parting adapter has an insert pocket including a base jaw configured to support a cutting insert. The holder has a holder head portion and a shank portion. The holder head portion has an adapter pocket into which the parting adapter is mounted. When the holder shank cross-sectional shape is square or rectangular, the forward-most cutting edge is directly above the forward-most holder shank face, and when the holder shank cross-sectional shape is circular, a centrally extending holder shank axis extends to the forward-most cutting edge.

Description

Technical Field

[0001]

[0001] The subject matter of the present invention relates to a parting adapter configured to perform a parting and grooving process along the Y-axis feed direction, and a holder configured to hold the parting adapter. The present invention also relates to a tool assembly including both the parting adapter and the holder, and a machining method using the tool assembly.

Background Art

[0002]

[0001] The present application relates to parting components and a machining process in which those components are used in a so-called Y-axis feed direction rather than in the X-axis direction.

[0003]

[0002] Such processes are disclosed in US Patent Application Publication No. 2020 / 0009757 regarding a Y-axis blade portion and US Patent Application Publication No. 2019 / 0358710 regarding a machining method related to the same structure (hereinafter referred to as "the said patent publication").

[0004]

[0003] Known product publications regarding blade portions corresponding to those shown in the said patent publication are disclosed in "Y-axis parting" by Sandvik Coromant (the said publication displays an identification footer: "C-1040:194 en-GB C AB Sandvik Coromant 2017"; hereinafter referred to as "the Sandvik publication") and "Parting Off in the Y-Axis" by Horn (the said publication displays an identification footer: "INFO11.19DE, 09 / 2019, Printed in Germany"; hereinafter referred to as "the Horn publication"). It should be understood that these product publications are examples and are not intended to be an exhaustive list of all catalog publications related to these products.

[0005]

[0004] Returning to the said patent gazette, it is described that there was a desire to reduce vibration in the conventional blanking or deep grooving process. Therefore, in summary, an alternative blade portion has been proposed in which the blade portion extends basically in the same direction as the major flank of the cutting insert mounted on the blade portion. The change briefly described in the Sandvik publication is that the insert pocket is rotated 90 degrees.

[0006]

[0005] The applicant also further discusses such tools in US Patent Application Publication No. 2019 / 0240741.

[0007]

[0006] This application is not related to the variable protruding blade discussed in the previous embodiments of the said patent gazette, but rather to a so-called "blanking adapter" having a cutting portion and an adapter shank portion that defines a single (non-variable) position of the adapter within a holder similar to the type illustrated in the last embodiment of the said patent gazette (specifically FIGS. 16 to 18 of both gazettes) and as shown in the Horn publication.

[0008]

[0007] The blanking adapter of the present invention is configured to be held by the said holder, similar to the above-mentioned gazette, and the said holder includes a holder head portion and a holder shank portion (also referred to as a "coupling portion" in the said patent gazette) configured to connect to a machine interface such as a turret or a tool post. The holder shank portion can be of any known type, such as a rectangular or square cross-section shank (as shown in the drawings of this application), or can be basically cylindrical or basically conical according to the type described in ISO standard 26623-1 or ISO12164-3 (also identified in the above-mentioned publications).

[0009]

[0008] An object of the present invention is to provide a novel and improved Y-axis blanking adapter, a tool assembly including the Y-axis blanking adapter, and methods of operating them.

Summary of the Invention

[0010]

[0002] Although the above-described Y-axis parting tool can provide good vibration control, it has been observed that its setting is difficult.

[0011]

[0003] 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 initialized without the need to offset the position of the tool assembly (i.e., adjust the setting of the non-zero position of the cutting edge; hereinafter referred to as "offset"). On the other hand, in a known Y-axis tool assembly, offsets are required along both the X-axis and the Y-axis.

[0012]

[0004] Machines capable of Y-axis feed machining can provide both of the above offsets, but it has been considered to reduce the complexity of 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 an offset, but it can still provide Y-axis stability (vibration reduction).

[0013]

[0005] According to a first aspect of the present invention, 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 a leading holder shank face and a holder shank cross-sectional shape, wherein the holder shank cross-sectional shape is square or rectangular, and the leading cutting edge is directly above the leading holder shank face; or the holder shank cross-sectional shape is circular, and the holder shank axis extends to the leading cutting edge.

[0014]

[0006] In particular, in the case of a square or rectangular holder shank (which is a standard type in the industry), the leading cutting edge needs to be aligned with the leading holder shank face, whereby it suffices to offset the tool assembly in a single direction, if necessary, in the X-axis direction (i.e., the direction parallel to the extension direction of the holder shank portion).

[0015]

[0007] 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 also understood that this is a standard shank type in the industry. In the case of such a shank type, the leading cutting edge needs to be aligned with the central holder shank axis, whereby it suffices to offset the tool assembly in a single direction, if necessary, i.e., in the X-axis direction.

[0016]

[0008] The alternative option is the same concept that consists of only 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 word "circular" is understood to cover various shank types (e.g., the types shown in the Horn publication entitled "C6" on page 6 and "HSKT63" on page 7, including their sizes), or rather, basically means that the alignment position is along the center of the shank.

[0017]

[0009] The advantages of the various aspects will be described below after the description of the various aspects.

[0018]

[0010] The first aspect is written concisely without defining features such as a reference direction understood by those skilled in the art. For the sake of completeness, more specifically, according to a second aspect of the present invention, a tool assembly is provided, the tool assembly comprising: a parting adapter; a cutting insert; and a holder, wherein the parting adapter comprises: a cutting portion; and an adapter shank portion connected to the cutting portion, the cutting portion 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-edges; and an upper sub-edge connecting the front and rear sub-edges, the first and second side surfaces defining a first lateral direction directed from the first side surface to the second side surface and a second lateral direction opposite the first lateral direction; a forward direction is defined to be perpendicular to the first and second lateral directions and directed from the rear sub-edge to the front sub-edge, a rearward direction is defined to be opposite the forward direction; an upward direction is defined to be perpendicular to both the first and second lateral directions and the forward and rearward directions and directed from the adapter shank portion to the cutting portion; a downward direction is defined to be opposite the upward direction; the cutting portion further comprises an insert pocket formed at an intersection of the front sub-edge and the upper sub-edge; the insert pocket comprising: a base jaw having a foremost base jaw face; a second jaw disposed at least partially 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 is fixed in the insert pocket, and the cutting insert comprises: an insert base face abutting the base jaw; an upwardly facing rake face disposed above the insert base face; an insert second face abutting the second jaw; a foremost relief face extending downward from the rake face; and a foremost cutting edge formed at an intersection of the rake face and the foremost relief face, the holder comprising: a holder head portion;A holder shank portion connected to the holder head portion, wherein the holder head portion includes an adapter pocket to which the adapter shank portion is fixed, and the holder shank portion includes: 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; a foremost holder shank face; and a virtual line extending upward from the foremost holder shank face, wherein the holder shank cross-sectional shape is square or rectangular and the foremost cutting edge is directly above the foremost holder shank face; or the holder shank cross-sectional shape is circular and the holder shank axis extends to the foremost cutting edge.;

[0019]

[0011] The second aspect has the same advantages as the first aspect.

[0020]

[0012] The standard definition regarding offset is as described above in relation to the cutting insert in the first and second aspects, although an alternative definition of the present invention can be made without the cutting insert.

[0021]

[0013] Accordingly, a third aspect of the present invention provides a tool assembly, the tool assembly comprising: a plunge cutting adapter; a holder comprising a foremost holder shank face, a virtual line extending upward from the foremost holder shank face, and a holder shank portion having a holder shank cross-sectional shape, wherein the plunge cutting adapter includes an insert pocket, the insert pocket comprising: a base jaw having a foremost base jaw face; and a second jaw connected to the base jaw via a slot end, wherein the holder shank cross-sectional shape is square or rectangular and the foremost base jaw face is within an allowable distance DT of 2 mm from the virtual line; or the holder shank cross-sectional shape is circular and the foremost base jaw face is within an allowable distance DT of 2 mm from the holder shank axis.

[0022]

[0014] The third aspect is written concisely without defining features such as a reference direction understood by those skilled in the art. For the sake of completeness, more specifically, according to a fourth aspect of the present invention, a tool assembly is provided, the tool assembly comprising: a parting adapter; and a holder, wherein the parting adapter comprises: a cutting portion; and an adapter shank portion connected to the cutting portion, the cutting portion 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 lateral direction directed from the first side surface to the second side surface and a second lateral direction opposite the first lateral direction; a forward direction is defined as being perpendicular to the first and second lateral directions and directed from the rear sub-periphery to the front sub-periphery, a rearward direction is opposite the forward direction; an upward direction is defined as being perpendicular to both the first and second lateral directions and the forward and rearward directions and directed from the adapter shank portion to the cutting portion; a downward direction is defined as being opposite the upward direction; the cutting portion further comprises an insert pocket formed at an intersection of the front sub-periphery and the upper sub-periphery; the insert pocket comprising: a base jaw having a foremost base jaw face; a second jaw disposed at least partially 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 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 foremost holder shank face;a virtual line extending upward from the frontmost holder shank surface, and the cross-sectional shape of the holder shank is square or rectangular, and the frontmost base jaw surface is within an allowable distance DT of 2 mm from the virtual line; or the cross-sectional shape of the holder shank is circular, and the frontmost base jaw surface is within an allowable distance DT of 2 mm from the holder shank axis.;

[0023]

[0015] The allowable distance DT is preferably less than 1 mm, and more preferably less than 0.5 mm.

[0024]

[0016] A preferred parting adapter that can be used in the above tool assembly embodiments will be described. Nevertheless, it should be understood that the tool assembly embodiments and method embodiments listed below are merely alternatives as they are advantageous over the prior art even without the features listed in the following parting adapter embodiments.

[0025]

[0017] According to a fifth aspect of the present invention, a parting adapter is provided, the parting adapter comprising: a blade region defined by having a blade portion thickness equal to the minimum thickness of the cutting portion of the parting adapter, the blade region having: a maximum height HM measurable parallel to the upward and downward directions and from the blade lowest point to the blade highest point; and a maximum width WM measurable parallel to the forward and backward directions and from the blade region foremost point to the blade region rearmost point, wherein the maximum width WM and the maximum height HM satisfy the condition WM≧HM.

[0026]

[0018] In particular, in contrast to the above-mentioned publications, the parting adapter defined above has a maximum width greater than its maximum height. This allows for smaller protrusion and cutting depths, but improves stability due to the forces acting on the cutting insert during machining and subsequently on the insert pocket. Nevertheless, as will be explained below, there are significant limitations to the range of widths that can be provided.

[0027]

[0019] The fifth aspect is written concisely without defining features such as a reference direction understood by those skilled in the art.

[0028]

[0020] For the sake of completeness, more specifically, according to a sixth aspect of the present invention, a plunge cutting adapter is provided, the plunge cutting adapter comprising: a cutting portion; and an adapter shank portion connected to the cutting portion, the cutting portion comprising: opposite first and second side surfaces; and a periphery connecting the first and second side surfaces, the periphery comprising: opposite front sub-periphery portions and rear sub-periphery portions; and an upper sub-periphery portion connecting the front sub-periphery portions and the rear sub-periphery portions, the first and second side surfaces defining: a first lateral direction directed from the first side surface to the second side surface; and a second lateral direction opposite to the first lateral direction; a forward direction is defined perpendicular to the first and second lateral directions and directed from the rear sub-periphery portion to the front sub-periphery portion; a rearward direction is opposite to the forward direction; an upward direction is defined perpendicular to both the first and second lateral directions and the forward and rearward directions and directed from the adapter shank portion to the cutting portion; a downward direction is defined opposite to the upward direction; the cutting portion further comprising: an insert pocket formed at an intersection of the front sub-periphery portion and the upper sub-periphery portion; a blade portion thickness measured parallel to the first and second lateral directions in the insert pocket; and a blade region defined by having a thickness corresponding to the blade portion thickness, the blade region having: a maximum height HM measurable parallel to the upward and downward directions and from a lowest point of the blade region to a highest point of the blade region; and a maximum width WM measurable parallel to the forward and rearward directions and from a foremost point of the blade region to a rearmost point of the blade region, the maximum width WM and the maximum height HM satisfying the condition WM≧HM.

[0029] According to a seventh aspect of the present invention, a tool assembly is provided, the tool assembly comprising: a longitudinal axis establishing opposite upward and downward directions; a transverse axis intersecting the longitudinal axis and perpendicular to the longitudinal axis, the transverse axis establishing opposite forward and rearward directions respectively; a thickness axis intersecting both the longitudinal axis and the transverse axis and perpendicular to both, the thickness axis establishing opposite first and second transverse directions respectively, the tool assembly comprising a holder having a holder shank with a holder shank axis extending along the center of the holder shank, the holder shank axis coinciding with the longitudinal axis, the holder shank comprising a foremost holder shank face that is foremost in the forward direction; a holder head connected to the holder shank and extending forward along the longitudinal axis from the holder shank, the holder head comprising an adapter pocket facing the first transverse direction; a parting adapter fixed in the adapter pocket of the holder head, the parting adapter comprising: an adapter shank having an adapter clamping device through which the parting adapter is fixed in the adapter pocket of the holder head; an adapter cutting part connected to the adapter shank, the adapter cutting part comprising: a first side face and a second side face facing the first and second transverse directions respectively; a periphery connecting the first side face and the second side face, the periphery comprising a front sub-edge part and a rear sub-edge part spaced apart from each other along the transverse axis, and an upper sub-edge part connecting the front sub-edge part and the rear sub-edge part; an insert pocket formed at the intersection line of the front sub-edge part and the upper sub-edge part, the insert pocket comprising: a base jaw having a foremost base jaw face; a second jaw at least partially disposed above the base seat jaw; and a slot end connecting the base jaw and the second jaw, in a plan view of the tool assembly, a virtual line extends from the foremost holder shank face, through at least a part of the holder head, beyond the parting adapter in the upward direction, parallel to the longitudinal axis, and passes within an allowable distance DT of 2 mm of the foremost base jaw face.

[0030]

[0022] The tool assembly may further include a cutting insert fixed to the insert pocket of the plunge cutting adapter, and the cutting insert includes: an insert base surface in contact with the base jaw; an insert second surface in contact with the second jaw; an upwardly facing rake surface in front of the insert base surface; a foremost relief surface extending downward from the rake surface; and a foremost cutting edge formed at the intersection of the rake surface and the foremost relief surface.

[0031]

[0023] According to an eighth aspect of the present invention, a method of plunge cutting in the Y-axis feed direction is provided, the method comprising: (a) fixing a plunge cutting adapter to a holder having an elongated shank; (b) fixing the holder to a machining interface before or after step (a); (c) setting an offset only in the X-axis direction defined as a direction parallel to the elongated shank of the holder; (d) subsequent to step (c), moving the plunge cutting adapter in the Y-axis direction defined as a direction perpendicular to the X-axis direction with respect to a rotating workpiece to plunge cut the workpiece.

[0032]

[0024] The above method is preferably carried out using the plunge cutting adapter or tool assembly defined in the previous aspect.

[0033]

[0025] On the one hand, it is understood that the method is more complex than the normal method of plunge cutting in the X-axis feed direction, but simpler than the currently known methods of plunge cutting in the Y-axis feed direction.

[0034]

[0026] Here, the advantages over the prior art will be described.

[0035] Although not bound by theory, it is believed that the known prior art Y-axis feed blades and parting adapters do not have the above-mentioned advantageous alignment for at least the following reasons. The first reason is that the force distribution in the prior art is more logical and the cutting edge appears to be in front of the front holder shank face or the center holder shank axis (depending on which shank type is used). This is because, as shown in FIG. 6 of the above-mentioned US Patent Application Publication No. 2019 / 0240741, the machining force is not exactly in the Y-axis direction (downward), but in the downward and rearward (diagonal) directions.

[0036] Since the overall purpose of the known prior art is to improve stability, it is logical for the machining interface to have downward and rearward cutting forces directed as much as possible to the area where the machining interface is fixed to the holder. Moving the cutting edge backward is expected to increase the vibration of the tool assembly.

[0037] Therefore, the present invention takes into account sacrificing some stability in exchange for another advantage of ease of setting.

[0038] The second reason is that although it may not seem beneficial that one offset is probably simpler for the operator than two offsets (since in any case an offset needs to be entered), the inventor is still convinced that such an advantage is preferable for a slight additional stability.

[0039] Furthermore, as further defined in the aspect of the parting adapter (and of course in the aspect of the tool assembly where it can be used), the height of the parting adapter is preferably smaller than the height of the known elongated (tall and thin) parting blades and adapters. Therefore, this reduces the overall protrusion amount (and thus the cutting depth capability), but the main cutting force is directed more by the machining interface than when the cutting edge is further separated upward from the machine interface.

[0040]

[0031] A second advantage of making the height smaller relative to the width is that it provides additional stability to the unsupported cutting portion of the plunge adapter (i.e., the portion that is not fixed to the holder and is thus more prone to bending).

[0041]

[0032] Without being bound by theory, it is believed that prior art blades and plunge adapters are preferably thinner and longer in order to provide a more advantageous depth of cut, and the stability of the tool is already provided by the advantages of machining in the Y-axis feed direction in which the machining force is already directed towards the machine interface.

[0042]

[0033] Nevertheless, since such tools are preferably designed to remain within the circumcircle of the desired dimensions (in end view), there is a limit to how much the plunge adapter of the present application can be widened (see, for example, page 6 of the Horn publication showing a circumcircle with a diameter of 104 mm in this figure). One of the known reasons for this size limitation is to enable the automatic tool change system to be able to change the tool assembly being used within the system. Beyond this size, there is a possibility that the two tool assemblies will collide with each other.

[0043]

[0034] Therefore, it may not have been considered that prior art tools could be wider than they actually are, or that the cutting edge could be displaced further back than it actually is (since the blade portion requires a certain amount of material behind it for stability to compensate for the stability).

[0044]

[0035] With the above limitations in mind, a preferred maximum width-to-height ratio is provided by the present invention, which is intended to benefit from higher stability, but in a preferred embodiment is still compatible with known automatic tool change systems.

[0045]

[0036] Accordingly, some preferred features according to any of the embodiments are as follows.

[0046]

[0037] Preferably, the maximum width WM and the maximum height HM satisfy the condition of WM ≧ 1.05HM, preferably WM ≧ 1.10HM. Nevertheless, for the reasons described above, it is preferable that the maximum width WM and the maximum height HM satisfy the condition of WM ≦ 1.30HM, preferably WM ≧ 1.20HM.

[0047]

[0038] Preferably, the punching adapter further includes a reinforcing region that is measured parallel to the blade portion thickness and has a reinforcing thickness greater than the blade portion thickness. Thereby, the stability of the cutting portion of the punching adapter not fixed to the holder can be improved.

[0048]

[0039] Such a reinforced portion is known, but the known prior art is not known to provide a very high reinforcing portion. In the present invention, the reinforcing region preferably extends upward from the lowest point of the blade region by a height HR of the reinforcing portion; the reinforcing portion height HR and the maximum height HM satisfy the condition of HR > 0.5HM, preferably HR > 0.65HM, and most preferably HR > 0.75HM.

[0049]

[0040] Nevertheless, despite the fact that such a reinforcing portion improves stability, in some embodiments, it is still preferably not extend over the entire height of the cutting portion. Therefore, it is preferable that the punching adapter satisfies the condition of HR < HM, preferably HR < 0.95HM.

[0050]

[0041] Preferably, the second jaw of the insert pocket is entirely disposed behind the base jaw. Alternatively or additionally, the second jaw and the base jaw of the insert pocket extend adjacent to each other in a direction parallel to the upward and downward directions.

[0051]

[0042] It is understood that the prior art Y-axis feed blade and parting adapter have a second jaw that extends on the base jaw. Thus, the slot ends (and more importantly the resilient grooves) extend behind the base jaw and the second jaw. This means that the blade or the parting adapter needs to extend a relatively large distance behind the insert pocket (i.e., behind the slot ends) in order to provide the same structural stability as the parting adapter with the insert pocket defined in the previous paragraph. Thus, this is yet another reason why prior art blades and parting adapters are designed to have cutting edges further forward than the positions defined in the present invention (also taking into account the size limitations mentioned regarding the circumscribed circle above).

[0052]

[0043] For similar reasons, the parting adapter according to the present invention preferably comprises only a single insert pocket.

[0053]

[0044] As described above, in some embodiments, a non-elongated cutting portion may be considered beneficial. Nevertheless, when measured parallel to the vertical direction, the overall shape of the insert adapter is preferably elongated.

[0054]

[0045] Specifically, instead of the three-component solution shown in US Patent Application Publication No. 2019 / 0240741 (i.e., a parting blade fixed to a holder, the holder is fixed to an additional holder, and the additional holder is configured to be fixed to a machining interface), by providing a two-component solution (i.e., a parting adapter fixed to a holder, the holder is configured to be fixed to a machining interface), this further helps to avoid exceeding the size limitations of the circumscribed circle shown in Figure 1A and reduces the protrusion length from the machining interface.

[0055]

[0010] The insert pocket of the present invention is preferably of the exemplary resilient type (i.e., non-threaded).

[0056]

[0011] The adapter clamping device of the plunge cutting adapter can have various structures such as a tapered blade similar to the plunge cutting blade, but the adapter clamping device has at least one screw hole for fixing it to the holder with at least one screw. This further provides the desired ease of setting as described above (rather than the slide variable depth blade of the prior art).

[0057]

[0012] The various features described above are explained using words such as "frontmost". It is understood that "frontmost" in the present application means that the feature is in a more forward direction with respect to the remaining part of the component (for example, the plunge cutting adapter). It is also understood that all the given directions are not in an absolute sense with respect to the ground, but are for the purpose of the reference of the features with respect to each other. Similarly, although the directions can be arbitrarily selected as defined for a specific component such as the plunge cutting adapter, it is understood that they can be defined in the same way with respect to the holder or the tool assembly.

[0058]

[0013] Finally, as is well known in the art, the rake face is the surface intended for the machined chips to flow thereon, and the flank face is usually designed to recede from the cutting edge.

[0059]

[0046] To better understand the subject matter of the present application and to show how the subject matter of the present application can actually be implemented, reference is now made to the accompanying drawings.

Brief Description of the Drawings

[0060]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 2E

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Figure 3E

DETAILED DESCRIPTION OF THE INVENTION

[0061] Referring to FIGS. 1A - 1E, a tool assembly 10 is shown, which comprises a holder 12, a parting adapter 14 fixed to the holder 12, and a cutting insert 16 fixed to the parting adapter 14. As can be seen in FIGS. 1B and 1C, the tool assembly 10 has a longitudinal axis A1 that establishes opposite upward direction DU and downward direction DD; a transverse axis A2 that intersects the longitudinal axis A1 and is perpendicular to the longitudinal axis A1, and that establishes opposite forward direction DF and rearward direction DR respectively; and a thickness axis A3 that intersects both the longitudinal axis A1 and the transverse axis A2 and is perpendicular to both of them, and that establishes opposite first transverse direction DS1 and second transverse direction DS2 respectively. As can be seen in FIGS. 2B - 2D, these same axes A1, A2, A3 and directions are also relevant to the holder 12.

[0062] Referring particularly to the plan view of the tool assembly 10 shown in FIG. 1B, the holder 12 is shown as being fixed to a schematic mechanical interface 18 shown by phantom lines and is positioned in proximity to a schematic cylindrical rotating workpiece 20 also shown by phantom lines.

[0063] For purposes of explanation, the figures show forward direction DF, rearward direction DR, upward direction DU, downward direction DD, first transverse direction DS1 and second transverse direction DS2.

[0064] As can be understood from FIG. 1B showing the tool assembly 10 with respect to the mechanical interface 18, the upward direction DU also constitutes an X - axis direction parallel to the longitudinal axis A1.

[0065] As can also be understood from FIG. 1B showing the tool assembly 10 with respect to the workpiece 20, the forward direction DF also constitutes a Y - axis feed direction parallel to the transverse axis A2.

[0066] Returning to the remaining portions of FIGS. 1A - 1E, the cutting insert 16 includes a rake face 22 and an opposing insert base face 24, a leading relief face 26A extending downwardly (and slightly inwardly) from the rake face 22 and an opposing insert rear face 28, opposing side relief faces 26B, 26C extending downwardly (and slightly inwardly) from the rake face 22, a leading cutting edge 30A formed at the intersection of the rake face 22 and the leading relief face 26A and having a maximum insert thickness TI; and side cutting edges 30B, 30C connected to the leading cutting edge 30A and formed at the intersections of the rake face 22 and the side relief faces 26B, 26C. U.S. Patent Application Publication No. 2007 / 0086864A1 discloses an exemplary cutting insert having the basic shape described above.

[0067]

[0053] Preferably, the rake face 22 includes a chip former 23.

[0068] Referring also to FIGS. 2A - 2E, the holder 12 includes a holder head portion 32 and a holder shank portion 34.

[0069]

[0055] The holder head portion 32 includes an adapter pocket 36, a plurality of coolant outlets 38A, 38B, 38C, and a plurality of threaded screw holes 40A, 40B, 40C, 40D.

[0070]

[0056] Of note is a lower head abutment face 42 that preferably abuts a machine interface 18 (not shown).

[0071]

[0057] The holder head portion 32 includes a holder concave front face 44 that curves concavely upward in the DU direction. The holder concave front face 44 is useful when the holder 12 is used with a standard parting adapter (not shown) in a machining process along the X - axis feed direction, but is optional in the present invention. Nevertheless, such a feature is preferred because it allows a single adapter to be used in both the X - axis feed direction and the Y - axis feed direction.

[0072]

[0058] Figure 2C is a plan view of the holder 12 and shows details of the adapter pocket 36. The adapter pocket 36 opens in a first lateral direction DS1 (as well as a forward direction DF and an upward direction DU), and includes an adapter pocket base 46 facing the first lateral direction DS1 and a pocket protruding wall 48 extending from there in the first lateral direction DS1.

[0073]

[0059] The pocket protruding wall 48 may include an adapter pocket lower contact surface 48A, a pocket first rear contact surface 48B, and a pocket second rear contact surface 48C.

[0074]

[0060] The holder shank portion 34 includes a plurality of coolant inlets 50A, 50B and a square cross-sectional shape 52 as best seen in Figure 2E. The square cross-sectional shape 52 is formed by a foremost shank surface 52A facing the forward direction DF, a rearmost shank surface 52B facing the rearward direction DR, and a first side shank surface 52C and a second side shank surface 52D facing the opposite first lateral direction DS1 and second lateral direction DS2, respectively. The foremost shank surface 52A extends along the longitudinal axis A1 and is parallel to the longitudinal axis A1.

[0075]

[0061] The holder shank portion 34 further has a holder shank axis AS extending in an upward direction DU and a downward direction DD parallel to the longitudinal axis A1. In the figure, the holder shank axis AS is shown to coincide with the longitudinal axis A1. The holder shank axis AS represents the center of the holder shank portion 34 in both the case of a shank having a square or rectangular cross-section and the case of a shank having a circular (round) cross-section.

[0076] As shown in the plan view of the tool assembly (FIG. 1B), the phantom line LI extends in the upward direction DU, parallel to the longitudinal axis A1, from the foremost holder shank face 52A to the foremost cutting edge 30A. Since the position of the holder shank portion 34 is set from its connection to the machine interface 18, the position of the foremost cutting edge 30A is likewise known and does not require an offset input. The necessary calibration is only in the upward direction DU and the downward direction DD, ensuring that the foremost cutting edge 30A is aligned with the workpiece center point WC, as schematically indicated by a virtual workpiece line WL that extends parallel to the forward direction DF and the rearward direction DR from the center point WC to the foremost cutting edge 30A.

[0077] As shown in the side view of FIG. 1B, even without the phantom line LI, which is a useful explanatory aid, it is understood that the foremost cutting edge 30A is directly above the foremost holder shank face 52A (i.e., in the upward direction DU parallel to the longitudinal axis A1 from the holder shank portion 34).

[0078] Now referring also to FIGS. 3A - 3E, the plunge cutter adapter 14 includes a cutting portion 54 and an adapter shank portion 56. Although it might be considered from the reference numeral "54" of the cutting portion 54 shown in FIG. 3D for reasons to be explained below, the cutting portion 54 does not include the first adapter screw hole 58 seen in FIG. 3B.

[0079] The cutting portion 54 includes opposing first side face 60A and second side face 60B, and a periphery 62. In the assembled tool, the first side face 60A faces the first transverse direction DS1, and the second side face 60A faces the second transverse direction DS2.

[0080] The periphery 62 includes opposing front sub - edge 62A and rear sub - edge 62B, and an upper sub - edge 62C.

[0081] The cutting portion 54 further includes an insert pocket 64.

[0082]

[0068] The cutting portion 54 has a blade portion thickness TB measured parallel to a first transverse direction DS1 and a second transverse direction DS2 (i.e., along the thickness axis A3) in the insert pocket.

[0083]

[0069] The blade portion thickness TB is thinner than the maximum insert thickness TI (shown in FIG. 1C).

[0084]

[0070] The blade region 66 is defined as any region of the cutting portion 54 of the plunge adapter having the blade portion thickness TB. It is understood that any portion of the cutting portion 54 that is not thinner than the maximum insert thickness TI limits the depth of cut to which the plunge adapter 14 can be adapted, since such a portion cannot enter the workpiece 20.

[0085]

[0071] In a given example, the plunge adapter 14 preferably further comprises a reinforcement region 68 defined by a reinforcement thickness TR.

[0086]

[0072] With particular reference to FIG. 1D also, the reinforcement region 68 comprises a concave edge 70 that merges with the blade region 66. The concave edge 70 defines the maximum depth of cut of the plunge adapter 14.

[0087]

[0073] The blade region 66 has a maximum height HM measurable from a blade region lowest point 72 to a blade region uppermost point 74.

[0088]

[0074] The reinforcement region 68 extends upwardly DU from the blade region lowest point 72 to a reinforcement portion height HR.

[0089]

[0075] In a given example, the reinforcement region 68 does not extend to the blade region uppermost point 74 and thus the reinforcement portion height HR is measured to a reinforcement portion uppermost point 76.

[0090]

[0076] For completeness, the blade region 66 further comprises a maximum width WM measurable from a blade region foremost point 80 to a blade region rearmost point 82.

[0091]

[0077] In any case, since the plunge cutting adapter 14 cannot enter the workpiece beyond the concave edge 70, it is understood that the first adapter screw hole 58 (hidden in FIG. 1D, but its position is schematically indicated by the arrow 78) is part of the adapter shank portion 56 rather than part of the cutting portion 54.

[0092]

[0078] The adapter shank portion 56 further includes an adapter clamping device 81, and the adapter clamping device 81 includes the first adapter screw hole 58, the second adapter screw hole 84, the third adapter screw hole 86, and the fourth adapter screw hole 88. A screw (not shown) passes through these to fix the plunge cutting adapter 14 to the threaded screw holes 40A, 40B, 40C, 40D of the holder.

[0093]

[0079] Further, the adapter shank portion 56 further includes an adapter shank edge 90 having an adapter edge lower contact surface 90A, an adapter edge first rear contact surface 90B, and an adapter edge second rear contact surface 90C.

[0094]

[0080] During assembly, the adapter pocket lower contact surface 48A contacts the adapter edge lower contact surface 90A, the adapter pocket first rear contact surface 48B contacts the adapter edge first rear contact surface 90B, and the adapter pocket second rear contact surface 48C contacts the adapter edge second rear contact surface 90C. In particular, this is an ideal situation, but in reality, only one of the adapter pocket first rear contact surface 48B and the adapter pocket second rear contact surface 48C may contact the plunge cutting adapter 14.

[0095]

[0081] The insert pocket 64 includes a base jaw 92, a second jaw 94, and a slot end 95. In this non-limiting example, the second jaw 94 is disposed behind the base jaw 92 along the lateral axis A2 and can thus be regarded as the rear jaw 94.

[0096]

[0082] The insert pocket central axis AC extends midway between the base jaw 92 and the second jaw 94. In the assembled tool, the insert pocket central axis AC extends in the upward direction DU and the downward direction DD, substantially parallel to the longitudinal axis A1. Thus, since the insert pocket 64 is different from a more general alternative insert pocket type (not shown) that extends basically in the forward direction DF and the rearward direction DR, the maximum dimension of the current insert pocket 64 is smaller than that of the alternative insert pocket having a second jaw extending on the base jaw (not shown).

[0097]

[0083] The foremost base jaw surface 96 extends downwardly DD from the base jaw 92.

[0098]

[0084] Referring particularly to FIGS. 1B and 3C, the cutting insert 16 is secured in the insert pocket 64. More specifically, the only points of contact between the cutting insert 16 and the insert pocket 64 are where the insert base surface 24 abuts against the base jaw 92 and the insert second surface 28 abuts against the second jaw 94.

[0099]

[0085] As seen in the plan view of the tool assembly 10 of FIG. 1B, since the plunge adapter 14 passes within the allowable distance DT of 2 mm from the foremost base jaw surface 96, the virtual line LI extends upwardly DU parallel to the longitudinal axis A1, from the foremost holder shank surface 52A, along at least a portion of the holder head 32, and beyond the plunge adapter 14. Briefly, the foremost base jaw surface 96 is within the allowable distance DT from the virtual line LI (FIG. 1B).

[0100]

[0086] Regarding the advantages and disadvantages of the shape of the plunge adapter 14, using the schematic elements (cutting force direction FC and machining interface 20) shown in FIG. 1B, as shown, the cutting force FC is greater in the downward direction DD than in the rearward direction DR.

[0101]

[0087] Nevertheless, in order to reduce vibration, the direction of the cutting force FC indicated by the virtual force extension line LF is preferably directed by the machine interface 18 to a location where the holder 12 is held, such that the higher the rigidity of the machining interface 18, the more effectively it resists the vibration of the holder 12.

[0102]

[0088] In the present invention where the insert pocket 64 and / or the cutting insert 16 are further rearward than those known in the prior art, when the plunge adapter 14 is made longer (and thus the cutting insert is further away from the machine interface), it is understood that the virtual force extension line LF is further away from the location where the holder is held by the machine interface 18. Therefore, the shape of the present plunge adapter 14 somewhat compensates for the disadvantages of the relatively more rearward insert pocket 64 and / or cutting insert 16.

[0103]

[0089] The illustrated wide plunge adapter 14 can provide advantageous structural strength, but it is still preferably not to exceed the circumcircle C (FIG. 1A) of the holder 12 in an end view of the tool assembly shown in FIG. 1A. This can be advantageous for maintaining a small structure for tool change purposes. For similar reasons (i.e., for tool change purposes), it is preferable that the entire plunge adapter 14 is slender.

Claims

【Claim 1】 A plunge cutting adapter, a cutting insert, and a holder, comprising: The plunge cutting adapter includes a cutting portion, and an adapter shank portion connected to the cutting portion, The cutting portion includes opposing first and second side surfaces, and a periphery connecting the first and second side surfaces, The periphery includes opposing front and rear sub-periphery portions, and an upper sub-periphery portion connecting the front and rear sub-periphery portions, The first and second side surfaces define a first lateral direction extending from the first side surface to the second side surface and a second lateral direction opposite to the first lateral direction, The forward direction is defined perpendicular to the first and second lateral directions and extending from the rear sub-periphery portion to the front sub-periphery portion, and the rearward direction is defined opposite to the forward direction, The upward direction is defined perpendicular to both the first and second lateral directions and the forward and rearward directions and extending from the adapter shank portion to the cutting portion, The downward direction is defined opposite to the upward direction, The cutting portion further includes an insert pocket formed at the intersection of the front sub-periphery portion and the upper sub-periphery portion, The insert pocket includes a base jaw having a foremost base jaw surface, a second jaw at least partially disposed above the base jaw, and a slot end connecting the base jaw and the second jaw, The adapter shank portion includes an adapter clamping device, The cutting insert is fixed in the insert pocket, and the cutting insert includes an insert base surface abutting against the base jaw, an upwardly facing rake surface disposed above the insert base surface, an insert second surface abutting against the second jaw, a foremost relief surface extending downward from the rake surface, and a foremost cutting edge formed at the intersection of the rake surface and the foremost relief surface, The holder includes a holder head portion, and a holder shank portion connected to the holder head portion, The holder head portion includes an adapter pocket for fixing the adapter shank portion, The holder shank portion includes a holder shank axis extending through the center of the holder shank portion and extending parallel to the upward and downward directions, extends perpendicular to the holder shank axis and has a holder shank cross-sectional shape that is either (a) square or rectangular, or (b) circular, a foremost holder shank face, and a virtual line extending upward from the foremost holder shank face, wherein the holder shank cross-sectional shape is square or rectangular and the foremost cutting edge is directly above the foremost holder shank face, or wherein the holder shank cross-sectional shape is circular and the holder shank axis extends to the foremost cutting edge, a tool assembly. **Claim 2** wherein the holder shank cross-sectional shape is square or rectangular and the foremost base jaw face is within an allowable distance DT of 2 mm from the virtual line; or wherein the holder shank cross-sectional shape is circular and the foremost base jaw face is within an allowable distance DT of 2 mm from the holder shank axis, the tool assembly according to claim 1. **Claim 3** wherein the allowable distance DT is less than 1 mm or less than 0.5 mm, the tool assembly according to claim 2. **Claim 4** The cutting portion further comprises a blade portion thickness measured parallel to the first lateral direction and the second lateral direction in the insert pocket, and a blade region defined by having the blade portion thickness, the blade region having a maximum height HM measurable parallel to the upward and downward directions and from the lowermost point to the uppermost point of the blade region, and a maximum width WM measurable parallel to the forward and rearward directions and from the foremost point to the rearmost point of the blade region, and the maximum width WM and the maximum height HM satisfy the condition WM ≧ HM, the tool assembly according to claim 1. **Claim 5** satisfies the condition WM ≧ 1.05HM or satisfies the condition WM ≧ 1.10HM, the tool assembly according to claim 4. **Claim 6** satisfies the condition WM ≦ 1.30HM, the tool assembly according to claim 5. **Claim 7** satisfies the condition WM ≧ 1.20HM, the tool assembly according to claim 6. **Claim 8**: The tool assembly according to claim 1, further comprising a reinforcing region that is measured parallel to the blade portion thickness and has a reinforcing thickness greater than the blade portion thickness, wherein the reinforcing region extends in the upward direction and has a reinforcing portion height HR measurable from the lowest point of the blade region, and the reinforcing portion height HR and the maximum height HM measurable from the lowest point to the highest point of the blade region parallel to the upward and downward directions satisfy the condition HR > 0.5HM. **Claim 9** The tool assembly according to claim 8, satisfying the condition HR > 0.65HM or satisfying the condition HR > 0.75HM. **Claim 10** The tool assembly according to claim 8, satisfying the condition HR < HM. **Claim 11** The tool assembly according to claim 10, satisfying the condition HR < 0.95HM. **Claim 12** The tool assembly according to claim 1, wherein the entire second jaw of the insert pocket is disposed behind the base jaw. **Claim 13** The tool assembly according to claim 12, wherein the second jaw and the base jaw of the insert pocket extend adjacent to each other in a direction parallel to the upward and downward directions. **Claim 14** The tool assembly according to claim 1, comprising only one insert pocket. **Claim 15** The tool assembly according to claim 1, wherein the overall shape of the cut-off adapter is elongated when measured parallel to the upward and downward directions.

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