U.S. patent application number 11/459996 was filed with the patent office on 2008-01-31 for tangential cutting insert and insert holder.
This patent application is currently assigned to Iscar, Ltd.. Invention is credited to Gil Hecht.
Application Number | 20080025803 11/459996 |
Document ID | / |
Family ID | 27772952 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080025803 |
Kind Code |
A1 |
Hecht; Gil |
January 31, 2008 |
Tangential Cutting Insert and Insert Holder
Abstract
An indexable cutting insert can be used for metal cutting
processes in general and for radial and axial turning of a stepped
square shoulder in particular. The cutting insert exhibits
180.degree. rotational symmetry about three mutually perpendicular
axes. The cutting insert has generally "S"-shaped cutting edges
extending between raised and lowered corners. The cutting edges and
side surfaces are concave in an end view of the cutting insert. The
cutting insert enables radial and axial turning operations of a
square shoulder with unlimited depth of cut.
Inventors: |
Hecht; Gil; (Nahariya,
IL) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
ATTN: PATENT DOCKETING 32ND FLOOR, P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Assignee: |
Iscar, Ltd.
Tefen
IL
|
Family ID: |
27772952 |
Appl. No.: |
11/459996 |
Filed: |
July 26, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11422454 |
Jun 6, 2006 |
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11459996 |
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10375112 |
Feb 28, 2003 |
7073987 |
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11422454 |
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Current U.S.
Class: |
407/42 ;
407/114 |
Current CPC
Class: |
B23B 2200/123 20130101;
B23B 27/1614 20130101; B23B 2205/16 20130101; B23B 2200/369
20130101; Y10T 407/1924 20150115; B23B 2200/3627 20130101; Y10T
407/235 20150115; B23B 27/1622 20130101; B23B 2200/202 20130101;
B23B 2200/0423 20130101; B23B 27/08 20130101; Y10T 407/2274
20150115; B23B 2200/082 20130101; B23B 2200/121 20130101; B23B
2200/083 20130101; B23B 2200/207 20130101; B23B 2205/12 20130101;
B23B 2200/161 20130101; Y10T 407/23 20150115 |
Class at
Publication: |
407/42 ;
407/114 |
International
Class: |
B23C 5/20 20060101
B23C005/20 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 6, 2002 |
IL |
148535 |
Claims
1-18. (canceled)
19. A cutting insert comprising: an insert body having a base
surface, a top surface and four side surfaces which, together with
each of the base surface and the top surface, define respective
cutting edges at the top and base surfaces; the insert body
defining a median plane M disposed midway between the top and base
surfaces; each of the side surfaces including four corners
including a first pair of diagonally opposed corners and a second
pair of diagonally opposed corners, the first pair of corners
spaced by equal first distances (y) from the median plane M, and
the second pair of corners spaced by equal second distances (z)
from the median plane M, wherein the second distances (z) are
longer than the first distances (y); each side surface defining a
first diagonal extending between the first pair of corners, and a
second diagonal, longer than the first diagonal, extending between
the second pair of corners; wherein the second diagonal of each
side surface is non-parallel relative to the second diagonal of an
opposing side surface.
20. The cutting insert according to claim 19, wherein: a distance
(2z) between raised corners of the top surface and the base surface
defines the height of the insert, in a side view of the insert.
21. The cutting insert according to claim 19, wherein: the cutting
insert further comprises an insert through bore having a bore
axis.
22. The cutting insert according to claim 19, wherein: The cutting
insert exhibits 180.degree. rotational symmetry about three
mutually perpendicular axes.
23. The cutting insert according to claim 19, wherein: in an end
view, the cutting insert is generally rectangular in shape.
24. The cutting insert according to claim 19, wherein: the four
side surfaces are oriented perpendicularly to the median plane.
25. The cutting insert according to claim 19, wherein: the four
side surfaces include a pair of opposing major side surfaces and a
pair of opposing minor side surfaces; and a first distance between
the minor side surfaces is greater than a second distance between
the major side surfaces.
26. The cutting insert according to claim 25, wherein: the major
side surfaces and the minor side surfaces intersect the top surface
and the base surface to form a peripheral edge at each; and the top
surface and the base surface each have four corners, two lowered
corners and two raised corners, the lowered corners being closer to
the median plane than the raised corners.
27. The cutting insert according to claim 26, wherein: each
peripheral edge has at least one major edge comprising a major
cutting edge which slopes from an associated raised corner towards
a first lowered corner for a major cutting edge length, the major
cutting edge length being greater than one half of the first
distance between the minor side surfaces.
28. The cutting insert according to claim 27, wherein: each
peripheral edge has at least one minor edge, the at least one minor
edge comprising a minor cutting edge which slopes from said
associated raised corner towards a second lowered corner for a
minor cutting edge length, the minor cutting edge length being
approximately one half of the second distance between the major
side surfaces.
29. The cutting insert according to claim 26, wherein: each
peripheral edge has at least one minor edge, the at least one minor
edge comprising a minor cutting edge which slopes from an
associated raised corner towards a first lowered corner for a minor
cutting edge length, the minor cutting edge length being
approximately one half of the second distance between the major
side surfaces.
30. The cutting insert according to claim 26, wherein: each
peripheral edge comprises generally "S"-shaped edges extending
between raised and lowered corners.
31. The cutting insert according to claim 19, wherein: each cutting
edge comprises a major cutting edge, a minor cutting edge and a
corner cutting edge, therebetween, the corner cutting edge being
formed at a raised corner.
32. The cutting insert according to claim 31, wherein: each major
cutting edge has a major cutting edge length that is greater than
one half of a first distance between the minor side surfaces.
33. The cutting insert according to claim 32, wherein: each minor
cutting edge has a minor cutting edge length that is approximately
one half of a second distance between the major side surfaces.
34. The cutting insert according to claim 31, wherein: each minor
cutting edge has a minor cutting edge length that is approximately
one half of a distance between the major side surfaces.
35. A cutting insert comprising: first and second opposing end
surfaces and four side surfaces; each of the four side surfaces
intersecting the first and second opposing end surfaces to define
respective cutting edges at the end surfaces; a median plane M
disposed midway between the first and second opposing end surfaces;
each of the side surfaces including four corners including a first
pair of diagonally opposed corners and a second pair of diagonally
opposed corners, the first pair of corners spaced by equal first
distances (y) from the median plane M, and the second pair of
corners spaced by equal second distances (z) from the median plane
M, wherein the second distances (z) are longer than the first
distances (y); each side surface defining a first diagonal
extending between the first pair of corners, and a second diagonal,
longer than the first diagonal, extending between the second pair
of corners; wherein the second diagonal of each side surface is
non-parallel relative to the second diagonal of an opposing side
surface.
36. The cutting insert according to claim 35, wherein: a distance
(2z) between raised corners of the top surface and the base surface
defines the height of the insert, in a side view of the insert.
37. A cutting tool comprising: the cutting insert according to
claim 19; and an insert holder having an insert pocket in which the
cutting insert is securely retained.
38. The cutting tool according to claim 37, wherein: the cutting
insert has an insert through bore; the insert pocket comprises a
base surface provided with a threaded receiving bore; a securing
screw extends through the insert through bore and threadingly
engages the threaded receiving bore of the base surface to secure
the cutting insert to the insert pocket.
Description
RELATED APPLICATIONS
[0001] This is a Continuation of U.S. patent application Ser. No.
11/422,454, filed Jun. 6, 2006, now U.S. Pat. No. ______ , which is
a Continuation of U.S. patent application Ser. No. 10/375,112 filed
Feb. 28, 2003, now U.S. Pat. No. 7,073,987. The contents of the
aforementioned parent applications are incorporated by reference in
their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a tangential indexable
cutting insert for use in metal cutting processes in general and
for radial and axial turning of a stepped square shoulder in
particular.
BACKGROUND OF THE INVENTION
[0003] Tangential cutting inserts, also known as on-edge, or lay
down, cutting inserts, are oriented in an insert holder in such a
manner that during a cutting operation on a workpiece the cutting
forces are directed along a major (thicker) dimension of the
cutting insert. An advantage of such an arrangement being that the
cutting insert can withstand greater cutting forces than when
oriented in such a manner that the cutting forces are directed
along a minor (thinner) dimension of the cutting insert. Another
advantage of such an arrangement is that with the minor dimension
directed perpendicular to the cutting forces it is possible to
maneuver the cutting insert between obstacles close to the
workpiece.
[0004] For turning a stepped square shoulder on a workpiece, a
cutting tool assembly requires a cutting insert with an acute
operative insert cutting corner, a tool back clearance angle along
its inoperative cutting edge and an obtuse entering angle along its
operative cutting edge. Such an entering angle enables an outwardly
directed feed out movement to square out a shoulder, in particular,
an outwardly directed radial feed out movement in the case of
external axial turning operations and an outwardly directed axial
feed out movement in the case of radial turning operations.
[0005] In view of these restrictions, cutting inserts for turning
stepped square shoulders are usually either rhomboidal or
triangular; thereby having respectively, two or three indexable
insert cutting corners for single-sided cutting inserts. Such
cutting inserts are, for example, as illustrated and described in
U.S. Pat. No. 4,632,608, each insert cutting corner being formed as
a protruding nose portion at the junction between centrally
depressed insert sides. The cutting inserts are preferably double
sided so as to be respectively formed with four or six indexable
insert cutting corners.
[0006] With a view to increasing the number of cutting corners, a
fully indexable non-tangential cutting insert is described in U.S.
Pat. No. 6,074,137. The cutting insert comprises four substantially
concave side edges extending between substantially square opposing
upper and lower surfaces. Adjacent side edges meet at a cutting
corner having an angle in the range of about
83.degree..+-.5.degree.. Although the cutting insert is
substantially square and although it offers eight cutting corners,
its depth of cut is limited. In fact, the maximal depth of cut is
limited to less than the length of a side of an imaginary square,
in which the insert is inscribed, in a top view of the insert.
Furthermore, it is not a tangential cutting insert.
[0007] FIGS. 1 and 2 show a cutting tool 20 with a tangentially
seated cutting insert 22 for both axial and radial turning
operations, also known as longitudinal and face turning operations.
The cutting insert 22 is oriented with relief angles .gamma.1 and
.gamma.2 for radial and axial turning operations, respectively. The
cutting insert 22 has one operative cutting corner 24, a first
trailing non-operative cutting corner 26 during axial turning
operations and a second trailing non-operative cutting corner 28
during radial turning operations. Major and minor cutting edges 30,
32 extend between the operative cutting corner 24 and non-operative
cutting corners 28, 26.
[0008] FIG. 3 is an illustrative drawing showing the cutting tool
20 during either radial or axial turning operations of a workpiece
33. Dashed lines 34 show an ideal square shoulder and the dash-dot
line 35 is an imaginary extension of the worked face 36 of the
workpiece 33. As can be seen, for a radial turning operation, the
second trailing non-operative cutting corner 28 and a portion of
the major cutting edge 30 are oriented such that they "extend
beyond" the imaginary extension 35 of the worked face 36 and would
engage the workpiece 33 if an attempt were made to increase the
depth of cut beyond a depth of cut, d, where the dashed line
intersects the major cutting edge 30. Thus, the depth of cut is
limited during radial turning of a square shoulder. For axial
turning in the configuration shown in FIG. 3, the depth of cut is
also limited to d. Any increase in the depth of cut would lead to a
non-square shoulder. Similarly, the insert could be configured with
an orientation such that for an axial turning operation, the first
trailing non-operative cutting corner 26 and a portion of the minor
cutting edge 32 are disposed such that they have a limited depth of
cut. Likewise, the insert could be configured with an orientation
so that it has a limited depth of cut for both axial and radial
turning operations due both to the first trailing non-operative
cutting corner 26 and a portion of the minor cutting edge 32 and
also to the second trailing non-operative cutting corner 28 and a
portion of the major cutting edge 30.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention there is provided
an indexable cutting insert, for use in a cutting tool for turning
operations, comprising:
[0010] two identical opposing end surfaces having 180.degree.
rotational symmetry about a first axis passing therethrough,
[0011] a peripheral side surface extending between the two opposing
end surfaces, and
[0012] a peripheral edge formed at the intersection of each end
surface and the peripheral side surface, at least two sections of
each peripheral edge constituting cutting edges;
[0013] the peripheral side surface comprising:
[0014] two identical opposing major side surfaces having
180.degree. rotational symmetry about a second axis passing
therethrough, the second axis being perpendicular to the first
axis;
[0015] two identical opposing minor side surfaces having
180.degree. rotational symmetry about a third axis passing
therethrough, the third axis being perpendicular to the first axis
and the second axis;
[0016] a major plane defined by the first axis and the second
axis;
[0017] a minor plane defined by the first axis and the third
axis;
[0018] a median plane being defined by the second axis and the
third axis;
[0019] each end surface having four corners, two lowered corners
and two raised corners, the lowered corners being closer to the
median plane than the raised corners;
[0020] in a side view of one of the minor side surfaces, all four
corners are equidistant from the minor plane;
[0021] in a side view of one of the major side surfaces, all four
corners are equidistant from the major plane.
[0022] In accordance with the present invention, the cutting insert
has a maximum distance D1 between the minor side surfaces that is
greater than a maximum distance D2 between the major side
surfaces.
[0023] In accordance with the present invention, in an end view of
the cutting insert, each major side surface is recessed.
[0024] In accordance with the preferred embodiment of the present
invention, in an end view, the distance between the opposing major
side surfaces varies from the maximum distance D2 adjacent the
corners of the cutting insert to a minimum distance d2 at the
intersection of the major side surfaces with the major plane.
[0025] In accordance with a specific application of the present
invention, the minimum distance d2 is given by d2=D2-t, where the
value t is given by 0.3 mm.ltoreq.t.ltoreq.0.4 mm.
[0026] In accordance with the present invention, in an end view of
the cutting insert, each minor side surface is recessed.
[0027] In accordance with the preferred embodiment of the present
invention, in an end view, the distance between the opposing minor
side surfaces varies from the maximum distance D1 adjacent the
corners of the cutting insert to a minimum distance d1 at the
intersection of the minor side surfaces with the minor plane.
[0028] In accordance with a specific application of the present
invention, the minimum distance d1 is given by d1=D1-s, where the
value s is given by 0.05 mm.ltoreq.s.ltoreq.0.25 mm.
[0029] In accordance with the present invention, each minor side
surface merges with an adjacent major side surface at a corner side
surface, wherein each corner side surface extends between a given
raised corner of one of the two opposing end surfaces and a given
lowered corner of the other of one of the two opposing end
surfaces.
[0030] In accordance with the preferred embodiment of the present
invention, each cutting edge comprises a major edge, a minor edge
and a corner edge, therebetween.
[0031] In accordance with the present invention, each major edge,
corner edge, and minor edge is formed at the intersection of
adjacent major side surface, corner side surface, and minor side
surface, respectively with an adjacent end surface.
[0032] In accordance with the preferred embodiment of the present
invention, the major edges are recessed in an end view.
[0033] In accordance with the preferred embodiment of the present
invention, the distance between the opposing major edges varies
from the maximum distance D2 adjacent the corner edges to the
minimum distance d2 at the intersection of the major edges with the
major plane.
[0034] In accordance with the preferred embodiment of the present
invention, the minor edges are recessed in an end view.
[0035] In accordance with the preferred embodiment of the present
invention, the distance between the opposing minor edges varies
from the maximum distance D1 adjacent the corner edges to the
minimum distance d1 at the intersection of the minor edges with the
minor plane.
[0036] In accordance with the preferred embodiment of the
invention, each raised corner forms a corner cutting edge and
adjacent major and minor edges form major and minor cutting edges,
respectively.
[0037] Generally, the major cutting edge has a length L1 that is
greater than half the distance D1.
[0038] Generally, the minor cutting edge has a length L2 that is
approximately half the distance D2.
[0039] In accordance with the preferred embodiment of the present
invention, the cutting insert further comprises an insert through
bore extending between the major side surfaces and having a bore
axis coinciding with the second axis.
[0040] In accordance with the present invention there is provided a
cutting tool comprising: the cutting insert in accordance with the
present invention, a shim, and an insert holder having an insert
pocket in which the shim and the cutting insert are securely
retained.
[0041] In the cutting tool, the insert pocket comprises: a base
surface, the base surface being abutted by a given major side
surface of the cutting insert, a first side wall extending
uprightly from the base surface, the first side wall being abutted
by a given minor side surface of the cutting insert, and a second
side wall extending uprightly from the base surface, the first side
wall being adjacent the major side surface and transverse
thereto;
[0042] the shim comprises a top surface that is abutted by a
non-operative end surface of the cutting insert, an opposing bottom
surface that abuts the first side wall, and a perimeter surface
extending therebetween;
[0043] a shim screw, extending through the shim through bore and
threadingly engaged with a threaded second bore of the second side
wall, secures the shim to the insert pocket; and
[0044] a securing screw, extending through the insert through bore,
threadingly engaged with a threaded receiving bore of the base
surface, secures the cutting insert to the insert pocket, the
securing screw.
[0045] If desired, each end surface of the cutting insert further
comprises two frustums extending away from the median plane located
on either side of the major plane, and the top surface of the shim,
in accordance with the present invention, further comprises a
raised area being a portion of the top surface of the shim
protruding from the top surface of the shim; wherein
[0046] the two frustums of the non-operative end surface abut the
raised area of the top surface of the shim.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] For a better understanding, the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:
[0048] FIG. 1 is of a side view of a typical prior art cutting
tool;
[0049] FIG. 2 is an end view of the cutting tool in FIG. 1;
[0050] FIG. 3 is a plan view of the cutting tool in FIG. 1 in a
turning operation.
[0051] FIG. 4 is a perspective view of the cutting insert in
accordance with the present invention;
[0052] FIG. 5 is a first side view of the cutting insert in FIG.
4;
[0053] FIG. 6 is a second side view of the cutting insert shown in
FIG. 4;
[0054] FIG. 7 is a cross-sectional view of the cutting insert shown
in FIG. 6 taken along C-C;
[0055] FIG. 8 is an end view of the cutting insert shown in FIG.
4;
[0056] FIG. 9 is a side view of a cutting tool in accordance with
the present invention;
[0057] FIG. 10 is an end view of the cutting tool in FIG. 9;
[0058] FIG. 11 is a plan view of the cutting tool in accordance
with the present invention in an axial turning operation;
[0059] FIG. 12 is a detailed view of FIG. 11;
[0060] FIG. 13 is a plan view of the cutting tool in accordance
with the present invention in a radial turning operation;
[0061] FIG. 14 is a detailed view of FIG. 13;
[0062] FIG. 15 is a perspective exploded view of cutting tool in
accordance with the present invention; and
[0063] FIG. 16 is an end view of a cutting insert shown insert in
accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0064] Attention is first drawn to FIGS. 4 to 8, showing a
tangential indexable cutting insert 38 in accordance with present
invention. The cutting insert 38 is generally manufactured by form
pressing and sintering a cemented carbide, such as tungsten
carbide, and can be coated or uncoated. The cutting insert 38 is
generally rectangular in an end view and comprises two identical
end surfaces 40, and a peripheral side surface 42 extending between
the end surfaces 40. The cutting insert 38 and the end surfaces 40
have 180.degree. rotational symmetry about a first axis R1 that
passes through the end surfaces 40. Since the end surfaces 40 are
identical, only one will be described, it being understood that the
other end surface 40 has identical structure.
[0065] The peripheral side surface 42 comprises two opposed
identical minor side surfaces 44, two opposed identical major side
surfaces 46, and four opposed corner side surfaces 48. Adjacent
major and minor side surfaces 46, 44 merge at a common corner side
surface 48. The cutting insert 38 and the major side surface 46
have 180.degree. rotational symmetry about a second axis R2
perpendicular to the first axis of rotational symmetry R1 and
passing through the major side surfaces 46. The cutting insert 38
and the minor side surface 44 also has 180.degree. rotational
symmetry about a third axis R3 that passes through the minor side
surfaces 44 and is perpendicular to both the first and second axis
of 180.degree. rotational symmetry R1, R2.
[0066] The peripheral side surface 42 intersects each end surface
40 at a peripheral edge 50. The peripheral edge 50 comprises two
identical opposed major edges 52, two identical opposed minor edges
54, and four opposed corner edges 56. Adjacent major and minor
edges 52, 54 merge at a common corner edge 56. The major edges 52
are formed at the intersection of the major side surfaces 46 with
the end surfaces 40, the minor edges 54 are formed at the
intersection of the minor side surfaces 44 with the end surfaces
40, and the corner edges 56 are formed at the intersection of the
corner side surfaces 48 with the end surfaces 40.
[0067] For further description of the geometrical properties of the
cutting insert 38, a minor plane P1, to which the major edges 52
are generally parallel in an end view of the cutting insert 38, is
defined by the first and third axis of rotational symmetry R1, R3.
A major plane P2, to which the minor edges 54 are generally
parallel in an end view of the cutting insert 38, is defined by the
first and second axis of rotational symmetry R1, R2. A median plane
M, which is perpendicular to both the minor and major plane P1, P2,
is defined by the second and third axis of rotational symmetry R2,
R3. A width dimension D1 of the cutting insert 38 is defined as a
maximum distance dimension between the minor side surfaces 44
measured parallel to the third axis R3. A length dimension D2 of
the cutting insert 38 is defined as a maximum distance dimension
between the major side surfaces 46 measured parallel to the second
axis R2. For the tangential cutting insert 38, the width dimension
D1 is greater than the length dimension D2.
[0068] Associated with each of the four corner edges 56 of a given
end surface are four corners comprising two diametrically opposed
raised corners 58 and two diametrically opposed lowered corners 60.
The lowered corners 60 are closer to the median plane M than are
the raised corners 58. In a side view of either of the minor side
surfaces 44, all four corners 58, 60 are equidistant from the minor
plane P1. In a side view of either of the major side surfaces 46,
all four corners 58, 60 are equidistant from the major plane P2.
Each corner side surfaces 48 extends between a given raised corner
58 of one end surface 40 and an adjacent lowered corner 60 on the
opposing end surface 40. Each corner side surface 48 has uniform
radius of curvature along its length, and typically forms an arc
angle of 95.degree..+-.3.degree.. The alternating raised and
lowered corners 58, 60 enable the cutting insert 38 to have four
same-handed raised corners 58 for indexing.
[0069] Turning to FIGS. 5 and 6, and as discussed above, the insert
body 57 has four side surfaces (two minor side surfaces and two
major side surfaces) and identical first and second end surfaces.
Without loss of generality, one of these end surfaces may be
considered the top surface 40a while the other end surface may be
considered the base surface 40b, in the orientation presented in
FIGS. 5 and 6. The four side surfaces, together with the top
surface 40a and the base surface 40b, define respective pairs of
major 52 and minor 54 cutting edges at the top 40a and base 40b
surfaces. Each side surface has two diagonally opposed lowered
corners 60 spaced by equal first distances y from the median plane
M of the insert body, and two diagonally opposed raised corners 58
spaced by equal second distances z from the median plane M, the
second distances z being longer than the first distances y, and the
distance 2z between raised corners 58 of the top surface 40a and
the base surface 40b defining the height of the insert, in either a
minor side view (FIG. 5) or major side view (FIG. 6) of the
insert.
[0070] Each member of a first pair of side surfaces has a long
diagonal S1 extending between the pair of raised corners 58 and a
short diagonal S2 extending between the pair of lowered corners 60.
Similarly, each member of a second pair of side surfaces has a long
diagonal T1 extending between the pair of raised corners 58 and a
short diagonal T2 extending between the pair of lowered corners 60.
The long diagonal (S1 or T1) of a given side surface is
non-parallel to the long diagonal of an opposite side surface of
the insert. For instance, in the side view of the insert body seen
FIG. 6, the long diagonal T1 of one side surface crosses, and so is
non-parallel to, the long diagonal T1' (shown in phantom) of the
opposite side surface found on the other side of the insert
body.
[0071] Adjacent major and minor edges 52, 54 extend from the corner
edge 56 of a given raised corner 58 with a variable slope to a
respective lowered corner 60. In a side view of the cutting insert
38, adjacent each raised corner 58, the slope of each major edge 52
(see FIG. 6) is generally constant with the major edge 52
substantially parallel to the median plane M. Moving along the
major edge 52 towards an adjacent lowered corner 60, the slope
gradually increases and finally decreases adjacent the lowered
corner 60. As can be seen in FIG. 5 each minor edge 54 has a
generally similar form to that of the major edges 52. Thus in a
respective side view, each major and minor edge 52, 54, has a
similar wavy elongated "S"-shape.
[0072] In an end view of the cutting insert 38, the major edges 52
are concave. In other words, the major edges 52 are recessed in an
end view wherein, the distance between the opposed major edges 52
varies from approximately D2 adjacent the corner edges 56 to a
minimum distance d2 at the intersection of the major edges 52 with
the major plane P2. The minimum distance d2 is defined by D2-t. In
a non-binding example, t is greater than or equal to 0.3 mm and
less than or equal 0.4 mm. In an end view of the cutting insert 38,
each major side surface 46 is also concave, being recessed in the
same manner as its associated major edge 52. It should be noted
that the variation of the distance between the opposed major edges
52 (and likewise the opposed major side surfaces 46) need not
decrease uniformly from the maximum value D2 to the minimum value
d2.
[0073] In an end view of the cutting insert 38, the minor edges 54
are also concave, in a similar manner to the major edges 52. The
distance between the opposed minor edges 54 in an end view, varies
from approximately D1 adjacent the corner edges 56 to a minimum
distance d1 at the intersection of the minor edges 54 with the
minor plane P1. The minimum distance d1 is defined by D1-s. In a
non-binding example, s is greater than or equal to 0.05 mm and less
than or equal 0.25 mm. Likewise, in an end view of the cutting
insert 38, each minor side surface 44 is concave, being recessed in
the same manner as its associated minor edge 54. The variation of
the distance between the opposed minor edges 54 (and likewise the
opposed minor side surfaces 44) need not decrease uniformly from
the maximum value D1 to the minimum value d1.
[0074] It will be appreciated that whereas the whole of the
peripheral edge 50 can function as a cutting edge, in practice,
sections of the peripheral edge 50 adjacent the lowered corners 60
will not function as cutting edges. In accordance with a specific
application of the present invention, each given peripheral edge 50
has an effective major cutting edge 66 that extends from an
associated given raised corner 58 along the given corner edge 56
and the given major edge 52 for a given major cutting edge length
L1, which is greater than one half of the width dimension D1.
Additionally, in accordance with the specific application of the
present invention, each peripheral edge 50 has an effective minor
cutting edge 68 that extends from an associated given raised corner
58 along the given corner edge 56 and the given minor edge 54 for a
given minor cutting edge length, L2, which is approximately one
half of the length dimension D2, and more preferably is slightly
greater than one half of D2.
[0075] Attention is now drawn to FIGS. 9 and 10, showing side views
of a cutting tool 70 in accordance with the present invention. The
cutting insert 38 has relief angles y1, y2 and presents an
operative raised corner 58' outward1y projecting from the cutting
tool 70.
[0076] Attention is now drawn to FIGS. 11 and 12, showing the
cutting insert 38 in an insert holder 72 in a plan view during an
axial turning operation of a stepped square shoulder 74 of a
workpiece 76 rotating about an axis A. Adjacent the stepped square
shoulder 74 is a operative major edge 52', an operative corner edge
56' of an operative raised corner 58' an operative minor edge 54',
and a trailing lowered corner edge 78'. It will be appreciated that
an operative minor edge 54' constitutes a secondary cutting edge or
wiper and that only a small section of it adjacent the operative
corner edge 56' contacts the workpiece 76. Due to the relief angles
y1, y2 and any other required orientation of the cutting insert 38,
an entering angle K is formed between the major edge 52 and the
feed direction F1, and a back clearance angle Kn is formed between
the operative minor edge 54' and a cylindrical surface 80 of the
workpiece 76. As can be seen, the trailing lowered corner edge 78'
is completely relieved from the cylindrical surface 80 of the
workpiece 76, whereby the depth of cut for axial turning is
unlimited.
[0077] Attention is now drawn to FIGS. 13 and 14, showing the
cutting insert 38 in an insert holder 72 in a plan view during an
radial turning operation of a cylindrical surface 80 of a workpiece
76 rotating about an axis A. Adjacent the cylindrical surface 80 is
an operative major edge 52', an operative corner edge 56' of the
operative corner edge 58' an operative minor edge 54', and a
trailing lowered corner edge 78''. It will be appreciated that an
operative major edge 52' constitutes a secondary cutting edge or
wiper and that only a small section of it adjacent the operative
corner edge 56' contacts the workpiece 76. Due to the relief angles
y1, y2 and any other required orientation of the cutting insert 38,
an entering angle K is formed between the operative minor edge 54'
and the feed direction F2, and a back clearance angle Kn is formed
between the operative major edge 52' and a stepped square shoulder
74 of the workpiece 76. As can be seen, the trailing lowered corner
edge 78'' is completely relieved from the stepped square shoulder
74 of the workpiece 76, whereby the depth of cut for radial turning
is unlimited.
[0078] The seating and securing of the cutting insert 38 will now
be described with reference to FIG. 15, showing various elements
not mentioned above. These elements include two frustums 82 on each
end surface 40, an insert pocket 84 of the insert holder 72, an
insert through bore 86, a securing screw 88, a shim 90, and a shim
screw 92.
[0079] The insert pocket 84 comprises first and second side walls
94, 96 uprightly extending from a base surface 98 of the insert
pocket 84. The shim 90 comprises a top surface 100, a flat opposing
bottom surface 102, and a perimeter surface 104 extending
therebetween. The top surface 100 of the shim 90 comprises a raised
area 106 extending away from the bottom surface 102 of the shim 90.
A shim through bore 108 extends between the top surface 100 and the
bottom surface 102. The two frustums 82 of each end surface 40
extend away from the median plane M and are located on either side
of the major plane P2. The frustums 82 are likely to impede chip
flow, thereby limiting the lengths L1, L2 of the major and minor
cutting edges 66, 68.
[0080] The shim 90 is secured in the insert pocket 84 with its
bottom surface 102 abutting the second side wall 96. The shim screw
92, extends through the shim through bore 108 and threadingly
engages with a threaded second bore 110 passing through the second
side wall 96, securing the shim 90 to the insert pocket 84. The
cutting insert 38 is secured in the insert pocket 84 with a
non-operative end surface 40 adjacent the top surface 100 of the
shim 90. The first side wall 94 abuts the minor side surface 44 of
the cutting insert 38, and the base surface 98 abuts the major side
surface 46. The two frustums 82 of a non-operative end surface 40
abut the raised area 106 of the top surface 100 of the shim 90. The
securing screw 88 extends through the insert through bore 86 and
threadingly engages a threaded receiving bore 112 in the base
surface 98 of the insert pocket 84.
[0081] It will be appreciated that the particular form of the end
surfaces 40 will depend on the design factors that take into
account various working conditions. For example, in order to
increase the effective cutting wedge angle, a land 114 is provided
adjacent the peripheral edge 50 (see FIG. 7). A rake surface 116
slopes downwardly and inwardly from the land 114. If desired the
rake surface can be provided with suitable chip control
elements.
[0082] It is advantageous to have recessed side surfaces and side
edges to take into consideration manufacturing tolerances so that
the sides will not become convex or partially convex, when viewed
in an end view, and interfere with the workpiece. It is possible to
use straight side edges, i.e., the major side surface 46 and the
major edges 52 could be straight, as in FIG. 16, either by tight
manufacturing tolerances during pressing and sintering or by
additional steps of grinding.
[0083] Although the present invention has been described to a
certain degree of particularity, it should be understood that
various alterations and modifications could be made without
departing from the spirit or scope of the invention as hereinafter
claimed.
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