Cutting inserts and cutting tool systems having sinusoidal and helical cutting edges

Patent metadata

Field	Value
Publication number	US-9700969-B2
Application number	US-201414186376-A
Country	US
Kind code	B2
Filing date	Feb 21, 2014
Priority date	Aug 10, 2011
Publication date	Jul 11, 2017
Grant date	Jul 11, 2017

Abstract

A cutting tool system is designed to have a combined sinusoidal-shaped and helical-shaped cutting edge formed by an assembly of aligned common cutting inserts each having a sinusoidal and helical cutting edge.

First claim

What is claimed is:

1. A cutting tool system comprising:
a tool holder comprising a plurality of common insert pockets positioned in a helical orientation about a longitudinal axis of the tool holder; and
a plurality of common cutting inserts removably attachable to the plurality of common insert pockets in the tool holder to form at least one cutting flute on the tool holder, the at least one cutting flute comprising a helical grouping of common cutting inserts positioned in the insert pockets;
wherein the common cutting inserts each comprise at least one sinusoidal and helical cutting edge;
wherein two or more of the cutting inserts combine to define a sinusoidal wavelength shape defined by one period per cutting insert; and
wherein the at least one cutting flute comprises a sinusoidal and helical cutting edge positioned about the longitudinal axis of the tool holder and formed by alignment of the individual sinusoidal and helical cutting edges of the common cutting inserts that comprise the at least one cutting flute.

2. The cutting tool system of claim 1 , wherein the common cutting inserts each comprise two or more sinusoidal and helical cutting edges that are indexable in the insert pockets.

3. The cutting tool system of claim 1 , wherein the common cutting inserts each comprise two sinusoidal and helical cutting edges that are indexable in the insert pockets.

4. The cutting tool system of claim 1 , wherein the common cutting inserts each comprise four sinusoidal and helical cutting edges that are indexable in the insert pockets.

5. The cutting tool system of claim 1 , further comprising an end-face cutting insert removably attachable to an insert pocket positioned at an engaging end of the tool holder, the end-face cutting insert having a shape that is different than a shape of the plurality of common cutting inserts.

6. The cutting tool system of claim 5 , wherein the end-face cutting insert comprises a helical cutting edge that helically aligns with the sinusoidal and helical cutting edges of the plurality of common cutting inserts forming the sinusoidal and helical cutting edge of the at least one cutting flute.

7. The cutting tool system of claim 5 , wherein the end-face cutting insert comprises a sinusoidal and helical cutting edge that helically aligns with the sinusoidal and helical cutting edges of the plurality of common cutting inserts forming the sinusoidal and helical cutting edge of the at least one cutting flute.

8. A cutting tool system comprising:
a tool holder comprising two or more series of common insert pockets, each series of common insert pockets positioned in a helical orientation about a longitudinal axis of the tool holder; and
a plurality of common cutting inserts removably attachable to the common insert pockets in the tool holder to form two or more cutting flutes on the tool holder, the two or more cutting flutes each comprising a helical grouping of the common cutting inserts positioned in the insert pockets;
wherein the common cutting inserts each comprise at least one sinusoidal and helical cutting edge;
wherein two or more of the cutting inserts combine to define a sinusoidal wavelength shape defined by one period per cutting insert; and
wherein the two or more cutting flutes each comprise a sinusoidal and helical cutting edge positioned about the longitudinal axis of the tool holder and formed by alignment of the individual sinusoidal and helical cutting edges of the common cutting inserts that comprise the two or more cutting flutes.

9. The cutting tool system of claim 8 , wherein the common cutting inserts each comprise two or more sinusoidal and helical cutting edges that are indexable in the insert pockets.

10. The cutting tool system of claim 8 , wherein the common cutting inserts each comprise two sinusoidal and helical cutting edges that are indexable in the insert pockets.

11. The cutting tool system of claim 8 , wherein the common cutting inserts each comprise four sinusoidal and helical cutting edges that are indexable in the insert pockets.

12. The cutting tool system of claim 8 , wherein adjacent helical groupings of the common cutting inserts are offset relative to each other along the longitudinal axis of the tool holder so that the inserts comprising adjacent helical flutes are not longitudinally aligned in a cross sectional plane perpendicular to the longitudinal axis.

13. The cutting tool system of claim 8 , further comprising two or more end-face cutting inserts, each end-face cutting insert being removably attachable to an insert pocket positioned at an engaging end of the tool holder helically aligned with one of the two or more series of common insert pockets, and each end-face cutting insert having a shape that is different than a shape of the plurality of common cutting inserts.

14. The cutting tool system of claim 13 , wherein the two or more end-face cutting inserts each comprise a helical cutting edge that helically aligns with the sinusoidal and helical cutting edges of the plurality of common cutting inserts forming the sinusoidal and helical cutting edges of the two or more cutting flutes.

15. The cutting tool system of claim 13 , wherein the two or more end-face cutting inserts each comprise a sinusoidal and helical cutting edge that helically aligns with the sinusoidal and helical cutting edges of the plurality of common cutting inserts forming the sinusoidal and helical cutting edges of the two or more cutting flutes.

16. The cutting tool system of claim 13 , wherein the two or more end-face cutting inserts have the same shape, are differently sized, and are positioned in respective insert pockets with a common longitudinal clearance, so that adjacent helical groupings of the common cutting inserts are offset relative to each other along the longitudinal axis of the tool holder so that the inserts comprising adjacent helical flutes are not longitudinally aligned in a cross sectional plane perpendicular to the longitudinal axis.

17. A cutting insert comprising two or more sinusoidal and helical cutting edges;
wherein at least one of the two or more sinusoidal and helical cutting edges defines one period of a sinusoidal wavelength shape.

18. The cutting insert of claim 17 , wherein the cutting insert comprises four sinusoidal and helical cutting edges.

19. A method for producing a cutting tool system comprising:
a tool holder comprising a plurality of common insert pockets positioned in a helical orientation about a longitudinal axis of the tool holder; and
a plurality of common cutting inserts removably attachable to the plurality of common insert pockets in the tool holder to form at least one cutting flute on the tool holder, the at least one cutting flute comprising a helical grouping of common cutting inserts positioned in the insert pockets;
wherein the common cutting inserts each comprise at least one sinusoidal and helical cutting edge;
the method comprising:
positioning a cutting insert having a sinusoidal-shaped cutting edge as if it were on the tool holder with a helix angle; and
modifying the sinusoidal shape of the cutting edge of the cutting insert to coincide with a cylindrical surface defined by a cutting radius centered at a cutting axis of the cutting tool system;
wherein two or more of the common cutting inserts combine to define a sinusoidal wavelength shape defined by one period per cutting insert.

20. The method of claim 19 , further comprising:
positioning a first common cutting insert having a sinusoidal-shaped c

Assignees

• Kennametal Inc
• Kennametal Inc

Inventors

• Fang X Daniel
• Palmer Frederick John
• Dufour Jean-Luc
• Wills David J

Classifications

• B23C5/202

  Plate-like cutting inserts with special form (special form related to securing of the insert B23C5/22) · CPC title

• B23C5/109 Primary

  with removable cutting inserts · CPC title

• Y10T407/1966

  Helical tooth · CPC title

• Y10T407/1924

  Specified tool shape · CPC title

• B23C2200/206

  Cutting edges having a wave-form · CPC title