瑞典专利SE1251391A1 Cutting with internal coolant supply and cutting units using this

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专利摘要:
A metalcutting insert that is useful in chipforming and material removal from a workpiece The metalcutting insert includes a metalcutting insert body, which includes a cutting edge having at least one discrete cutting location. The metalcutting insert body further contains a distinct interior coolant passage communicating with the discrete cutting location. The distinct interior coolant passage has a coolant passage inlet defining a coolant passage inlet cross-sectional area, a coolant passage discharge defining a coolant passage discharge cross-sectional area, and an axial coolant passage length. The distinct interior coolant passage defines a coolant flow cross-sectional area along the axial coolant passage length thereof. The coolant passage inlet cross-sectional area is substantially the same as the coolant passage discharge cross-sectional area. The geometry of the coolant flow area changes along the axial coolant passage length.
公开号:SE1251391A1
申请号:SE1251391
申请日:2011-04-13
公开日:2012-12-07
发明作者:Joseph V Nelson；Linn R Andras；Thomas O Muller；Paul D Prichard；Brad D Hoffer
申请人:Kennametal Inc；
IPC主号:

专利说明:

[5] Other patents describe various methods of delivering or systems for delivering coolant to the cutting-chip interface. U.S. Patent 7,625,157 (Prichard et al.) To COOLING CUTTERS AND MILLING CUTTERS relates, for example, to a cutting insert which includes a cutting body having a central coolant inlet. The insert further comprises a positionable deflector.
[6] U.S. Patent 6,045,300 (Antoun) for INTEGRATED COOLANT PASSAGE HOLDER AND REPLACABLE NOZZLE describes the use of a high pressure, high volume liquid coolant for the purpose of addressing heat in the cutting chip interface. U.S. Patent 6,652,200 (Kraemer) relating to a TOOL HOLDER WITH COOLANT SYSTEM discloses grooves between the insert and an upper plate. Coolant flows through the grooves to address the heat in the cutting-chip interface. U.S. Patent 5,901,623 (Hong) to KRYOGEN PROCESSING discloses a coolant supply system for applying surface nitrogen to the cutting chip interface.
[7] It is obvious that in a chip-forming and material-removing operation, higher operating temperatures in the cutting-chip interface can have a detrimental effect on the useful tool life due to premature breakage and / or excessive wear.
[8] In a chip-forming material removal operation, the chips generated from the workpiece can sometimes adhere (eg by welding) to the surface of the insert.
[9] In a chip-forming material removal operation, there may be times when the chip does not come out of the area of the insert-chip interface when the chip is at the insert. When a chip does not come out of the area of the cut-chip interface, there is the possibility that a chip can be cut again. It is undesirable for the cutter to cut a chip that has already been removed from the workpiece once more. A coolant ﬂ destiny for the cutting-chip interface will facilitate the removal of chips from the cutting-chip interface thereby minimizing the possibility of a chip being cut again. It would be highly desirable to provide an insert used for chip-forming material removal operations in which there is improved supply of coolant to the insert-chip interface to reduce the possibility that a chip will be cut again. The consequence of improved coolant ﬂ fate to the cutting-chip interface is better drainage of chips from the interface environment with a consequent reduction in the possibility of a chip being cut again.
[10] A number of factors can affect the extent of the coolant delivered to the shaving chip interface. For example, the size of the structure that transfers the coolant to the insert may be a limiting factor in the amount of coolant supplied to the insert. Thus, it would be highly desirable to provide supply holes that are equal to or larger than the inlets in the insert to maximize the coolant flow to the insert. It would be highly desirable to provide an insert in which two or more coolant channels transfer coolant to a single discrete cutting point. Furthermore, in order to tailor the coolant supply, the use of irregular coolant channels and variable areas of the inlet and the outlet in the insert will enable such specific adaptation. One such phenomenon is to enable a range of diversion angles for the coolant, which may be between about 10 degrees and about 60 degrees.
[11] In order to improve the coolant supply, it is advantageous to enable the coolant to flow into the insert through the holder. This may involve the use of an external coolant supply or an internal coolant supply.
[12] With regard to the manufacture of an insert, there may be advantages in using several parts, which together form the insert. For example, in some cases a blade formed by a base having the cutting edge and a core may lead to improved service life because only the base needs to be replaced when the end of the useful tool life has been reached. In such an arrangement, the core is releasably connected to the base, the core being reused when the base becomes worn. The base and the core can be connected to each other by co-sintering, soldering and / or gluing.
[13] When the preferred embodiment of the insert has a round geometry, certain advantages may exist. For example, when the insert has a round geometry, the composition of several components, e.g. a foundation and a core, not indexed. A round insert is not mirror-inverted so it can be used in left, right and neutral positions. For profile turning, up to 50% of the round insert can act as a cutting edge. A round insert is also provided to engage an anti-rotation device.
[14] In one form, the invention relates to a metal insert which is useful in chip formation and material removal from a workpiece. The metal cutting insert comprises a metal cutting body, which comprises a cutting edge with at least one discrete cutting point.
[15] In another form, the invention relates to a metal cutting unit which is useful in chip formation and material removal from a workpiece, wherein a source of coolant supplies coolant to the metal cutting unit. The metal cutting assembly comprises a holder having a pocket, the. Having a flat surface containing a coolant port, having a coolant port cross-sectional area, in communication with the coolant source. The pocket receives a metal insert. The metal cutting insert comprises a metal cutting body, which comprises a cutting edge with at least one discrete cutting point.
[16] The following is a brief description of the drawings which form a part of this patent application:
[17] Fi g. 1 is an isometric view of a specific embodiment of a milling assembly, the milling assembly having a milling body carrying a plurality of inserts, which in this particular embodiment are five inserts, one pocket carrying a single one of the inserts;
[18] Fi g. 1A is a front view of one of the sockets of the milling unit in ﬁg. 1 wherein the ﬁ ckan does not have the insert therein; -5-
[19] Fig. 2 is an isometric view of a specific embodiment of a KM® holder body carrying an insert in a pocket with the insert not in the pocket, and KM being a registered trademark of Kennametal Inc., Latrobe, Pennsylvania. 15650;
[20] Fi g. 2A is a plan view of the pocket, which does not have the insert therein, of the KM® holder body in ﬁ g. 2;
[21] Fi g. 3 is an isometric view of a specific embodiment of a screw-on tool holder body carrying an insert in a pocket, the insert not being in the pocket, illustrating in schematic form the connection between the coolant source and the coolant outlet port in the flat surface of the pocket;
[22] Fig. 3A is a plan view of the pocket, which does not have the insert in it, of the screw-on tool holder body in ﬁ g. 3;
[23] Fig. 4 is an isometric view of the base member of the insert showing the chip surface and clearance surface of the base member;
[24] Fi g. 4A is an enlarged view of a portion of the base member of ﬁg. 4 showing in detail the channel delimited between two ribs;
[25] Fi g. 5 is an isometric view of the base member of the insert showing the bottom surface and clearance surface of the insert;
[26] Fi g. 6 is an isometric view of the core member of the insert showing the top surface and side surface of the core member;
[27] Fi g. 7 is an isometric view of the core member of the insert showing the bottom surface and side surface of the core member;
[28] Fig. 7A is an isometric view of the base member and the core member with the core member removed from the base member;
[29] Fig. 8 is an isometric view of the assembly formed by the base member and core member of the insert showing the chip surface and clearance surface of the insert;
[30] Fig. 9 is an isometric view of the bottom surface of the insert;
[31] Fi g. 10 is an enlarged view of the portion of the bottom surface showing a location for the connection of the base member and the core member;
[32] Fig. 11 is a bottom view of the specific embodiment of the insert shown in Fig. 5; _7-
[33] Fi g. 12 is a side view of the specific embodiment of the insert shown in Fig. 5;
[34] Fi g. 13 is an isometric view with a portion of the insert and holder removed for the purpose of showing the supply of coolant to a discrete insert; and
[35] Fi g. 14 is a plan view of a specific embodiment of the insert;
[36] Fi g. 14A is an enlarged view of a portion of the cross-sectional view in ﬁg. 14B showing the distinct internal coolant passages;
[37] Fi g. 14B is a cross-sectional view of the insert in ﬁ g. 14 taken along section line 14B-14B;
[38] Fi g. 15 is a cross-sectional view of the insert illustrating the distinct internal coolant passage and is taken along section line 15-15 in ﬁ g. l4B;
[39] Fi g. 15A is an enlarged view of a portion of the cross section of ﬁ g. 15 in the circle designated 15A illustrating the geometry of the inner coolant passage;
[40] Fi g. 16 is a cross-sectional view of the insert illustrating the distinct internal coolant passage and is taken along section line 16-16 in. G. l4B;
[41] Fi g. 16A is an enlarged view of a portion of the cross section of ﬁ g. 16 in the circle designated 16A illustrating the geometry of the inner coolant passage;
[42] Fi g. 17 is a cross-sectional view of the insert illustrating the distinct internal coolant passage taken along section line 17-17 of ﬁg. 14B, the section line 17-17 being taken at an angle "M" equal to 30.18 degrees;
[43] Fi g. 18 is a cross-sectional view of the insert illustrating the distinct internal coolant passage and is taken along section line 18-18 in. G. 14B, the section line 18-18 being taken at an angle "N" equal to 50.10 degrees;
[44] Fi g. 19A is a plan view illustrating the insert in the insert in a cutting position with the coolant inlets communicating with the coolant source and the abutment member engaging the clearance surface;
[45] Fi g. 19B is a plan view illustrating the insert in the pocket in an indexed insert position with the coolant inlets communicating with the coolant source and the abutment member engaging the release surface;
[46] Fi g. 20 is a plan view of the insert illustrating coolant fate; and _g_
[47] Fi g. 2l is a cross-sectional view of the insert showing the coolant flow through the inner coolant passage.
[48] The drawings show that the insert according to the invention, as well as the cutting unit according to the invention, can work in a number of different applications. The insert, which has an internal coolant supply, is intended for use in chip-forming removal of material from a workpiece. In this case, the insert is intended for use in a chip-forming material removal operation in which there is an improved supply of coolant adjacent to the interface between the insert and the workpiece (ie the cutting chip interface) in order to reduce excessive heat in the insert-chip interface.
[49] The improved supply of coolant to the cutting-chip interface leads to certain advantages. For example, improved supply of coolant to the cutting-chip interface leads to improved lubrication in the cutting-chip interface, which reduces the chip's tendency to adhere to the insert. Furthermore, improved coolant ﬂ fate of the cutting-chip interface leads to better drainage of chips from the interface environment with a consequent reduction in the possibility of a chip being cut again.
[50] As will be apparent from the description below, the nature of the coolant dispersion or spray is such that it is continuous between the adjacent so-called activated internal coolant passages. The coolant actually flows out of the activated coolant passages in the form of a continuous cone of coolant. By providing such a coolant dispersion, the insert provides improved supply of coolant to the cutting chip interface.
[51] It should also be appreciated that the inner coolant passage outlet has an orientation that allows the coolant to strike below the chip surface. Such an orientation of the coolant improves the cooling properties, which improves the overall performance of the insert.
[52] The description in this specification of specific applications should not be construed as limiting the scope and extent of the use of the insert.
[53] In the chip-forming material removal operation, the insert 150 engages a workpiece to remove material from a workpiece typically in the form of chips. A material removal operation which removes material from the workpiece in the form of chips is typically known to those skilled in the art as a chip forming material removal operation. The book Machine Shop Practice [Industrial Press Inc., -9- New York, New York (l 981)] by Moltrecht presents on pages I99-204 a description, among other things, of chip formation, as well as different types of chips (ie continuous chip, discontinuous chip, segmented chip). Moltrecht says [in part] on pages 199-200 "When the cutting tool body first comes into contact with the metal, it compresses the metal in front of the cutting edge. As the tool moves forward, the metal in front of the cutting edge is loaded to the point where it will shear internally. the metal is deformed and flows plastically along a plane called the shear plane. When the type of metal being cut is ductile, such as steel, the chips will come loose in a continuous band ". Moltrecht goes on to describe the formation of a discontinuous chip and a segmented chip.
[54] As another example, the text on pages 302-315 of the ASTE Tool Engineers Handbook, McGraw Hill Book Co., New York, New York (1949) gives a long description of chip formation in the metal cutting process. On page 303, the ASTE Handbook makes a clear connection between chip formation and machining operations such as turning, milling and drilling. The following patents discuss the formation of chips in a material removal operation: U.S. Patent 5,709,907 (Battaglia et al .; assigned to Kennametal Inc.), U.S. Patent 5,722,803 (Battaglia et al.; Assigned to Kennametal Inc.). ), and U.S. Patent 6,161,990 (Oles et al .; assigned to Kennametal Inc.),
[55] In the drawings, ﬁ g. 1 is an isometric view of a cutter assembly having the general reference numeral 40. The cutter assembly 40 has a cutter body 42 having a central cutter body portion 44. A plurality of lobes 46 extend radially outwardly from the central cutter body portion 44. Each has an off. radial inner edge 46 and a radial outer edge 48. Each lobe 46 further has a distal end 47.
[56] At the distal end 47, each of the lobes 46 includes a square 54 having a flat surface 56. The flat surface 56 is substantially circular and has a circumferential edge 57. An upright wall 58 is located at one end of the flat surface. the surface 56 with the upright wall 58 extending around a portion of the circumferential edge 57.
[57] The flat surface 56 further contains an arcuate opening (arcuate recess) 60 which extends in a parallel manner over a part of the circumferential edge 57. A coolant discharge port 62 is arranged in communication with the arcuate opening 60. The coolant discharge port 62 is in communication with a _10- coolant passage, which has a coolant inflow port. Coolant from a coolant source flows into the coolant passage through the coolant inflow port and moves so that it flows out at the coolant discharge port into the arcuate opening 60. Coolant flowing into the arcuate opening 60 then passes into the insert 150, as will be described below. The arcuate opening 60 extends around 90 degrees so that it communicates with two adjacent internal coolant passages. The specific design of the coolant source, coolant passage and coolant inflow port is not illustrated, but is substantially the same as the corresponding design illustrated and discussed in connection with the screw-on tool holder 114.
[58] I ﬁ g. 1A, as mentioned above, the milling body 42 has a pocket 54 and an adjacent upright wall 58. The upright wall 58 includes a counter-rotation stop 70 which extends radially inwardly from the upright wall 58. The anti-rotation stop 70 has further a circumferential abutment edge 72. As described in more detail below, the circumferential abutment edge 72 has a geometry arranged to engage the insert 150 whereby the anti-rotation stop 70 prevents rotation of the insert 150 when it is in the corner 54. The anti-rotation abutment 70 and its interaction with the insert conform to the principles of the construction shown and described in U.S. Patent 6,238,133 B1 (DeRoche et al.) regarding the ROTATION AGAINST MOUNTING CUTTING MECHANISM.
[59] The insert 150 can be used with holders other than the cutters 40 described above. For example, and as shown in Figures 2 and 2A, the insert 150 may be used with a KM® holder 80. The KM® holder 80 has a distal end portion 82 and a proximal end portion 84. The KM® holder 80 further has a pocket 86 having a flat surface 88 at the distal end portion 82 thereof. The flat surface 88 has a circular geometry and a circumferential edge 89.
[60] An upright wall 90 is located adjacent the flat surface 88. The upright wall 90 extends over a portion of the circumferential edge 89 of the flat surface 88. The flat surface 88 further includes an arcuate opening 92 which is in communication with a coolant outlet port. 94. The flat surface 88 further has a threaded opening 96 which facilitates attachment of the insert 150 to the KM® holder 80 therein.
[61] Although not shown in the drawings, the KM® holder 80 further has an _11 coolant passage, which has a coolant inflow port.
[62] The KM® holder 80 further includes an anti-rotation stop 104 extending radially inwardly away from the upright wall 90.
[63] As yet another example of a holder suitable for use with the insert 150, Figures 3 and 3A illustrate a screw-on tool holder 114 having a tool holder body 116.
[64] The flat surface 124 further includes a threaded opening 132 which facilitates attachment of the insert 150 to the screw-on tool holder 114 therein.
[65] The flat surface 124 includes an arcuate opening 128 which communicates with a coolant outlet port 130. The screw tool holder 114 further has a coolant passage 134 having a coolant inflow port 135 and a pair of forming coolant outlet ports 136 and 136. a coolant source. As described in more detail below, the coolant from the coolant source 138 passes through the coolant inflow port 135 into the coolant passage 134 and flows out of the coolant discharge passage 134 via the coolant discharge ports 136, 137. The coolant then passes into the arcuate opening, as described above. The arcuate opening extends about 180 degrees so that it communicates with three _12- adjacent internal coolant passages.
[66] It will be appreciated that any of a number of different types of liquid or coolant are suitable for use in the insert. In general, there are two basic categories of ﬂ uider or coolants; namely oil-based ider uides which include straight oils and soluble oils, and chemical ﬂ uids which include synthetic and semi-synthetic coolants. Straight oils are composed of a base mineral or petroleum oil and often contain polar lubricants such as fats, vegetable oils and esters, as well as high pressure additives of chlorine, sulfur and phosphorus. Soluble oils (also called emulsion liquids) are composed of a base of petroleum or mineral oil in combination with emulsifiers and blending agents. Petroleum or mineral oil combined with emulsifiers and blending agents are basic components of soluble oils (also called emulsifiable oils).
[67] The tool holder body 16 further comprises a counter-rotation stop 140 which extends in a radially inwardly directed manner from the upright wall 126. The anti-rotation stop 140 has a circumferential stop surface 142.
[68] With reference to the other drawings, a description follows of a preferred specific embodiment of the insert 150 (see Figs. 8 and 9) which is suitable for use with any of the holders, i.e. the cutter body 42, the KM® holder 80 and the screw-on tool holder 114. The insert 150 is useful for chip-forming material removal from a workpiece whereby a source of coolant supplies coolant to the insert. The insert 150 includes a cutting body 151 (see Fig. 8) which includes a base member 152 and a core member 154. As described in more detail below, the base member 152 and the core member 154 cooperate to form the cutting body 151. As will be apparent from the discussion below, the base member and core member may be connected to each other and form a part in one piece or be compressed while maintaining their individual separate and distinct nature.
[69] The components, i.e. the base member 152 and the core member 154, of the insert 150 may be made of any number of materials suitable for use as a insert. The following materials are exemplary materials that are useful for a cutting edge: tool steel, cemented carbides, cermet or ceramic materials. The specific materials and combinations of materials depend on the specific application of the insert. Applicants think that the base member and the core member may be made of other materials.
[70] In the case of tool steels, the following patents describe tool steels suitable for use as a cutting insert: U.S. Patent 4,276,085 for high speed steels, U.S. Patent 4,880,461 for superhard high speed tool steels, and U.S. Patent 5,252,119 for high speed tool steels made of centrifugal steel. powder and process for its manufacture. In the case of cemented carbides, the following patent specifications describe cemented carbides suitable for use as an insert: U.S. Pat. binder-enriched cemented carbide and manufacturing process, and U.S. Pat. No. 5,955,186 relating to a coated insert with a C-porosity substrate with non-stratified surface binder enrichment. As to the cermet, the following patents describe the cermet suitable for use as an insert: U.S. Patent 6,124,040 for composite and process for its manufacture, and U.S. Patent 6,010,283 for an insert of a cermet having a Co-Ni-Fe - binder. In the case of ceramic material, the following patents describe ceramic materials suitable for use as a cutting insert: U.S. Patent 5,024,976 for a ceramic alumina-zirconia-kise1-carbide-magnesium oxide material cutting tool, U.S. Patent 4,880,755 for a SiAlON cutting tool composition , U.S. Patent 5,525,134 for a silicon nitride ceramic material and cutting tools made therefrom, U.S. Patent 6,905,992 for a ceramic body reinforced with coarse silicon carbide whiskers and a method of making the same, and U.S. Patent 7,094,717 for a SiAlON containing ytterbium and manufacturing process.
[71] In the case of the base element 152, in particular the illustrations of the base element 152 in Figures 4, 4A and 5, the base element 152 comprises a chip surface 156 and a clearance surface 158. Since the core element 154 fits into the base element 52 to form the insert 150, the clearance surface 158 of the base element 152 is the cutting surface 150 of the insert. Similarly, due to the dimensioning and placement of the core member 154 relative to the base member 152, the chip surface 156 of the base member 152 provides the effective chip surface of the insert 150.
[72] The cut between the chip surface 156 and the clearance surface 158 forms a cutting edge 160, which in this embodiment is a substantially round cutting edge. As described in more detail below, the cutting edge 160 has a number of discrete cutting points. In this embodiment, there are six discrete cutting points 16lA to 16lF. The discrete cutting points (161A-16 IF) are separated by about 60 degrees from each other. Furthermore, each discrete cutting point (161A-1 61F) is located halfway between each pair of adjacent ribs 170.
[73] The chip surface 156 of the base member 152 has a radially outwardly facing surface 162, which is located radially inwardly of the cutting edge 160 and extends around the entire circumference of the chip surface 156. Located radially inwardly from the radially outwardly facing surface 162 is a first transition surface 164 and located radially inwardly from the first transition surface 164 is a second transition surface 166. Each of the first and second transition surfaces faces the bottom of the insert as it enters a radial direction. inward direction. The second transition surface 166 joins either a channel 168 or a rib 170.
[74] It should be understood that the surfaces, i.e. the radially outwardly facing surface 162, the first transition surface 164 and the second transition surface 166, may have any of a number of different geometric or surface configurations. A seam with these surfaces is to provide a transition between the cutting edge 160 and the inner part of the base element 152 comprising the channels 168 and the ribs 170. Furthermore, a special specific geometry can be effective to improve a chip breaking function of the insert. A special specific geometry can also be effective for improved coolant supply to the insert-chip interface as coolant can act on this area of the insert.
[75] I ﬁ g. 4A, which is an enlargement of a batch in ﬂ g. 4, each of the channels 168 has a pair of forming opposite channel circumferential surfaces, i.e. a channel circumferential surface 172 and a channel circumferential surface 174. Each channel 168 further has a central groove 176.
[76] The base member 152 further defines a central core receiving port 186. The central core receiving port 186 receives the core member 154. The following is a discussion of the assembly formed by the base member 152 and the core member 154.
[77] The base member 152 also has a clearance surface 158. The clearance surface 158 has a cylindrical clearance surface portion 200 in the vicinity of the chip surface 156. The cylindrical clearance surface portion 200 extends a selected distance towards the bottom surface, at which point it merges into a surface portion of substantially frustoconical shape. bracket 202).
[78] The surface portion 202 of substantially frustoconical shape has a sinusoidal geometry having a plurality of sinusoidal valleys or waveforms 206. Each of the sinusoidal valleys 206 has an opposite side 208, another opposite side 210, and an arcuate intermediate portion 212. For each sinusoidal valley 206 increases the circumferential width from the top to the bottom of the base member 152. Between each of the sinusoidal valleys 206 are sinusoidal islands 220. Each sinusoidal island 220 has opposite sides 221, 222 and an arcuate intermediate portion 223. For each sinusoidal island 220 decreases the circumferential width from the top to the bottom of the base element 15 2.
[79] Each sinusoidal valley 206 defines a depression that has an arcuate surface. As discussed below, the sinusoidal valley 206 may cooperate with a counter-rotating abutment, the abutment engaging the immersion of the sinusoidal valley 206 in order to prevent rotation of the insert 150 when it is in the holder. It should be understood that the geometry of the clearance surface does not have to exhibit the sinusoidal waveforms. The clearance surface can assume other geometries such as, for example, a smooth surface without waveforms or depressions.
[80] The base member 152 further has a bottom surface 226. The bottom surface 226 has a sinusoidal circumferential edge 228. The sinusoidal circumferential edge 228 has a plurality of peaks 230A to 230F and a plurality of valleys 232A to 232F.
[81] The bottom surface 226 of the base member 152 further includes grooves 238A to 238F and unprocessed surfaces 240A to 240F. These grooves (23 8A-23 8F) and unprocessed surfaces (240A-240F) de nine the edge profile at the end of the central core receiving port 186.
[82] As for the construction of the core element 154, and in particular the gurus 6 and 7, the core element 154 comprises an upper end 244 and a bottom end 246. At the upper end 244 there is a substantially circular portion 248, and next to the bottom end 246 there is an integrated substantially truncated conical portion 250, which extends from the substantially circular portion 248 via an arcuate transition 251.
[83] As for the inner surface of the integrated substantially frustoconical portion 250, in a direction toward the bottom end 246, there is an inner transition surface 258 which merges into an inner cylindrical surface 262. As for the outer surface of the integrated substantially frustoconical portion 250 there is an arcuate outer surface 264 and a frustoconical outer surface 266. A lower cylindrical surface 268 having a radial outer peripheral edge 270 is provided at the bottom end 246.
[84] As will become clearer from the description below, the cutting body 151 contains a number of distinct internal coolant passages 300 (see ﬁ g. 14) formed between the base member 152 and the core member 154. As described in more detail, when attached to the holder of an holder, an adjacent pair of the distinct internal coolant passages 300 each of the discrete cutting points.
[85] To form the complete insert 150, as shown, for example, in ﬁ g. 8, the base member 152 and the core member 154 are connected to each other.
[86] The contact points between the base member 152 and the core member 154 are very secure. This very secure contact between the base member 152 and the core member 154 is shown in ﬁ g. 10 and in ﬁ g. 15. The extent of the contact is sufficiently secure for the tightness of the contact points. The extent of the contact is sufficiently secure that the components will not be separated during use.
[87] The contact between the base element and the core element can be effected by actually connecting these components to each other. The connection of the base member 152 and the core member 154 can be accomplished in any of a number of ways. For example, methods such as co-sintering, soldering and / or gluing are suitable. The specific method may be particularly applicable to certain materials. For example, co-sintering may be applicable in a situation in which the base element and the core element are of the same material, (eg tungsten carbide cobalt material). Bonding can be applicable in a situation in which the materials of the base element and the core element are different (eg a steel core element and a tungsten carbide-cobalt base element). The contact can also be made by compressing the components while still keeping them separate and distinct from each other. For example, the insert can be securely threaded on the holder, whereby there is a very strong surface-to-surface contact between the base element and the core element due to the very close connection between the insert and the holder.
[88] The choice of specific materials for the components depends on the specific applications of the insert. The use of ceramic material-ceramic material or carbide-carbide or steel-carbide combinations of the components gives the insert a variety of material options. In this way, the insert has extensive material selection options that enable optimal adaptation of the insert from a material perspective. _18-
[89] As can be seen, the components, and thus the insert, have a round geometry. By using a round geometry, the unit of ﬂ your components, eg, a base and a core, do not need to be indexed to work. The absence of indexing or special orientation reduces manufacturing costs and makes the unit simpler, unlike components that require special orientation. This is especially the case for the core element. The core element has a generally cylindrical / conical geometry. It does not have external phenomena that require special orientation or orientation when mounting on the base. Thus, the assembly of the core on the base is simple and not expensive compared to the assembly of components, each of which has complex geometric phenomena.
[90] As mentioned above, the insert 150 has a number of distinct internal coolant passages 300. The following description of an internal coolant passage 300 is sufficient for a description of all such internal coolant passages 300.
[91] In the case of each of the inner coolant passages 300, selected surfaces on the base member 152 and on the core member 154 define the boundaries of the inner coolant passage 300. More specifically, some of the selected surfaces of the base member 152 are those defining the channel 168, i.e. the channel circumferential surfaces 172, 174 and the central groove 176. Other selected surfaces of the base member 152 include the radially inwardly facing barrier 178 of a rib 170 and the radial inwardly facing barrier 180 of an adjacent rib 170. As for the core member 154, the outer surface helps to define it internal coolant passage 300.
[92] The inner coolant passage 300 has an inner coolant passage outlet 302 and an inner coolant passage inlet 304. As can be seen, coolant flows into the inner coolant passage 300 through the inner coolant passage inlet 304, moves through the inner coolant inlet outlet 300, and 302. After leaving the inner coolant passage 300, coolant sprays against the discrete cutting site in engagement with the workpiece.
[93] Fig. 14 is a plan view of the insert 150 providing a reference point for the discussion of the inner coolant passage 300, particularly the geometry of the inner coolant passage 300, in a preferred specific embodiment of the insert 150. Fig. 14B is a cross-sectional view of the insert. 150 in Fig. 14 taken along section line 14B-14B in ﬁ g. Fig. 14A is an enlarged view of the portion of the circle 14A in ﬁ g. 14B showing the internal coolant passage 300. As shown in ﬁ g. 14B, the cross-sectional views 15, 15A, 16, 16, 16A, 17 and 18 are taken in a direction substantially perpendicular to the general direction of the coolant. The cross-sectional area can be considered as the coolant flow area at the specific location along the internal coolant passage.
[94] In this preferred specific embodiment, it is clear that the geometry of the coolant flow cross-sectional area of the inner coolant passage 300 changes along the axial length of the inner coolant passage 300, i.e. the axial coolant passage length. Furthermore, it should be appreciated that the coolant flow cross-sectional area may vary to provide a specific desired fate configuration or spray pattern in the cutting-chip interface. In this specific embodiment, the spray pattern is of a continuous nature to exhibit a continuous cone of coolant in the vicinity of the discrete cutting point. In doing so, ﬂ g illustrates. In schematic form the coolant spray pattern (arrows marked "CF") when two adjacent internal coolant passages are activated, i.e. in communication with the coolant source, during a material removal operation.
[95] Table I below shows the coolant flow areas in the locations shown by cross sections 15-15 to 18-18 in ﬁ g. 14B for a specific embodiment of the insert. The specific values in this table apply only to a preferred specific embodiment and there is no intention to limit the scope of the invention as defined by the appended claims. Table I also shows the distance of each cross-section from the inner coolant passage inlet 304. The reference letters "W", "X", "Y" and "Z" correspond to the locations of the cross-sections as indicated in Table I. More specifically, the distances are "W", "X" , "Y" and "Z" in the places where the cross-sectional line passes through the radially inward-facing surface of the inner coolant passage 300.
[96] Based on data from Table 1, the coolant passage inlet area is substantially the same as the coolant passage outlet area, the coolant flow area changes along the axial coolant passage length, and the coolant passage inlet is smaller than the coolant port area. As for the latter phenomenon, in this preferred specific embodiment of the insert, the coolant port with which it is in communication has a coolant port area equal to 7.06 square millimeters.
[97] Figures 15A and 16A show that the inner coolant passage may be defined in cross section by an arcuate radially inwardly facing surface 600, a pair of forming sides 602, 604 extending in a substantially radially outward direction, and a pair of forming converging radially outwardly facing surfaces 606, 608, which connect to each other in a peak 610. It appears from a comparison between the coolant flow areas in ﬂ g. 15A and frg. 16A that the coolant flow area of the inner coolant passage 300 from the inner coolant passage inlet 304 to the point at which the cross section 16-16 is taken increases. The arcuate radial inwardly facing surface 600 widens to some extent, as does the length of the pair of converging radially outwardly facing surfaces 606, 608, which connect to each other in a top 610. The pair of forming sides 602, 604 extending in a generally radial outward direction remain slightly constant in this region of the inner coolant passage 300. The increase in the coolant flow area occurs due to the increase in the width of the arcuate radial inwardly facing surface 600 and the consequent increase in the dimensions of the pair of converging radial outwardly facing surfaces 606, 608 which connect to each other in a top 610.
[98] The coolant flow area increases to a lesser extent from the point of cross section 16-16 and cross section 17-17. A comparison of the coolant flow area at the points in the inner coolant passage 300 shown by cross-sections 16-16 and 17-17 shows a further widening of the inner coolant passage. The coolant flow area as shown in ﬁ g. 18 represents the coolant flow area of the inner coolant passage outlet 302. It can be seen that overall there is a lateral expansion and radial decrease of the inner coolant passage as it passes from the inlet to the outlet.
[99] Fig. 15A illustrates the geometry of the inner coolant passage inlet 304. Fig. 18 illustrates the geometry of the inner coolant passage inlet 302. A comparison of these geometries shows that the geometry of the inner coolant passage inlet 304 is different from the coolant passage 21 of the geometry 21. This is the case even though the coolant passage inlet area is substantially the same as the coolant passage outlet area.
[100] [0100] Av ﬁ g. 19 and ﬁ g. 19A it is seen that the insert during driving is held in the hole of a holder such as, for example, the cutter 40. In a holder similar to the cutter 40, the insert 150 is held in the hole by means of a screw which passes through the insert and into the threaded opening in the hole. To fasten the insert in the corner, the insert has an orientation in such a way that the anti-rotation stop 70 engages with the clearance surface of the insert. In this case, the circumferential abutment edge 72 has a geometry which corresponds to the geometry of the sinusoidal valley 206. This engagement creates an abutment which limits the rotational movement of the insert when it is in the angle.
[101] In order to perform cutting (ie material removal), the insert 150 is in a state in which there is a selection of said discrete cutting sites which engage with the workpiece. Arrow "DCLl" i ﬁ g. 19A generally shows the selected discrete cutting point. In this state, corresponding pairs of the distinct internal coolant passages 300A and 300B communicate with the arcuate opening through the coolant passage inlets 304A and 304B, which in turn communicate with the coolant source via a coolant port.
[102] [0102] I ﬁ g. 19A shows the relative location between the insert and the axle that the arcuate aperture is in communication with the adjacent pair of internal coolant passage inlets 304A and 304B. It will be appreciated that coolant from the coolant source flows simultaneously to both the inner coolant passage 300A and 300B whereby the inner coolant passages 300A and 300B can be considered activated. It will be appreciated that it may include an arcuate opening (or a similar phenomenon) which enables a trio of internal coolant passages to communicate simultaneously with the coolant source.
[103] [0103] I ﬁ g. 21, as can be seen, the coolant follows the surfaces defining the inner coolant passage 300. As the coolant follows the arcuate surface of the core, the coolant drives toward the inner coolant passage outlet 302 in a radially outward direction.
[104] Due to the nature of the geometry of the internal coolant passage, the dispersion of coolant leads to a continuous spray of coolant. Fig. 20 is a schematic view representing this continuous coolant spray. The continuous spray of coolant ensures that the cutting-chip interface at the discrete cutting point receives sufficient ﬂ depletion of coolant, and consequently sufficient coolant-induced cooling. As mentioned above, there are a number of advantages due to the supply of sufficient coolant to the cutting-chip interface.
[105] [0105] When the discrete cutting point has been worn to a point where replacement is required, the operator can index the cutting edge to the next cutting position. I ﬁ g. 19B shows the next cutting position. Arrow "DCL2" i ﬂ g. 19B generally shows the next selected discrete cutting point. In the new mode, the corresponding pair of distinct internal coolant passages (300B and 30OC) communicate with the coolant source via the coolant passage inlets 304B and 304C to supply coolant to the insert 150 at the selected discrete insert. Thus, coolant is supplied to the cutting-chip interface corresponding to the new discrete cutting point.
[106] Test results were performed in order to compare a specific embodiment of the inventive (with coolant flow) insert against a commercial insert (standard insert) manufactured and sold by Kennametal Inc., Latrobe, Pennsylvania 15650. Both inserts were made of the same degree of cemented (cobo1t) tungsten carbide, the same type of insert (except for the coolant flow-through property of the insert) and the same edge preparation, the ISO designation for the inserts including edge preparation being RCGX64SFG. The test results are given in Table II below as the number of working runs before the insert was worn to the following point where the error ions were either 0.015 inch maximum clearance surface wear or a maximum chip new chip of 0.030 inch; what appeared first.
[107] Other test parameters are listed below. Workpiece material: Ti6Al4V.
[108] As can be seen from the test results, the inventive insert shows significant improvements over the commercial insert. The number of work runs before a change was required increased from an average of 4.33 to an average of 11.33.
[109] It is clear that the present inserts and cutting assemblies enable the improved supply of coolant to the interface between the milling insert and the workpiece (ie the cutting-chip interface, which is the place on the workpiece where the chips are generated). In this way, the present insert and Cutting unit enable improved supply of coolant to the Cutting-Chip interface, which leads to improved Lubrication in the Cutting-Chip interface. The consequence of improved lubrication in the Cut-chip interface is a reduction in the chip's tendency to adhere to the insert, as well as better removal of chips from the interface environment with a consequent reduction in the possibility of a chip being cut again.
[110] With the present inserts and inserts, factors are obtained which influence the extent to which the coolant is delivered to the Insert-Chip interface. For example, the size of the structure which transfers the coolant to the insert may be a limiting factor for the extent of coolant supplied to the insert. The present inserts and insert units provide supply holes (coolant ports) that are equal to or Larger than the inlets in the insert in order to maximize the ﬂ fate of coolant to the insert.
[111] The present inserts and cutting assemblies provide advantages in terms of manufacture and performance. There are advantages to using several parts, which together form the insert. For example, in some cases a blade formed by a base having the cutting edge and a core may lead to improved service life because only the base needs to be replaced when the end of the useful tool life has been reached. In such an arrangement, the core is releasably connected to (or works with) the base, whereby the core is reused when the base becomes worn. The base and the core can be connected to each other by co-sintering, soldering and / or gluing. Furthermore, the base and the core can be compressed tightly against each other still while maintaining their separate and distinct nature. For improved performance, the base and core may also be of the same or different materials depending on the specific application.
[112] When the preferred specific embodiment of the insert has a round geometry in one or more places, certain advantages may exist. When, for example, the insert has a round geometry at the place where several components are assembled, the unit needs several components, e.g. a base and a core, not indexed.
[113] The insert is also arranged to engage with an anti-rotation function.
[114] The patents and other documents identified in this document are hereby incorporated by reference. Other embodiments of the invention will become apparent to those skilled in the art upon study of the description or application of the invention described herein. The description and examples are intended to be illustrative only and are not intended to limit the scope of the invention. The true scope and spirit of the invention are set forth in the following claims.

权利要求:
Claims (14)
[1]
A metal insert for use in chip forming and material removal from a workpiece, the metal insert comprising: a metal insert body comprising a cutting edge having at least one discrete cutting point; wherein the metal cutting body further contains a distinct internal coolant passage communicating with the discrete cutting site; the distinct inner coolant passage having a coolant passage inlet defining a coolant passage inlet cross-sectional area, a coolant passage outlet defining a coolant passage outlet cross-sectional area, and an axial coolant passage length; the distinct internal coolant passage defines a coolant flow cross-sectional area along the axial coolant passage length thereof; wherein the coolant passage inlet cross-sectional area is substantially the same as the coolant passage outlet cross-sectional area; and wherein the geometry of the coolant flow cross-sectional area changes along the axial coolant passage length.
[2]
A metal insert according to claim 1, wherein the metal insert body comprises a base member and a core member, and the base member has a base chip surface and a base release surface, and each of the discrete cutting sites comprises a discrete portion of a cutting edge formed in the intersection between the base chip surface and the base release surface.
[3]
A metal insert according to claim 1, wherein the cutting body comprises a base element and a core element, and the base element is made of one of the materials selected from the group consisting of tool steels, cemented carbides, cermets and ceramics by means of a powder metallurgical method, and the core element is made of one of the materials selected from the group consisting of tool steel, cemented carbides, cermet and ceramic material by means of a powder metallurgical method. _26-
[4]
A metal insert according to claim 3, wherein the core element is made of the same material as the core element.
[5]
A metal insert according to claim 3, wherein the core element is made of a material other than the core element.
[6]
A metal insert according to claim 1, wherein the cutting body comprises a base member and a core member, and the base member is releasably connected to the core member.
[7]
The metal insert of claim 1, wherein the geometry of the coolant passage inlet cross-sectional area is different from the geometry of the coolant passage outlet cross-sectional area.
[8]
A metal insert according to claim 1, wherein the insert is received in a hole of the holder, the cup having a coolant port therein, the coolant port having a coolant port cross-sectional area, and the coolant inlet cross-sectional area being smaller than the coolant port cross-sectional area in the pocket.
[9]
A metal cutting assembly for use in chipping and removing material from a workpiece, wherein a source of coolant supplies coolant to the cutting assembly, the metal cutting assembly comprising: a holder comprising a pocket, the surface comprising a flat surface containing a coolant port; cooling fluid port of coolant port wherein the pocket occupies an insert; the metal insert comprising: a cutting body comprising a cutting edge having at least one discrete cutting point; Wherein the cutting body further contains a distinct internal coolant passage communicating with the discrete cutting site; the distinct inner coolant passage having a coolant passage inlet defining a coolant passage inlet cross-sectional area, a coolant passage outlet defining a coolant passage outlet cross-sectional area, and an axial coolant passage length; wherein the distinct internal coolant passage defines a coolant flow cross-sectional area along the axial coolant passage length thereof; wherein the coolant passage inlet cross-sectional area is substantially the same as the coolant passage outlet cross-sectional area; and wherein the geometry of the coolant flow cross-sectional area changes along the axial coolant passage length.
[10]
The metal cutting assembly of claim 9, wherein the coolant passage inlet cross-sectional area is smaller than the coolant port cross-sectional area in the pocket.
[11]
The metal cutting assembly of claim 9, wherein the metal cutting body further includes a second distinct internal coolant passage communicating with the discrete cutting site.
[12]
The metal cutting assembly of claim 11, wherein the second distinct inner coolant passageway has a second coolant passage inlet defining a second coolant passage inlet cross-sectional area, a second coolant passage outlet defining a second coolant passage outlet coolant cross-section and axial cross-section wherein the second distinct internal coolant passage defines a second coolant flow cross-sectional area along the second axial coolant passage length thereof; wherein the second coolant passage inlet cross-sectional area is substantially the same as the second coolant passage outlet cross-sectional area; and wherein the geometry of the second _28- coolant flow cross-sectional area changes along the second axial coolant passage length.
[13]
The metal cutting assembly of claim 11, wherein the metal cutting body further includes a third distinct internal coolant passage that communicates with the discrete cutting site.
[14]
A metal cutting assembly according to claim 13, wherein the third distinct inner coolant passage has a third coolant passage inlet defining a third coolant passage inlet cross-sectional area, a third coolant passage outlet defining a third coolant passage outlet coolant cross-section and axial cross-section wherein the third distinct internal coolant passage defines a third coolant flow cross-sectional area along the third axial coolant passage length thereof; wherein the third coolant passage inlet cross-sectional area is substantially the same as the third coolant passage outlet cross-sectional area; and wherein the geometry of the third coolant flow cross-sectional area changes along the third axial coolant passage length.

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同族专利:

公开号 | 公开日

US20110027021A1|2011-02-03|

US8328471B2|2012-12-11|

JP2013528126A|2013-07-08|

CN103097057A|2013-05-08|

WO2011156050A3|2012-02-02|

CN103097057B|2016-01-20|

WO2011156050A2|2011-12-15|

DE112011101974B4|2022-03-17|

DE112011101974T5|2013-06-27|

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法律状态:
2016-02-23| NAV| Patent application has lapsed|

优先权:

申请号 | 申请日 | 专利标题

US12/797,249|US8328471B2|2007-01-18|2010-06-09|Cutting insert with internal coolant delivery and cutting assembly using the same|

PCT/US2011/032239|WO2011156050A2|2010-06-09|2011-04-13|Cutting insert with internal coolant delivery and cutting assembly using the same|

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