Method for Manufacturing a Rotatable Tool Body to Minimize Cutting Insert Runout, a Tool Body Produced Therefrom, and a Method of Using Such a Tool Body

Abstract

A method for manufacturing a rotatable tool body with pockets positioned circumferentially between flutes about a cylindrical body to accept removable cutting inserts and to distribute the circular runout in a fashion among all of the insert pockets to minimize impact on any particular insert and to increase tolerances. A rotatable tool body also includes these features and a method for utilizing such a rotatable tool body is disclosed.

Claims

1. A method for manufacturing a rotatable tool body with pockets positioned circumferentially between flutes about a cylindrical body to accept removable cutting inserts, wherein the method is comprised of the steps of: a) beginning with a cylindrical blank having a longitudinal axis, identifying a plurality of concentric circles along the cylindrical blank, wherein the concentric circles are spaced along the longitudinal axis and define rows and wherein a plurality of insert pocket locations are spaced circumferentially about the cylindrical blank in each row and each pocket location is defined by a radial line perpendicular to the longitudinal axis; and b) machining a plurality of pockets at the pocket locations of each row, wherein all of the pockets associated with one row are machined before proceeding to machine all of the pockets associated with another row and wherein machining a pocket comprises the steps of machining a radial side wall surface and a back wall surface upon which a cutting insert contacts when secured within the pocket.

2. The method according to claim 1, wherein the machining is performed in the following sequence at each row: a) first machining the blank at a primary pocket location to form a primary pocket; b) then machining the blank at a pair of secondary pocket locations adjacent to the primary pocket location and away from the primary pocket location to form a pair of secondary pockets; c) then machining the blank at a pair of tertiary pocket locations, wherein each tertiary pocket location is adjacent to one of the secondary pocket locations and away from the primary pocket location to form a pair of tertiary pockets; and d) then, to the extent they exist, continuing to machine the blank at a pair of next pocket locations, wherein each next pocket location is adjacent to one of the tertiary pocket locations and away from the primary pocket location to form another pair of pockets; and ¶ continuing this progression on the remaining pairs of pocket locations.

3. The method according to claim 2, wherein if there are an even number of pockets, then machining the remaining single pocket location after all of the pairs of pocket locations have been machined.

4. The method according to claim 2, wherein each pocket further includes an axial side wall surface and the step of machining the pocket locations include machining the axial side wall surface.

5. The method according to claim 2, wherein there is a sequence for machining pairs of adjacent pocket locations along a row comprising the steps of: a) machining a first pocket at a primary pocket location; b) then machining a secondary pocket at a secondary pocket location immediately adjacent to the primary pocket location in an intended angular direction of rotation of the tool body away from the primary pocket location; c) then machining another secondary pocket at a secondary pocket location immediately adjacent to the primary pocket location in an opposite angular direction from the primary pocket location; and d) continuing to machine adjacent pairs of pockets in an alternating fashion at locations in an angular direction away from the most recently machined pocket.

6. The method according to claim 5, wherein if there are an even number of pockets, then machining the remaining single pocket location after all of the pairs of pocket locations have been machined.

7. The method according to claim 1, wherein the pocket locations associated with each row are arranged at equal angles about the longitudinal axis.

8. The method according to claim 1, wherein the machining is performed by one of using a ball nose end mill, grinding, or electro-discharge machining.

9. The method according to claim 1, wherein the flutes are parallel to the longitudinal axis.

10. The method according to claim 1, wherein the flutes are helical along the longitudinal axis.

11. The method according to claim 1, wherein the circular runout is 5 microns or less for each pocket.

12. A rotatable tool body comprising: a) a cylindrical body with a longitudinal axis extending therethrough; b) pockets arranged between flutes in rows along concentric circles spaced apart along the longitudinal axis of the cylindrical body, wherein each pocket has a radial side wall surface and a back wall surface upon which a cutting insert contacts when secured within the pocket; c) wherein the pockets are spaced circumferentially in rows defined by each concentric circle; d) wherein the radial side wall of a primary pocket has a value X for circular runout; and e) wherein the radial side wall circular runout for each pocket is progressively greater than the value of X as pockets extend circumferentially away from the primary pocket.

13. The rotatable tool body according to claim 1, wherein in an alternating pattern extending circumferentially away from the primary pocket, the circular runout increases from a value of X at the primary pocket.

14. The rotatable tool body according to claim 2, wherein when viewed toward a distal end of the tool body, the pocket closest to the primary pocket in the counterclockwise direction has a circular runout Y greater than X but with the smallest deviation from the circular runout value of X of the primary pocket relative to the remaining pockets.

15. The rotatable tool body according to claim 2, wherein when viewed toward a distal end of the tool body, the pocket closest to the primary pocket in the clockwise direction has a circular runout Y greater than X but with the smallest deviation from the circular runout value of X of the primary pocket relative to the remaining pockets.

16. The rotatable tool body according to claim 3, wherein when viewed toward a distal end of the tool body, the pocket closest to the primary pocket in the clockwise direction has a circular runout Z greater than Y but with the next smallest deviation from the circular runout value of X of the primary pocket.

17. The rotatable tool body according to claim 3, wherein when viewed toward a distal end of the tool body, the pocket closest to the primary pocket in the counterclockwise direction has a circular runout Z greater than Y but with the next smallest deviation from the circular runout value of X of the primary pocket.

18. The rotatable tool body according to claim 1, wherein the circular runout of the radial side walls is measured from the tool body longitudinal axis and an envelope defined by the circular runout values generally defines a lobe shape about the longitudinal axis with the smallest circular runout at the primary pocket.

19. The rotatable tool body according to claim 3, wherein the lobe shape is an eccentric circle about the longitudinal axis.

20. The rotatable tool body according to claim 1, wherein the circular runout for each pocket is 5 microns or less.

21. A method of machining a workpiece with a tool body with inserts, wherein the tool body has: a) a cylindrical body with a longitudinal axis extending therethrough; b) pockets arranged between flutes in rows along concentric circles spaced apart along the longitudinal axis of the cylindrical body, wherein each pocket has a radial side wall surface and a back wall surface upon which a cutting insert contacts when secured within the pocket; c) wherein the pockets are spaced circumferentially in rows defined by each concentric circle; d) wherein the radial side wall of a primary pocket has a value X for circular runout; and e) wherein the radial side wall circular runout for each pocket is progressively greater than the value of X as pockets extend circumferentially away from the primary pocket, and wherein the method of machining is comprised of the step of: rotating the tool body in a direction from the primary pocket where the runout is the least to an adjacent second pocket where the runout is greater than but not as great as the runout of a third pocket adjacent to the primary pocket.

22. The method according to claim 1, wherein looking at the distal end of the tool body, the tool body is rotated in a counterclockwise direction.

23. The method according to claim 1, wherein looking at the distal end of the tool body, the tool body is rotated in a clockwise direction.

24. The method according to claim 1, wherein the circular runout for each pocket is 5 microns or less.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a perspective view of a tool body having insert pockets in accordance with one embodiment of the subject invention;

[0022] FIG. 2 is an enlargement of a portion of FIG. 1;

[0023] FIG. 3 is a perspective view of a rectangular insert with sides defining a trapezoid that may be suitable for mounting within pockets of a tool body assembled in accordance with the subject invention;

[0024] FIG. 4 is a schematic illustrating a machining operation in accordance with a prior art arrangement;

[0025] FIG. 5A is a side view of a tool body with a cutting insert in a pocket of a tool body used to illustrate the subject invention;

[0026] FIG. 5B is an end view of the side view of FIG. 5A;

[0027] FIG. 6 is an enlargement of a portion of FIG. 5B illustrating the influence of the radial side wall surface of the pocket on the circular runout;

[0028] FIG. 7 is an enlargement of FIG. 5B illustrating the influence the back wall surface of the pocket has on circular runout;

[0029] FIG. 8 is a cylindrical blank showing concentric circles defining rows upon which pockets are machined; and

[0030] FIG. 9 is an end view of a tool body illustrating an ideal cylindrical envelope of the cutting path of the cutting inserts superimposed over an actual envelope of the cutting path of the cutting inserts that may be achieved using the method of the subject invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0031] For purposes of the description hereinafter, the terms “upper”, “lower”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof, shall relate to the invention as is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

[0032] As a general overview, the process described herein is intended to make a better pocketed tool body, to minimize the step change from insert edge to edge (in the same row) to avoid large thickness variations of cut stock that then result in large variations of concentrated cutting force on the PCD cutting edge. With carbide inserts, tool manufacturers have not had to worry about this situation because of the toughness of a carbide edge and its ability to better absorb those cutting forces in the form of impacts and survive them. In light of the toughness of carbide inserts, there is less focus on the consequences of impact, which has a more significant effect on PCD inserts. As a result, the traditional use of carbide inserts does not focus on the different operational needs of PCD insert. The method of spreading out the pocket manufacturing tool's wear over pockets in the same row as opposed to each flute and all rows as described herein achieves better in-row runout control. Current machining methods involve first machining of the rows of one flute along the length of the tool, then machining the rows of the next flute.

[0033] Directing attention to FIGS. 5A and 5B, a typical primary pocket 20A is illustrated in a tool body 16 with a cutting insert 45A illustrated in phantom and mounted within the primary pocket 20A. It should be noted that while a single pocket is discussed, such a discussion may be applied to other pockets in the tool body 16. The primary pocket 20A is comprised of a back wall surface 30A and a radial side wall surface 35A. The primary pocket 20A may also include an axial side wall surface 40A. The back wall surface 30A is measured from the longitudinal axis 17 of the tool body 16 and this measurement is shown by the dimension L. The radial side wall surface 35A is also measured from the longitudinal axis 17 of the tool body 16 and this measurement is shown by the dimension R. Finally, the axial side wall surface 40A is measured from the distal end of the tool body 16 and this measurement is shown by the dimension A. The locations of the back wall surface 30A and the radial side wall surface 35A are critical to the determination of the circular runout, while the dimension of the axial side wall surface 40A is important for axial runout.

[0034] FIG. 6 illustrates the influence the radial side wall surface 35A of a pocket primary 20A has on the circular runout. In particular, using a cutting tool on a machine with preprogrammed dimensions for pocketing, the radial side wall surface 35A is machined. However, for machining a next pocket 20A′ with the same cutting tool, the cutting tool experiences wear such that when applied to the tool body 16, the same programmed dimensions for machining will produce a radial side wall surface 35A′ that is slightly shifted from the original radial side wall surface 35A. It should be appreciated that for illustrative purposes, two separate pockets 20A and 20A′ have been superimposed to highlight the difference in circular runout. As a result, a cutting insert 45A, when placed in the first primary pocket 20A, will extend the radial length R1 to the end of the cutting insert 45A, while for the next pocket 20A′, the cutting end of an identical cutting insert 45A′ will extend a distance R2 from the longitudinal axis 17 of the tool body 16 such that the circular runout created by the radial side wall surface 35A of these two pockets 20A and 20A′ is the difference between R2 and R1.

[0035] Directing attention to FIG. 7, the location of the back wall surface 30A also influences the circular runout. In particular, a machining operation may be used to form the back wall surface 30A in primary pocket 20A using a particular cutting tool. The level of the back wall surface 30A is indicated by L and the cutting edge of cutting insert 45A within such a primary pocket 20A is indicated by CE. However, that same cutting tool, if used to machine a next pocket 20A′, for example, would be worn and would not remove the same amount of material. As a result, the position of the back wall surface 30A′ of next pocket 20A′ is shifted from the position of the back wall surface 30A of primary pocket 20A. The level of the back wall surface 30A′ is indicated by L′ and the cutting edge of a cutting insert 45A′ within such a next pocket 20A′ is indicated by CE′. It should be appreciated that for illustrative purposes, two separate pockets 20A and 20A′ have been superimposed to highlight the difference in circular runout. As a result, the radial distance to the cutting edge CE of the insert 45A within the primary pocket 20A extends a radial distance R3, while the cutting edge CE′ of an identical cutting insert 45A′ placed within the next pocket 20A′ against the back wall surface 30A′ extends a radial distance R4 to the cutting edge CE′ of the cutting insert 45A′ such that the circular runout is the difference between R4 and R3. As previously mentioned, both the location of the radial side wall surface 35A and the location of the back wall surface 30A contribute to the walls of the pocket that determine the circular runout of a cutting insert placed within the pocket.

[0036] FIG. 8 illustrates a cylindrical blank 105 that may be machined to produce a tool body 16. The cylindrical blank 105 has a longitudinal axis 17 and a plurality of concentric circles 110, 115, 120, 125 spaced along the longitudinal axis 17 and define rows 130, 135, 140, 145, similar to rows 22, 23, 24, and 25 of FIG. 1.

[0037] At this point, a single row 130 will be discussed with the understanding that the same discussion applies to the remaining rows 135, 140, and 145.

[0038] Directing attention to row 130, a plurality of insert pocket locations 150A-150C are spaced circumferentially about the cylindrical blank 105 in each row. For example, in row 130, each pocket location 150A-150C is defined by a radial line 155A-155C along a plane perpendicular to the longitudinal axis 17.

[0039] FIG. 8 shows three radial lines representing three inserts. Other designs may include more pockets/inserts and, under the circumstances, each pocket/insert will have a radial line spaced about the centerline of a cylindrical blank.

[0040] In a method according to the subject invention, a plurality of pockets, such as pockets 20A, 20B, 20C illustrated in FIG. 1, are machined at the insert pocket locations 150A-150C associated with one row 130 before proceeding to machining any of the pockets associated with the remaining rows 135, 140, and 145. As previously mentioned, machining a pocket comprises at least the steps of machining a radial side wall surface 35A and a back wall surface 30A (FIGS. 1 and 2) upon which a cutting insert contacts once secured within the pocket. As previously discussed, it is also possible to machine an axial side wall surface 40A. The sequence of machining the pockets about each row along the cylindrical blank is important.

[0041] FIG. 9 illustrates an end view of a cylindrical tool body 106 machined from a cylindrical blank 105 (FIG. 8) for a milling cutter with nine insert pocket locations, 250A-250I, at which locations insert pockets 255A-255I may be machined. For illustrative purposes, cutting inserts 260A-260I are shown because it is from the edge of these cutting inserts 260A-260I that circular runout is measured.

[0042] In one embodiment, machining in accordance with the subject invention involves the following steps:

[0043] a) first machining the cylindrical blank 105 at a primary insert pocket location 250A to form a primary insert pocket 255A;

[0044] b) then machining the cylindrical blank 105 at a pair of secondary insert pocket locations 250B, 250I adjacent to the primary insert pocket location 250A and away from the primary insert pocket location 250A to form a pair of secondary insert pockets 255B, 255I;

[0045] c) then machining the cylindrical blank 105 at a pair of tertiary insert pocket locations 250C, 250H, wherein each tertiary insert pocket location 250C, 250H is adjacent to one of the secondary insert pocket locations 250B, 250I and away from the primary insert pocket location 250A to form a pair of tertiary insert pockets 255C, 255H; and

[0046] d) then, to the extent they exist, continuing to machine the cylindrical blank 105 at a pair of next insert pocket locations 250D, 250G wherein each next insert pocket location 250D, 250G is adjacent to one of the tertiary insert pocket locations 250C, 250H and away from the primary insert pocket location 250A to form another pair of insert pockets 255D, 255G.

[0047] To the extent that they exist, this progression is continued on the remaining pairs of pocket locations. As an example, in FIG. 9, there is a single remaining pair of insert pocket locations 250E, 250F. It should be appreciated that in FIG. 9, there is an odd number of pockets and, as a result, machining pairs of pockets relative to the primary insert pocket 250A will address all of the pocket locations. However, although not illustrated, when there are an even number of pockets, then machining the remaining single pocket location after all of the pairs of pocket locations have been machined is appropriate.

[0048] While FIG. 1 illustrates a milling cutter with rows of three pockets and FIG. 9 illustrates a row of nine pockets, it should be understood that the invention should not be limited by these embodiments. It is possible for cutters to have any combination of rows and pockets including one row of three inserts up to, but not limited to, 32 rows of 5 pockets. As more pockets are machined with the same tool, the benefits of the subject invention become more prominent.

[0049] As previously mentioned, each pocket may further include an axial side wall surface and when that is the case, the step of machining the pocket locations may also include machining the axial side wall surface.

[0050] As can be appreciated, by machining the cylindrical blank 105 in such a fashion, there will be varying amounts of runout in each of the insert pockets. However, by sequentially machining pockets as described herein, the circular runout is distributed about the circumference of the cylindrical blank 105 such that there is a relatively smooth progression of increasing runout to a point furthest away from the primary pocket location 250A. This not only allows the end product, which may be a milling cutter, to maintain closer tolerances, but, furthermore, distributes the cutting load more evenly among cutting inserts within the pockets and minimizes impact upon the cutting edges that may be produced by a cutting insert with a maximum cylindrical runout.

[0051] FIG. 9 further illustrates, by arrow 109, a preferred direction of rotation intended for a milling cutter produced from the cylindrical blank 105 (FIG. 8). This is significant because even though what has been discussed so far is machining pairs of insert pockets, further refinement of the invention may be achieved by selecting one of those insert pocket locations of a pair to be machined before the other of those insert pockets locations.

[0052] In particular, there is a sequence for machining pairs of adjacent pocket locations along a row comprising the steps of:

[0053] a) machining a first insert pocket 255A at a primary insert pocket location 250A;

[0054] b) then machining a secondary insert pocket 255I at a secondary insert pocket location 250I immediately adjacent to the primary insert pocket location 250A in an intended first angular direction of rotation 265 of the tool body away from the primary insert pocket location 250A;

[0055] c) then machining another secondary insert pocket 255B at a secondary insert pocket location 250B immediately adjacent to the primary insert pocket location 250A in an opposite second angular direction 270 from the primary insert pocket 250A; and

[0056] d) continuing to machine adjacent pairs of pockets in an alternating fashion at pocket locations at an angular direction away from the most recently-machined pocket.

[0057] In particular, for the arrangement illustrated in FIG. 9, the following sequence of pocket locations would be machined—250H, 250C, 250G, 250D, 250F, and 250E.

[0058] Once again, if there is an even number of pockets, then it will be necessary to machine the remaining single pocket location after all of the pairs of pocket locations have been machined.

[0059] As illustrated in the row of insert pockets in FIG. 9, each pocket location is arranged at an equal angle about the longitudinal axis 17. This is an optional feature and may hold true for the remaining rows along the cylindrical blank 105 of FIG. 8.

[0060] It should be noted that the methods and techniques for machining cylindrical blanks to produce inset pockets is well known and the important feature of the subject invention is the sequence for machining multiple pockets within a row.

[0061] In one preferred embodiment, the machining of pockets in accordance with the subject invention is performed using a ball nose end mill. However, it should be appreciated that any number of different metalworking tools or machining processes, including grinding and electro-discharge machining (EDM), may also be used. The same wear phenomena discussed herein with respect to cutting tools will also apply to other metalworking tools, including grinding tools or electrodes used in an EDM process.

[0062] Briefly, returning to the embodiment illustrated in FIG. 1, there are flutes extending in a helical direction along the longitudinal axis. It should be noted that the flutes may also be parallel to the longitudinal axis.

[0063] What has been described so far is a method for manufacturing a rotatable tool body with pockets positioned circumferentially between flutes about a cylindrical body wherein the pockets accept removable cutting inserts. It should be appreciated that this method may also be applied to the milling cutter illustrated in FIGS. 1 and 2. The subject invention may also be directed to the rotatable tool body itself.

[0064] In particular, again directing attention to FIG. 9, with occasional reference to FIG. 1, a rotatable tool body 16 may comprise a cylindrical tool body 106 made from a cylindrical blank 105 with a longitudinal axis 17 extending therethrough. Pockets 255A-255I are arranged between flutes and extend along concentric circles (FIG. 8) spaced apart along the longitudinal axis 17 of the cylindrical tool body 106. Each pocket, for example, insert pocket 255A, has a radial side wall surface 35A (FIG. 2) and a back wall surface 30A upon which a cutting insert contacts when secured within the pocket. Pockets are spaced circumferentially in rows defined by each concentric circle as illustrated in FIG. 8.

[0065] Directing attention to FIG. 9, the radial side wall of the primary insert pocket 255A has a value of X for circular runout. Thereafter, the radial side wall circular runout for each pocket is progressively greater than the value of X as pockets extend circumferentially away from the primary insert pocket 255A. As previously discussed, in an alternating pattern extending circumferentially away from the primary insert pocket 255A, the circular runout increases from a value of, for example, X at the primary insert pocket 255A. The applicant has further realized that with a known direction of rotation 109 of the milling cutter, the sequence of machining pockets within a pair may provide yet another benefit.

[0066] Therefore, with respect to the rotatable cylindrical tool body 106, when viewed toward a distal end 18 of the cylindrical tool body 106, the pocket 255I closest to the primary pocket 255A in the counterclockwise direction 265 has a circular runout Y greater than X but with the smallest deviation from the circular runout value of X of the primary pocket 255A relative to the remaining pockets. Furthermore, when viewed toward a distal end 18 of the cylindrical tool body 106, the pocket 255B closest to the primary pocket 255A in the clockwise direction 270 has a circular runout Z greater than Y but with the next smallest deviation from the circular runout value of X of the primary pocket 255A.

[0067] As further illustrated in FIG. 9, the circular runout of the radial side walls is measured from the tool body longitudinal axis 17 and envelope 275 defined by the circular runout values generally defined as a lobe shape about the longitudinal axis 17 with the smallest circular runout at the primary pocket 255A. The lobe shape may be a concentric circle about the longitudinal axis 17.

[0068] While the cylindrical tool body 106 illustrated in FIG. 9 is designed to rotate in a counterclockwise direction 109 and is used for a right-handed cutter, it should be appreciated that cutters exist where the inserts and pockets are facing in the opposite direction, i.e., flipped 180° about the longitudinal axis 17, such that the cutter would then be designed to rotate in the clockwise direction and is used for a left-handed cutter. The features discussed herein with respect to cylindrical tool body 106 for a right-handed cutter also apply to such a tool body for a left-handed cutter.

[0069] In particular, if the pockets/inserts are facing in the opposite direction, i.e. flipped 180° about the longitudinal axis 17 to that of the tool body 106 of the milling cutter 100 illustrated in FIG. 9, then the milling cutter will be intended to rotate in the clockwise direction (opposite to counterclockwise direction 109) and the pocket 255B closest to the primary pocket 255A in the clockwise direction 270 will have a circular runout Y greater than X but with the smallest deviation for the circular runout X of the primary pocket 255A relative to the remaining pockets. Furthermore, when viewed toward a distal end 18 of the cylindrical tool body 106 of the pocket 255I closest to the primary pocket 255A in the clockwise direction will have a circular runout Z greater than Y but the next smallest deviation from the circular runout value of X of the primary pocket 255A relative to the remaining pockets.

[0070] It should be appreciated that the features of this rotatable tool body may also be applied to the milling cutter in FIGS. 1 and 2.

[0071] The subject invention is further directed to a method of machining a workpiece with a tool body having inserts using a tool body 16 as described herein and wherein the method of machining is comprised of the step of rotating the tool body 16 in a direction from the primary pocket 255A where the runout is the least to an adjacent second pocket 255I where the runout is greater, but not as great as the runout of a third pocket 255B. With this arrangement, the tool body 16 is rotated in a counterclockwise direction 109 to maximize performance.

[0072] It should be appreciated that this method may also be applied to the milling cuter in FIGS. 1 and 2.

[0073] An additional benefit to the tool body in accordance with the subject invention is that when PCD cutting inserts are utilized within the pockets of the tool body, it is possible to limit the circular runout of each pocket to 5 microns or less, thereby allowing lower tolerances to produce a higher quality part.

[0074] Although the invention has been described in detail for the purposes of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, it is intended to cover modifications and equivalent arrangements. Furthermore, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.