TANGENTIAL CUTTING INSERT AND A MILLING TOOL

Abstract

A tangential cutting insert includes two opposing main surfaces having a triangular shape, three identical side surfaces extending between the main surfaces, and at least three identical and indexable major cutting edges formed at the intersection of at least one of the main surfaces and the three identical side surfaces. Each side surface includes three flat support surfaces recessed in relation to the major cutting edge and arranged one after another in a longitudinal direction of each side surface. A first flat support surface is disposed centrally in each side surface and forms the lowermost recessed support surface in relation to the major cutting edge. Second and third flat support surfaces are located on opposite sides of the first flat support surface and extend at an obtuse angle with the first flat support surface. A milling tool having a plurality of insert seats receiving the tangential cutting insert is provided.

Claims

1. A tangential cutting insert for a milling tool, the tangential cutting insert comprising: two opposing main surfaces having a triangular shape; and three identical side surfaces extending between the main surfaces; and at least three identical and indexable major cutting edges formed at the intersection of at least one of the main surfaces and the three identical side surfaces, wherein each side surface includes three flat support surfaces being recessed in relation to the major cutting edge and arranged one after another in a longitudinal direction of each side surface, wherein a first flat support surface is disposed at a centre of each side surface and and forms a lowermost recessed support surface in relation to the major cutting edge, and wherein second and third flat support surfaces are located on opposite sides of the first flat support surface and extends at an obtuse angle with the first flat support surface.

2. The tangential cutting insert according to claim 1, wherein the first flat support surface extends in parallel with the major cutting edge.

3. The tangential cutting insert according to claim 1, wherein the first flat support surface is larger, by having a longer extension, than each one of the second and third flat support surfaces in the longitudinal direction of each side surface.

4. The tangential cutting insert according to claim 3, wherein the first flat support surface is 30%-70% longer than each one of the second and third flat support surfaces in the longitudinal direction of each side surface.

5. The tangential cutting insert according to claim 1, wherein the second and third flat support surfaces are of equal size and length in the longitudinal direction of each side surface.

6. The tangential cutting insert according to claim 1, wherein the three flat support surfaces have substantially an equal width extension as seen in a direction transverse the longitudinal direction of each side surface.

7. The tangential cutting insert according to claim 1, wherein the obtuse angle is larger than 150°, and preferably larger than 160°.

8. The tangential cutting insert according to claim 1, wherein the three flat support surfaces are arranged successively and extend along the entire side surface as seen in the longitudinal direction.

9. The tangential cutting insert according to claim 1, wherein each major cutting edge has an adjacent rake surface in the side surface, wherein the rake surface extends at a positive rake angle between the entire major cutting edge and three flat support surfaces.

10. The tangential cutting insert according to claim 1, wherein the tangential cutting insert is a double-sided tangential cutting insert including six identical and indexable major cutting edges formed at the intersections of each of said two opposing main surfaces and the three identical side surfaces, wherein the three flat support surfaces of each side surface are recessed in relation to two opposite indexable major cutting edges.

11. A milling tool comprising a tool body rotatable around a central rotation axis and having a plurality of insert seats configured to receive a tangential cutting insert according to claim 1, wherein the tool body has a front end and a rear end, each insert seat being formed in an envelope surface extending between the front end and the rear end of the tool body, wherein a bottom of the insert seat includes a main contact surface arranged to provide support against the main surface of the tangential cutting insert, a first side wall of the insert seat including a first contact surface arranged to provide support against the first flat support surface on one side surface of the tangential cutting insert, and a second side wall of the insert seat including a second and third contact surface arranged to provide support against the second and third flat support surfaces respectively on another side surface of the tangential cutting insert.

12. The milling tool according to claim 11, wherein the first side wall of the insert seat is located closer to the rear end of the tool body in relation to the second side wall, which is located closer to the front end of the tool body, in each of said insert seats.

13. The milling tool according to claim 11, wherein the milling tool is a long edge milling cutter, the tool body including a cylindrical envelope surface, wherein the plurality of insert seats are placed one after the other in a common helix flute along the cylindrical envelope surface of the tool body.

14. The milling tool according to claim 13, wherein the major cutting edge of the tangential cutting insert, which is received in an insert seat placed relatively closer to the front end in the common helix flute, is arranged to overlap a portion of the next major cutting edge of an adjacent tangential cutting insert, which is received in an insert seat placed relatively closer to the rear end in the common helix flute.

15. The milling tool according to claim 11, wherein each insert seat is configured with an orientation on said contact surfaces in the first and second side walls so that the active major cutting edge extends at a positive axial rake angle in relation to the central rotation axis when the tangential cutting insert is received in the insert seat.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Embodiments are described with references to the drawings, in which:

[0022] FIG. 1a shows a side view of a milling tool in the form of a long edge milling cutter,

[0023] FIG. 1b shows a perspective view of the milling tool/long edge milling cutter,

[0024] FIGS. 2a-d show side views of a tangential cutting insert mounted in the milling tool/long edge milling cutter,

[0025] FIGS. 3a-d show a side view of the mounted tangential cutting insert including different cross-sections IIIb-IIIb to IIId-IIId showing the support of the tangential cutting insert,

[0026] FIGS. 4a-d show a perspective view of the tangential cutting insert including different side views and a main planar view of the tangential cutting insert.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0027] FIGS. 1a-1b show different views of a milling tool 11 according to an embodiment of the invention. The milling tool is a long edge milling cutter 11 comprising a tool body 12 being rotatable around a central rotation axis R. The tool body has a front end 12a and a rear end 12b, which is configured to be mounted to a spindle of a milling machine (not shown). The tool body 12 comprises a plurality of insert seats 13 being formed in a cylindrical envelope surface 12c of the tool body. The insert seats 13 are placed one after the other in a common helix flute 20 extending along the cylindrical envelope surface 12c of the tool body 12. This specific embodiment comprises five helix flutes 20 along the envelope surface 12c of the tool body 12. The insert seats 13 (except an axially foremost insert seat arranged at the front end 12a) are configured to receive a tangential cutting insert 1 according to an embodiment of the invention.

[0028] FIGS. 4a-4d show different views of the tangential cutting insert 1 of the embodiment. The tangential cutting insert 1 comprises two opposing main surfaces 2, 3 having a triangular shape and three identical side surfaces 4 extending between the main surfaces 2, 3. The tangential cutting insert 1 includes three identical and indexable major cutting edges 5 formed at the intersection of one main surface 2 and the three identical side surfaces 4.

[0029] Furthermore, as can be seen, the embodiment is a double-sided tangential cutting insert including an additional set of three identical and indexable major cutting edge 5′ formed at the intersection of the other main surface 3 and the three identical side surfaces 4. Hence, the double-sided tangential cutting insert includes six identical and indexable major cutting edges 5, 5′. Each side surface 4 includes three flat support surfaces 6, 7, 8 being recessed in relation to the major cutting edges 5, 5′. The three flat support surfaces 6, 7, 8 are arranged one after the other in a longitudinal direction 9 of each side surface 4, wherein a first flat support surface 6 is disposed a centre of each side surface 4 and is forming the lowermost recessed support surface in relation to the major cutting edge 5. The second and third flat support surfaces 7, 8 are located on opposite sides of the first flat support surface 6 and extend at an obtuse angle β with the first flat support surface 6 (see also FIG. 2d).

[0030] Accordingly, the double-sided and triangular shaped tangential cutting insert 1 is provided with the three flat support surfaces 6, 7, 8 in each side surface 4 for a stable fixation/support of the tangential cutting insert 1 and an efficient distribution of large and/or varying cutting forces. As can be seen, the three flat support surfaces 6, 7, 8 are also recessed in relation to the major cutting edge 5, 5′ to provide a positive rake angle γ and an enhanced/easy cutting action along the extension of the major cutting edge 5, 5′. The first flat support surface 6 is disposed at a centre of each side surface 4, 4′ and is forming the lowermost recessed support surface in relation to the major cutting edge 5, 5′, wherein the second and third flat support surfaces 7, 8 are located on opposite sides of the first flat support surface 6 and extend at an obtuse angle β with the first flat support surface 6.

[0031] The obtuse angle β between the first and second or third flat supports surfaces is larger than 150°, and preferably larger than 160°. More precisely, in the shown embodiment the obtuse angle β is 167.5°. The first flat support surface 6 extends in parallel with the major cutting edge 5, 5′. Furthermore, the first flat support surface 6 is relatively larger by having a longer extension that each one of the second and third flat support surface 7, 8 in the longitudinal direction 9 of each side surface 4. The cutting forces/loads are hereby beneficially distributed in the insert seat, since the first flat support surface 6 will support the tangential cutting insert in one direction and the second and third support surfaces 7, 8 collectively support the tangential cutting insert in other directions. In the embodiment, the first flat support surface 6 is approximately 40% longer than the second or third flat support surface 7, 8 as seen in the longitudinal direction 9 in the middle of each side surface 4. As can be seen in the figures the second and third support surfaces 7, 8 is slightly longer if measure in a longitudinal direction 9, which is located nearer either of the major cutting edges 5, 5′. The effective length of each support surface 6, 7, 8 for supporting the insert should in this case be considered when comparing the relative lengths between the support surfaces 6, 7, 8. Hence, in this embodiment, the relative lengths are measured along the middle of each side surface 4, 4′ of the insert.

[0032] The second and third flat support surfaces 7, 8 are of equal size and length in the longitudinal direction 9 of each side surface 4. This provides a symmetry in the support/load on the second and third flat support surfaces 7, 8. Furthermore, this symmetry also provides the same cutting performance as the double-sided tangential cutting insert 1 is reversed with the additional set of three identical and indexable cutting edges 5′ at the intersection of the other main surface 3 and the three identical side surfaces 4, 4′.

[0033] Moreover, the three flat support surfaces 6, 7, 8 are arranged successively and extend along the entire side surface 4, 4′ as seen in the longitudinal direction 9. Accordingly, the three flat support surfaces 6, 7, 8 extend along the whole longitudinal extension of each side surface 4, 4′ to enhance the beneficial distribution of the cutting forces and further reduce the load on each contact surface in the insert seat 13. As can be seen, the tangential cutting insert hereby merely includes small transition surfaces arranged between the three differently oriented flat support surfaces 6, 7, 8 in each side surface 4, 4′ as well as small radius transitions surfaces as the ends of each third/second flat support surface 7, 8 (corners of the insert). The shown three flat support surface 6, 7, 8 also have substantially an equal width W as seen in a direction transverse (perpendicular) to the longitudinal direction 9 of the side surface 4. Each major cutting edge 5, 5′ has an adjacent rake surface 10, 10′ in the side surface 4, wherein the rake surface 10 extends at a positive rake angle γ between the entire major cutting edge 5, 5′ and the tree flat support surfaces 6, 7, 8. The rake surface 10, 10′ has a uniform width and rake angle γ between the major cutting edge 5, 5′ and the first flat support surface 6, wherein the width on the rake surface 10, 10′ successively decreases between major cutting edge 5, 5′ and the second and third flat support surfaces 7, 8 in a direction toward the corners of the insert.

[0034] FIGS. 2a-2d show the tangential cutting insert 1 mounted in the insert seat 13 of the tool body 12. A bottom of the insert seat 13 comprises a main contact surface 14 arranged to provide support against the main surface 2, 3 of the tangential cutting insert 1. A first side wall 15 of the insert seat 13 comprises a first contact surface 16 arranged to provide support against the first flat support surface 6 on one side surface 4 of the tangential cutting insert 1. A second side wall 17 of the insert seat 13 comprises a second and third contact surface 18, 19 arranged to provide support against the second and third flat support surfaces 7, 8 respectively on another side surface 4′ of the tangential cutting insert 1. The first side wall 15 of each insert seat 13 is located closer to the rear end 12b of the tool body 12 in relation to the second side wall 17, which is located closer to the front end 12a of the tool body 12.

[0035] As previously mentioned, the tangential cutting insert 1 is hereby supported by three distinct, differently oriented and relatively large flat support surfaces 6, 7, 8 in each side surface 4, 4′, which are abutting three corresponding seat contact surfaces 16, 18, 19 to effectively constrain insert movement and safeguard the integrity (reduce load/plastic deformation) on the seat contact surfaces 16, 18, 19. This achieves a stable support and efficient distribution of the large/varying cutting forces, which are also effectively reduced by the enhanced/easy cutting action provided by the recessed flat support surfaces 6, 7, 8.

[0036] Furthermore, each insert seat 13 is configured with an orientation on said contact surfaces 16, 18, 19 in the first and second side walls 15, 17 so that the active major cutting edge 5 is extending at a positive axial rake angle α in relation to the central rotation axis R when the tangential cutting insert is mounted in the insert seat 13. This further contributes to a positive/easy cutting action and a beneficial chip evacuation as the major cutting edge gradually enters the workpiece at said positive axial rake angle α. The positive axial rake angle α further enhances the toughness behaviour of the major cutting edge 5, 5′ such that it may withstand relatively higher cutting forces without breaking or chipping.

[0037] A major cutting edge 5 on a tangential cutting insert 1, which is received in an insert seat 13 placed relatively closer to the front end 12a in the common helix flute 20, is arranged to overlap a portion of the next major cutting edge 5 of an adjacent tangential cutting insert 1, which is received in an insert seat 13 placed relatively closer to the rear end 12b in the common helix flute 20 (see also FIGS. 1a-1b). Hence, an end portion on the major cutting edge 5 on a leading tangential cutting insert 1 is arranged to overlap an initial portion on the adjacent major cutting edge 5 on a trailing (rear) tangential cutting insert 1 in the common helix flute 20. This provides an uninterrupted (axially continuous, but tangentially stepwise) single cutting edge configuration formed collectively by the major cutting edges 5 along the common helix flute 20 of the long edge milling cutter 11.

[0038] FIGS. 3a-3d show an enlarged view of the insert seat including different cross-sections of the tangential cutting insert 1 arranged in the insert seat 13 of the tool body 12. FIG. 3b is showing cross-section IIIb-IIIb in FIG. 3a. As can be seen, FIG. 3b shows the second flat support surface 7 of the tangential cutting insert 1 abutting a corresponding flat second contact surface 18 of the second side wall 17 in the insert seat 13. The cross-section is also showing the main surface 3 of the tangential cutting insert abutting the main contact surface 14 in the bottom of the insert seat 13. FIG. 3c is showing cross-section IIIc-IIIc in FIG. 3a. FIG. 3c shows the third flat support surface 8 of the tangential cutting insert abutting a corresponding flat third contact surface 19 of the second side wall 17 in the insert seat 13. FIG. 3d is showing cross-section IIId-IIId in FIG. 3a. FIG. 3d shows the first flat support surface 6 abutting a corresponding flat first contact surface 16 of the first side wall 15 in the insert seat 13.

[0039] The invention is not limited to the embodiment disclosed but may be varied and modified within the scope of the appended claims. For example, the tangential cutting insert may be formed as a single-sided insert with three indexable major cutting edges at the intersection of only one main surface and the three side surfaces.