U.S. patent application number 09/774050 was filed with the patent office on 2001-06-07 for cutting tool and method for producing the same.
This patent application is currently assigned to MITSUBISHI MATERIALS CORPORATION. Invention is credited to Fujii, Yasuyoshi, Kaneko, Kazuhiro, Matsuura, Seiji.
Application Number | 20010002559 09/774050 |
Document ID | / |
Family ID | 27282641 |
Filed Date | 2001-06-07 |
United States Patent
Application |
20010002559 |
Kind Code |
A1 |
Fujii, Yasuyoshi ; et
al. |
June 7, 2001 |
Cutting tool and method for producing the same
Abstract
A method for producing cutting tools incorporated in the present
invention is carried out as follows: a shank portion and a drill
portion are formed separately such that the inner diameter of a
hole made in the shank portion is slightly smaller than the outer
diameter of the drill portion. The rear of the drill portion is
forcibly inserted into the hole of the shank portion at normal
temperature which is room temperature. The diameter of the inner
wall of the hole is thereby enlarged, resulting in a tight fitting.
After the insertion of the drill portion in the shank portion, the
drill portion may be ground to form a drill edge. Before the
insertion of the drill portion in the shank portion, the shank
portion may be quenched under vacuum or the like, or the surface of
the shank portion may be hardened by nitriding.
Inventors: |
Fujii, Yasuyoshi;
(Ibaraki-ken, JP) ; Matsuura, Seiji; (Ibaraki-ken,
JP) ; Kaneko, Kazuhiro; (Ibaraki-ken, JP) |
Correspondence
Address: |
OBLON SPIVAK MCCLELLAND MAIER & NEUSTADT PC
FOURTH FLOOR
1755 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Assignee: |
MITSUBISHI MATERIALS
CORPORATION
1-5-1, Ohtemachi, Chiyoda-ku
Tokyo
JP
|
Family ID: |
27282641 |
Appl. No.: |
09/774050 |
Filed: |
January 31, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09774050 |
Jan 31, 2001 |
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09497858 |
Feb 4, 2000 |
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6200076 |
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09497858 |
Feb 4, 2000 |
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09015664 |
Jan 29, 1998 |
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6058807 |
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Current U.S.
Class: |
76/108.6 |
Current CPC
Class: |
Y10T 29/49833 20150115;
B23B 2231/0204 20130101; Y10T 403/4949 20150115; B23B 31/005
20130101; B23B 51/00 20130101; B23B 51/011 20220101; Y10T 408/907
20150115; B23P 15/32 20130101; Y10T 403/4966 20150115; B23B 2240/28
20130101; B23B 2251/426 20130101; B23B 51/02 20130101; B23B 2251/02
20130101; Y10T 29/49945 20150115 |
Class at
Publication: |
76/108.6 |
International
Class: |
B21K 005/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 31, 1997 |
JP |
9-019485 |
Jun 18, 1997 |
JP |
9-161393 |
Aug 1, 1997 |
JP |
9-208101 |
Claims
WHAT IS CLAIMED AS NEW AND DESIRED TO BE SECURED BY LETTERS Patent
of the United States is:
1. A method for producing a cutting tool comprising a drill portion
and a shank portion, the method comprising the steps of: forming a
hole in the shank portion such that an inner diameter of the hole
is slightly smaller than an outer diameter of the drill portion;
and fitting the drill portion into the shank portion by pressing a
rear of the drill portion into the hole of the shank portion at
normal temperature.
2. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of grinding the drill portion to form a
drill edge after said fitting step.
3. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of quenching the shank portion before
said fitting step.
4. A method for forming a cutting tool as set forth in claim 3,
wherein said step of quenching is carried out under a vacuum.
5. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of hardening a surface of the shank
portion by nitriding before the fitting step.
6. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of forming a space for storing chips
produced by shaving the inner wall of the hole of the shank portion
by insertion of the drill portion during said step of fitting, the
space formed at a bottom of the hole of the shank portion.
7. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of chamfering the rear edge of the drill
portion so as to form a rounded chamfer.
8. A method for forming a cutting tool as set forth in claim 1,
further comprising a step of chamfering the rear edge of the drill
portion so as to form a linear chamfer.
9. A method for forming a cutting tool as set forth in claim 1,
wherein the rear edge of the drill portion is sharp.
10. A cutting tool comprising: a shank portion having a hole; and a
drill portion fitted into said hole of said shank portion to form a
joint, said drill portion having a drill edge, wherein a step is
formed at said joint.
11. A cutting tool according to claim 10, wherein a surface of said
shank is hardened.
12. A cutting tool according to claim 10, wherein a rear edge of
said drill portion has a rounded chamfer.
13. A cutting tool according to claim 10, wherein a rear edge of
said drill portion has a linear chamfer.
14. A cutting tool according to claim 10, wherein a rear edge of
said drill portion forms a sharp point.
15. A cutting tool according to claim 10, further comprising a
space between a rear edge of said drill portion and a bottom of
said hole of said shank portion.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to composite-type cutting
tools, whose drill portion and shank portion are made of different
materials, and a method for producing such tools, for example,
miniature drills used for making small-diameter holes in a printed
circuit board.
[0003] This application claims priority of Japanese Patent
Application Nos. 9-19485, 9-161393, and 9-208101 which are hereby
incorporated by reference.
[0004] 2. Discussion of the Background
[0005] Generally, miniature drills are used for making holes having
extremely small-diameters. Thus, miniature drills have: a
cylindrical drill portion having a diameter of approximately 0.1 to
3.175 mm at the tip end of the drill body; and a larger-diameter
shank portion at the rear end, which is used for holding the drill
body in the axis of rotation of the machine tools. In general, the
drill portion is formed from a cemented carbide.
[0006] Thus, to produce a solid-type miniature drill, the drill
portion and the shank portion are integrally formed, for example,
by grinding a cylindrical cemented carbide. Since such a cemented
carbide is expensive and a large amount of the cemented carbide is
ground for forming the drill portion, the cost inevitably
increases.
[0007] Meanwhile, composite drills have been suggested which are
produced as follows: a small-diameter drill portion is formed from
a substantially cylindrical cemented carbide; a large-diameter
shank portion is made from a low-cost material, such as steel or
SUS, different from the material used for the drill portion; and
the rear of the drill portion is allowed to fit into a hole made in
the tip end of the shank portion.
[0008] FIGS. 12(A) to 12(E) show a method for producing such a
conventional composite drill.
[0009] A shank portion 1 shown in FIG. 12(A) has a tapered portion
1a at the tip end and a hole 1b made in the end face of the tapered
portion 1a.
[0010] According to shrinkage fitting, a substantially cylindrical
drill portion 2 is pressed into the hole 1b while enlarging the
diameter of the hole 1b by high-frequency heating (see FIG. 12(B)).
Since the outer diameter of the drill portion 2 is set to be
slightly larger than the inner diameter of the hole 1b, the inner
wall of the hole 1b is shaved to produce chips by the insertion.
The chips are pushed into the bottom of the hole 1b by the drill
portion 2. The diameter of the hole 1b is then shrunk by cooling to
achieve a tight fit.
[0011] The drill portion 2 can also be fitted to the hole 1b by
brazing as follows: the drill portion 2 is pressed into the hole 1b
having an inner diameter slightly larger than the outer diameter of
the drill portion 2, and then, brazed.
[0012] Both sides of a joint 3, shown in FIG. 12(C), formed between
the tapered portion 1a of the shank portion 1 and the drill portion
2 are finely ground to form a tapered face 3a having a smooth
linear taper from the shank portion 1 to the drill 2 (see FIG.
12(D)), and the tip end of the drill portion 2 in succession to the
tapered face 3a is ground to form a drill edge 2a (see FIGS. 12(D)
and 12(E)).
[0013] However, since such methods for producing composite drills
need a large number of steps, the process becomes complicated and
laborious, disadvantageously increasing the cost. Furthermore,
before pressing the drill portion 2 into the shank portion 1, the
shank portion 1 is annealed by high frequency heating in the case
of shrinkage fitting and by a flux in the case of brazing. Thus,
the hardness of the shank portion 1 decreases so that the fastening
strength due to the fitting to the drill portion 2 is
disadvantageously reduced.
[0014] Furthermore, the drill portion 2 heated by high frequency
heating is undesirably deformed when it is pressed into the hole
1b. The fastening strength due to fitting is also lowered by
shaving the inner wall of the hole 1b. Furthermore, since the
length of the drill portion 2 exposed outside the shank portion 1
varies with the amount of the shaved chips, it is necessary to
adjust the length of the shank portion 1 to achieve a constant
total length of the miniature drills.
[0015] Moreover, disadvantageously, the inner wall of the hole 1b
is readily corroded by the flux at the time of brazing.
[0016] In addition, since the shank portion 1 and the drill portion
2 are made of different materials, it is difficult to
simultaneously grind both of them into the linearly tapered face 3a
over both sides of the joint 3 between the shank portion 1 and the
drill portion 2.
SUMMARY OF THE INVENTION
[0017] Accordingly, an object of the present invention is to
provide a method for producing a cutting tool, by which method the
drill portion is not deformed by fitting to the shank portion, and
a cutting tool that can be easily produced having a high fastening
strength.
[0018] Another object of the present invention is to provide a
cutting tool whose drill portion and shank portion are joined by a
joint having high fastening strength and which can be easily
produced.
[0019] To achieve the above objects, a method for producing a
cutting tool incorporated in the present invention is characterized
in that where a cutting tool prepared by fitting a drill portion
into a hole of a shank portion, the inner diameter of the hole of
the shank portion is formed slightly smaller than the outer
diameter of the drill portion, and the rear of the drill portion is
pressed into the hole of the shank portion at normal temperature
which is room temperature.
[0020] By forcibly pressing the drill portion into the hole of the
shank portion at normal temperature, the drill portion shaves the
inner wall of the hole while enlarging the hole, and is tightly
fitted into the hole. Since the joint is achieved without brazing,
the number of steps is low and the procedure is simplified, and
furthermore, the drill portion, which is to be used for cutting, is
not deformed because the procedure is carried out at normal
temperature which is room temperature.
[0021] Moreover, according to one preferred embodiment of the
present invention, the drill edge of the drill portion is formed by
grinding after pressing the drill portion into the shank portion.
Thus, only the drill portion is required to be ground to form the
drill edge, resulting in easier grinding.
[0022] According to another preferred embodiment of the present
invention, the shank portion is quenched before fitting. Therefore,
the hardness of the resulting shank portion increases, and a
cutting tool having a high joint strength can be formed with high
accuracy because the inner diameter of the hole is enlarged by
pressing the drill portion into the hole of the shank portion
without being readily shaved. Thus, the shank portion is not
damaged by shaved chips produced by processing. Furthermore, a less
deformed shank portion having a smooth surface can be achieved by
quenching under vacuum. Moreover, if the surface of the shank
portion is hardened by nitriding before fitting, the shank portion
becomes harder, the joint strength with the drill portion
increases, and deformation does not occur because heat treatment
such as quenching is not required.
[0023] The rear of the drill portion has a rounded or linearly
chamfered edge, or the like. Thus, when the drill portion is
pressed into the hole, the chamfered edge presses and enlarges the
inner diameter of the hole without shaving the inner wall,
resulting in a reliable fastening fit. If the rear of the drill
portion has a sharp edge, the inner wall of the hole is shaved by
pressing the drill portion into the hole.
[0024] A cutting tool incorporated into the present invention is
characterized in that a small-diameter drill portion is fitted to a
hole of a large-diameter shank portion, a step is formed at the
joint between the shank portion and the drill portion, and the
drill portion is formed into a drill edge.
[0025] The diameter of the shank portion is larger than that of the
drill portion by the height of the step formed at the joint between
the shank portion and the drill portion. Therefore, the strength of
the cutting tool increases and the tool life is extended.
Additionally, it is not necessary to grind the joint into a tapered
shape over the shank portion and the drill portion. Thus, the
grinding step becomes simpler, resulting in simplified
production.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] A more complete appreciation of the invention and many of
the attendant advantages thereof will be readily obtained as the
same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0027] FIG. 1 is a cross-sectional diagram showing a drill portion
and a shank portion of a composite drill incorporated in the first
embodiment of the present invention before fitting;
[0028] FIG. 2 is a cross-sectional diagram showing the drill
portion and the shank portion of the composite drill incorporated
in the first embodiment of the present invention during
fitting;
[0029] FIG. 3 is a cross-sectional diagram showing the drill
portion and the shank portion of the composite drill incorporated
in the first embodiment of the present invention after fitting;
[0030] FIG. 4 is a diagram showing the rear edge of a drill portion
incorporated in a modification;
[0031] FIG. 5 is a diagram showing the rear edge of a drill portion
incorporated in another modification;
[0032] FIG. 6 is a side view showing a miniature drill incorporated
in the second embodiment of the present invention;
[0033] FIGS. 7(A) to (D) show production steps of the miniature
drill shown in FIG. 6, FIG. 7(A) is a side view of a shank portion,
FIG. 7(B) is a diagram showing a drill portion and the shank
portion before inserting the drill portion into the shank portion,
FIG. 7(C) is a diagram showing the drill portion and the shank
portion after the insertion, and FIG. 7(D) is a diagram showing a
tapered portion of the drill portion and a drill edge both formed
by grinding;
[0034] FIG. 8 is a cross-sectional diagram showing a drill portion
and a shank portion of a composite drill incorporated in the third
embodiment before inserting the drill portion into the shank
portion;
[0035] FIG. 9 is a cross-sectional diagram showing the drill
portion and the shank portion of a composite drill incorporated in
the third embodiment during insertion;
[0036] FIG. 10 is a cross-sectional diagram showing the drill
portion and the shank portion of a composite drill incorporated in
the third embodiment after the insertion;
[0037] FIG. 11 is a side view of a cylinder of material before
being machined into a shank portion; and
[0038] FIGS. 12(A) to 12(E) show production steps of a conventional
miniature drill, FIG. 12(A) is a side view of a shank portion, FIG.
12(B) is a diagram showing a drill portion and the shank portion
before inserting the drill portion into the shank portion, FIG.
12(C) is a diagram showing the drill portion and the shank portion
after the insertion, FIG. 12(D) is a diagram showing a tapered
portion of the shank portion and a drill portion both formed by
simultaneously grinding, and FIG. (E) is a side view of the
miniature drill provided with a twist through flute.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to the drawings, wherein like reference
numerals designate identical or corresponding parts throughout the
several views, and more particularly to FIGS. 1 through 3 thereof
which show the first embodiment of the present invention. For
example, a miniature drill 10 shown in FIG. 1 is formed from a
substantially cylindrical drill portion 11 which has a diameter of
approximately 0.1 to 3.175 mm and which is made of cemented carbide
and a substantially cylindrical shank portion 12 which has a larger
diameter (e.g., 3 to 6 mm as the outer diameter) and which is made
of SUS, steel, or the like.
[0040] A rear edge 11b of a rear 11a of the drill portion 11 has a
sharp square edge (e.g., not more than 90.degree.) which is not
chamfered. The shank portion 12 has a substantially cylindrical
hole 13 coaxially formed from the tip end face 12a along the
longitudinal axis of the shank portion 12. The inner diameter of
the hole 13 is, for example, 1.4 mm, and is smaller than the outer
diameter of the drill portion 11 by a small amount (e.g., by 10
.mu.m).
[0041] Although the difference between the inner diameter of the
hole 13 and the outer diameter of the drill portion 11 alters
according to the size of the drill portion 11 and the shank portion
12, for example, the difference is set above 0 and not more than
100 .mu.m. If the difference is larger than 100 .mu.m, the force
fitting becomes difficult. Preferably, the difference is not more
than 50 .mu.m, and more preferably, not more than 20 .mu.m.
[0042] The opening of the hole 13 of the shank portion 12 is not
chamfered, and the outer edge of the tip end face 12a is chamfered
leaving the shoulder 12b. The depth of the hole 13 is set to be
slightly longer than the length of the rear 11a of the drill
portion 11 to be fitted into the hole 13. The inner wall 13a of the
hole 13 is gradually narrowed near the bottom of the hole 13 so
that a space 13b is formed for storing chips when the rear 11a of
the drill portion 11 is fitted (see FIG. 3).
[0043] This embodiment has the above-described structure. A method
for assembling the miniature drill 10 will be explained below.
[0044] At normal temperature, which is room temperature, the rear
11a of the drill portion 11 is coaxially put onto the hole 13 made
in the tip end face 12a of the shank portion 12 and pressed into
the hole 13 with high strength or force (FIG. 1). As a result, the
diameter of the inner wall 13a of the hole 13 is enlarged and
shaved, little by little, by the rear edge 11b of the drill portion
11, and the rear 11a of the drill portion 11 is pressed into the
hole 13 (see FIG. 2). The shaved chips are gradually pushed to the
bottom of the hole 13.
[0045] As is shown in FIG. 3, the fitting between the drill portion
11 and the shank portion 12 is completed when the rear 11a of the
drill portion 11 is pushed into the bottom of the hole 13 with the
chips shaved from the inner wall 13a being stored in the space 13b
formed in the bottom of the hole 13.
[0046] The drill portion 11 may then be ground to a more slender
shape, as is shown by the single dot chain line in FIG. 3.
[0047] As is mentioned above, according to the first embodiment,
the drill portion 11 can be tightly fitted to the shank portion 12
at normal temperature, which is room temperature, without brazing
or shrinkage fitting. Thus, low-cost production is achieved by a
small number of steps, and highly accurate miniature drills can be
readily produced since the drill portion 11 and the shank portion
12 are not deformed by heat. Since the rear edge 11b is sharp, the
drill portion 11 can be easily produced at low cost, and the inner
wall 13a of the hole 13 is shaved by the rear edge 11b when the
drill portion 11 is pressed into the hole 13.
[0048] The rear edge 11b is not always required to be sharp. For
example, the rear edge 11b may be chamfered in a circular arc
(R.gtoreq.0.1 mm), as is shown in FIG. 4. In such a case, the drill
portion 11 can be more readily pressed into the hole 13, and also,
more easily produced by barrel finishing or the like. Furthermore,
the rear edge 11b may be linearly chamfered (C.gtoreq.0.1 mm), as
is shown in FIG. 5. Although the processing costs for such
chamfered shapes are higher than those for other shapes, the drill
portion 11 can be fitted to the hole 13 while enlarging the
diameter of the inner wall of the hole 13 without producing shaved
chips from the inner wall if the rear edge 11b is chamfered.
Therefore, the length of the miniature drill 10 can be made a
certain value by setting the lengths of the drill portion 11 and
the shank portion 12, resulting in a reliable joint between the
drill portion 11 and the shank portion 12 by fitting, and easier
insertion.
[0049] Other embodiments of the present invention will be described
below. The numerals in the different views identify substantially
identical parts in the first embodiment, and detailed explanations
thereof are omitted.
[0050] FIGS. 6 and 7(A) to 7(D) show the second embodiment of the
present invention.
[0051] A miniature drill 20 shown in FIG. 6 has a substantially
cylindrical drill portion 21 having a small diameter and a
substantially cylindrical shank portion 22 having a larger
diameter.
[0052] The diameter of the tip side of the shank portion 22 is
gradually reduced to form a conically tapered portion 22a, and the
tip end face of the tapered portion 22a has a circular planar
shoulder 22b. The diameter of the shoulder portion 22b is larger
than the outer diameter of the drill portion 21, and a hole 13 is
made from the shoulder 22b towards the inside of the shank portion
22, coaxially with the shank portion 22.
[0053] The drill portion 21 has: a substantially cylindrical stem
21a having a relatively large diameter; a cylindrical drill edge
21c having a smaller diameter; and a tapered portion 21b formed
between the stem 21a and the drill edge 21c such that the diameter
of the tapered portion 21b is gradually decreased from the stem 21a
to the drill edge 21c. The rear of the stem 21a is pressed into the
hole 13 of the shank portion 22 to fit the drill portion 21 to the
shank portion 22. For example, the drill edge 21c has: a twist
through flute 24; and a cutting edge 25, which is the cross ridge
line made by a wall of the twist through flute 24 facing the
rotating direction and the tip end face of the drill edge 21c.
[0054] As a result, a step 26 having a shoulder 22b is formed
between the tapered portion 22a of the shank portion 22 and the
stem 21a of the drill portion 21, and at the tip side of the drill
portion 21, a certain distance from the step 26, the tapered
portion 21b and the drill edge 21c are continuously formed.
[0055] The miniature drill 20 of the second embodiment has the
above structure. A method for producing the miniature drill 20 will
be explained with reference to FIGS. 7(A) to 7(D).
[0056] In FIGS. 7(A) to 7(D), the shank portion 22 has the same
shape as that shown in FIG. 6, the drill portion 21 to be fitted to
the shank portion 22 is formed in a substantially cylindrical shape
having the same outer diameter as that of the stem 21a shown in
FIG. 6, and the rear end of the drill portion 21 is chamfered with
a taper into a chamfered portion C. The minimum diameter of the
chamfered portion C is smaller than the inner diameter of the hole
13 of the shank portion 22, and the maximum diameter of the
chamfered portion C is the same as the stem 21a which is slightly
larger than the inner diameter of the hole 13.
[0057] The inner diameter of the hole 13 of the shank portion 22
is, for example, approximately 1.4 mm, and is set to be smaller
than the outer diameter of the drill portion 21 (the stem 21a),
except for the chamfered portion C, by a slight value (e.g. 10
.mu.m).
[0058] For producing the miniature drill 20, the chamfered portion
C of the rear end of the drill portion 21 is coaxially pressed into
the hole 13 of the shoulder 22b of the shank portion 22 at normal
temperature which is room temperature. The inner wall of the hole
13 is thereby pressed by the chamfered portion C of the drill
portion 21 and its diameter is enlarged, little by little, to allow
the rear of the drill portion 21 to be inserted into the hole
13.
[0059] The total length of the miniature drill 20 is determined by
allowing the drill portion 21 to be inserted into the shank portion
22 until the length from the rear end of the shank portion 22 to
the tip of the drill portion 21 reaches the predetermined value,
and the fitting step of pressing the drill portion 21 into the
shank portion 22 is completed (see FIG. 7(C)). As a result, a step
26 having a shoulder 22b is formed between the tapered portion 22a
and the drill portion 21 at the joint between the shank portion 22
and the drill portion 21.
[0060] A portion of the drill portion 21, at a predetermined
distance from the shoulder 22b, is then ground to form the tapered
portion 21b and the cylindrical drill edge 21c having a small
diameter. The drill edge 21c is provided with the twist through
flute 24 and the cutting edge 25.
[0061] By the above procedure, the miniature drill 20 shown in FIG.
6 is produced.
[0062] As is mentioned above, according to the miniature drill 20
of the second embodiment, the shank portion 22 has a step 26 due to
the shoulder 22b. Thus, the strength of the miniature drill 20 is
higher than that of conventional miniature drills because of the
height of the step 26, resulting in longer tool life.
[0063] Furthermore, according to a method for producing the
miniature drill 20 incorporated in the second embodiment of the
present invention, in addition to the advantages due to the first
embodiment, grinding can be carried out more readily and accurately
because the tapered portion 22a of the shank portion 22 and the
tapered portion 21b of the drill portion 21 are not formed in a
continuous linear shape and only the tapered portion 21b of the
drill portion 21 is ground.
[0064] Although, the tapered portion 21b of the drill portion 21 is
formed in a portion at a predetermined distance from the step 26 of
the shank portion 22 in the second embodiment, the present
invention is not restricted, and the tapered portion 21b may be
formed continuously from the step 26 (shoulder 22b). Furthermore,
the shank portion 22 is not always required to have the tapered
portion 22a. In such a case, the step 26 is determined by the
difference between the outer diameter of the shank portion 22 and
the drill portion 21.
[0065] The third embodiment of the present invention will be
described with reference to FIGS. 8 to 11.
[0066] For example, a miniature drill 30 shown in FIG. 8 has: a
substantially cylindrical drill portion 31 having a diameter of
approximately 0.1 to 3.175 mm; and a substantially cylindrical
shank portion 32 having a larger diameter (e.g., 3 to 6 mm as the
outer diameter).
[0067] A rear edge 31b of a rear 31a of the drill portion 31 has a
sharp square edge (e.g., not more than 90.degree.) without being
chamfered. The shank portion 32 has a substantially cylindrical
hole 13 coaxially formed with the shank portion 32 from the tip end
face 32a along its longitudinal axis. For example, the inner
diameter of the hole 13 is set to 1.4 mm, which is smaller than the
outer diameter of the drill portion 31 by a small amount (e.g., by
10 .mu.m).
[0068] The shank portion 32 is prepared as follows: a cylinder of
material of approximately 35 to 50 HRC is obtained by vacuum
quenching (prism-shaped materials or the like may be used instead);
and is machined such that the opening of the hole 13 is not
chamfered and the outer edge of the tip end face 32a is chamfered
leaving a shoulder 32b. The depth of the hole 13 is set to be
slightly longer than the rear 31a to be pressed into the hole 13 of
the drill portion 31. Near the bottom of the hole 13, the inner
diameter of the hole 13 is gradually decreased to form a space 13b
for storing shaved chips when the rear 31a of the drill portion 31
is fitted (see FIG. 10).
[0069] This embodiment has the above-described structure. A method
for assembling the miniature drill 30 will be explained below.
[0070] A cylinder of material 40 shown in FIG. 11 to be formed into
the shank portion 32 is vacuum quenched so as to achieve
approximately 35 to 50 HRC, which is higher than that obtained
without quenching (approximately 24 HRC). As compared with
conventional quenching under a normal atmosphere, a smoother
surface can be obtained with less deteriorated accuracy in size by
quenching under vacuum because of less deformation and no
oxidation. Therefore, the polishing step for surface treatment
after quenching becomes unnecessary or simplified.
[0071] The resulting cylinder of material 40 is then machined into
the shank portion 32 as is shown in FIG. 8.
[0072] Coaxially with the hole 13 formed in the tip end face 32a of
the shank portion 32, the rear 31a of the drill portion 31 is then
inserted into the hole 13 with high strength or force at normal
temperature which is room temperature. As a result, the diameter of
the inner wall 33a of the hole 13 is enlarged by the rear edge 31b
of the drill portion 31, and the rear 31a of the drill portion 31
is pressed into the hole 13 (see FIGS. 8 and 9).
[0073] Since the whole shank portion 32 is hardened by quenching,
when the rear edge 31b of the drill portion 31 is pressed into the
hole 13 of the shank portion 32, the inner wall 33a of the hole 13
is not largely shaved and the inner diameter is gradually enlarged,
resulting in an increased joint strength with the drill portion
31.
[0074] Meanwhile, assuming that the drill portion 31 is pressed
into the shank portion 32 made of an unquenched material, such as
untreated SUS, the inner wall 33a of the hole 13 is
disadvantageously damaged by being shaved or the shank portion 32
may be damaged by cutting chips while using the miniature drill 30
for cutting.
[0075] As is shown in FIG. 10, the rear 31a of the drill portion 31
is pressed into the bottom of the hole 13 with a small amount of
chips shaved from the inner wall 33a being stored in the space 13b
formed in the bottom of the hole 13.
[0076] The drill portion 31 may then be ground to a more slender
shape, as is shown by the single dot chain line in FIG. 10.
[0077] As is mentioned above, according to the third embodiment of
the present invention, the shank portion 32 is hardened beforehand
by vacuum quenching. Thus, when the diameter of the inner wall 33a
is enlarged by fitting the drill portion 31 into the hole 13, the
fastening joint strength due to the enlargement of the inner wall
33a increases. Furthermore, the drill portion 31 has a smoother
surface and is not deformed by heat, resulting in a highly accurate
miniature drill. Moreover, the shank portion 32 is not damaged by
cutting chips while using the miniature drill 30 for cutting.
[0078] Although the cylinder of material 40 to be formed into the
shank portion 32 is vacuum quenched in the third embodiment, the
shank portion 32 may be vacuum quenched after being machined. In
such a case, the forming accuracy of the resulting shank portion 32
deteriorates to some extent, and surface treatment is required;
also quenching under a normal atmosphere may be employed instead of
vacuum quenching.
[0079] Nitriding can also be employed instead of quenching. For
example, after forming the cylinder of material 40 into the shank
portion 32 shown in FIG. 8, the shank portion is heated at
approximately 500.degree.C. for 18 to 19 hours in a gaseous
ammonium atmosphere, and then, allowed to stand for cooling. The
surface of the shank portion 32 is thereby hardened. Furthermore,
deformation does not occur because heat treatment such as quenching
is unnecessary.
[0080] The materials used for the drill portions 11, 21, and 31 are
not limited to cemented carbide, and other suitable materials such
as cermet can be employed as long as they are harder than the shank
portions. The materials used for the shank portions 12, 22, and 32
are not restricted to SUS and steel, and other materials such as
aluminum alloys may be used.
[0081] The hole 13 of the shank portions 12, 22, and 32 and the
rear 11a, 21a, and 31a of the drill portions 11, 21, and 31,
respectively, are not limited to cylindrical shapes, and may be
prismatic shapes.
[0082] The present invention can be applied not only to miniature
drills but also to other cutting tools such as drilling tools,
small-diameter end mills, and the like.
[0083] Obviously, numerous modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
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