ROTATABLE CUTTING TOOL WITH CUTTING INSERT AND BOLSTER

Abstract

A rotatable cutting tool (10) includes a cutting tool body (12) having an axial forward end (14) and an axial rearward end (16). A bolster (46) at least partially received in a head portion (22) and includes a convex-shaped head portion (56) with a socket (20), a collar portion (58) and a tapered shank portion (60). The socket (20) is formed with a substantially planar side wall (20a), a bottom wall (20b), and a radius blend (20c). A hard tip or cutting insert (18) is at least partially received in the socket (20) of the bolster (46) and includes a convex-shaped conical head portion (72), a collar portion (74) and an axially-rearward portion (76) that generally conforms to the geometry of the socket (20) of the bolster (46). Between about sixty percent (60%) and about ninety percent (90%) of the cutting insert (18) is received in the socket (20) of the bolster (46), thereby reducing forces and stresses transmitted to the cutting tool (10) during a machining operation.

Claims

1. A rotatable cutting tool (10), comprising: a cutting tool body (12), the cutting tool body (12) having an axial forward end (14) and an axial rearward end (16), a head portion (22) axially rearward of the axial forward end (14), a collar portion (24) axially rearward of the head portion (22), and a shank portion (26) axially rearward of the collar portion (24) and axially forward of the axial rearward end (16); a bolster (46) at least partially received in the head portion (22), the bolster (46) including a convex-shaped head portion (56) formed with a radius, R1, a collar portion (58) and a tapered shank portion (60), the convex-shaped head portion (56) including a socket (20) formed with a side wall (20a), a bottom wall (20b), and a radius blend (20c) formed with a radius, R2, extending between the side wall (20a) and the bottom wall (20b); and a cutting insert (18) at least partially received in the socket (20) of the bolster (46), the cutting insert (18) including a convex-shaped conical head portion (72), a collar portion (74) and an axially-rearward portion (76), the axially-rearward portion (76) including a forward cylindrical section (84) proximate the collar portion (74), a radius blend (86) formed with a radius, R5, and a rearward section (88), wherein between about sixty percent (60%) and about ninety percent (90%) of the cutting insert (18) is received in the socket (20) of the bolster (46), thereby reducing forces and stresses transmitted to the cutting tool (10) during a machining operation.

2. The rotatable cutting tool (10) according to claim 1, wherein the cutting insert (18) comprises a super hard material (78) bonded to a cemented metal carbide substrate (80).

3. The rotatable cutting tool (10) according to claim 2, wherein the super hard material (78) comprises diamond, polycrystalline diamond (PCD), natural diamond, synthetic diamond, vapor deposited diamond, silicon bonded diamond, cobalt bonded diamond, thermally stable diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, infiltrated diamond, layered diamond, monolithic diamond, polished diamond, course diamond, fine diamond, cubic boron nitride, diamond impregnated matrix, diamond impregnated carbide, non-metal catalyzed diamond, or combinations thereof.

4. The rotatable cutting tool (10) according to claim 2, wherein the super hard material (78) is bonded only to the convex-shaped conical head portion (72) and the collar portion (74) of the cutting insert (18).

5. The rotatable cutting tool (10) according to claim 1, wherein the collar portion (74) and the axially rearward portion (76) of the cutting insert (18) is received within the socket (20) of the bolster (46).

6. The rotatable cutting tool (10) according to claim 1, wherein the head portion (72) of the cutting insert (18) has a substantially pointed geometry with an apex (82) having a radius, R3.

7. The rotatable cutting tool (10) according to claim 1, wherein the the head portion (72) of the cutting insert (18) is formed with a radius, R4.

8. The rotatable cutting tool (10) according to claim 1, wherein the head portion (72) has a length, L1, the collar portion (72) has a length, L2, and the axially-rearward portion (76) has a length, L3.

9. The rotatable cutting tool (10) according to claim 8, wherein the length, L3, of the axially-rearward portion (76) is between about sixty percent (60%) and about ninety percent (90%) of the length, L1, of the head portion (72).

10. The rotatable cutting tool (10) according to claim 1, wherein the the convex-shaped head portion (56) of the bolster (46) is formed with a radius, R1.

11. The rotatable cutting tool (10) according to claim 1, wherein the bolster (46) further includes a plurality of dimples (64) formed in the tapered shank portion (60) for engaging a pocket (48) formed in a base portion (44) of the head portion (22).

12. The rotatable cutting tool (10) according to claim 11, wherein the plurality of dimples (64) lie in two circumferential rows about the tapered shank portion (60) of the bolster (46).

13. The rotatable cutting tool (10) according to claim 1, wherein the cutting insert (18) is affixed to the side wall (20a) of the socket (20) with a tolerance of about 0.005 in (0.13 mm) and affixed to the bottom wall (20b) of the socket (20) with a tolerance of about 0.003 in (0.08 mm).

14. The rotatable cutting tool (10) according to claim 1, wherein the radius, R2, is approximately equal to the radius, R5.

15. The rotatable cutting tool (10) according to claim 1, wherein the bottom wall (20b) of the socket (20) and the rearward section (88) of the cutting insert (18) are substantially planar.

16. A cutting insert (18) for being at least partially received in a socket (20) of a bolster (46) of a rotatable cutting tool (10), the cutting insert (18) comprising a convex-shaped conical head portion (72) having a length, L1, a collar portion (74) having a length, L2, and an axially-rearward portion (76) having a length, L3, the axially-rearward portion (76) including a forward cylindrical section (84) proximate the collar portion (74), a radius blend (86) formed with a radius, R5, and a rearward section (88), wherein the length, L2 of the collar portion (74) and the length, L3, of the axially-rearward portion (76) is between about sixty percent (60%) and about ninety percent (90%) of the length, L1, of the head portion (72).

17. The cutting insert (18) according to claim 16, wherein the cutting insert (18) comprises a super hard material (78) bonded to a cemented metal carbide substrate (80).

18. The cutting insert (18) according to claim 17, wherein the super hard material (78) comprises diamond, polycrystalline diamond (PCD), natural diamond, synthetic diamond, vapor deposited diamond, silicon bonded diamond, cobalt bonded diamond, thermally stable diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, infiltrated diamond, layered diamond, monolithic diamond, polished diamond, course diamond, fine diamond, cubic boron nitride, diamond impregnated matrix, diamond impregnated carbide, non-metal catalyzed diamond, or combinations thereof.

19. The rotatable cutting tool (10) according to claim 17, wherein the super hard material (78) is bonded only to the convex-shaped conical head portion (72) and the collar portion (74) of the cutting insert (18).

20. The cutting insert (18) according to claim 16, wherein the head portion (72) has a substantially pointed geometry with an apex (82) having a radius, R3.

21. The cutting insert (18) according to claim 16, wherein the head portion (72) is formed with a radius, R4.

22. The cutting insert (10) according to claim 16, wherein the rearward section (88) is substantially planar.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] While various embodiments of the invention are illustrated, the particular embodiments shown should not be construed to limit the claims. It is anticipated that various changes and modifications may be made without departing from the scope of this invention.

[0009] FIG. 1 is a side view of a rotary cutting tool with a cutting insert and a bolster according to an embodiment of the invention;

[0010] FIG. 2 is a cross-sectional view of the cutting insert, bolster and head portion of the rotary cutting tool taken along line 2-2 of FIG. 1;

[0011] FIG. 3 is a side view of the bolster according to an embodiment of the invention;

[0012] FIG. 4 is a bottom view of the bolster of FIG. 3;

[0013] FIG. 5 is a cross-sectional view of the bolster taken along line 5-5 of FIG. 3;

[0014] FIG. 6 is an enlarged cross-sectional view of a dimple of the tapered shank portion of the bolster;

[0015] FIG. 7 is an enlarged view of the dimple of the tapered shank portion of the bolster;

[0016] FIG. 8 is a side view of the cutting insert according to an embodiment of the invention;

[0017] FIG. 9 is a top view of the cutting insert of FIG. 8;

[0018] FIG. 10 is a cross-sectional view of the cutting insert taken along line 10-10 of FIG. 8; and

[0019] FIG. 11 is a side view of the cutting insert with dimples according to an alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Referring to the drawings wherein like reference characters designate like elements, a rotatable cutting tool 10 is generally shown in FIGS. 1 and 2 according to an aspect of the invention. The rotatable cutting tool 10 comprises an elongate cutting tool body, generally designated as 12. The cutting tool body 12 is typically made of steel, such as Mn—B steel alloy, and the like. The cutting tool body 12 has an axial forward end 14 and an axial rearward end 16. A hard tip or cutting insert 18 is affixed (such as by brazing or the like) into a socket 20 in the axial forward end 14 of the cutting tool body 12.

[0021] The cutting tool body 12 is divided into three principal portions; namely, a head portion 22, a collar portion 24 and a shank portion 26. The most axial forward portion is the head portion 22 that begins at the axial forward end 14 and extends along longitudinal axis X-X in the axial rearward direction. The mediate portion is the collar portion 24 that begins at the juncture with the head portion 22 and extends along the longitudinal axis X-X in the axial rearward direction. The collar portion 24 comprises a tapered neck section 28 followed by a cylindrical collar section 30.

[0022] The most axial rearward portion is the shank portion 26 that begins at the juncture with the collar portion 24 and extends along the longitudinal axis X-X in the axial rearward direction. The shank portion 26 comprises a forward cylindrical tail section 32, followed by a mid-section 34, followed by a retainer groove 36, followed by a rearward cylindrical tail section 38 and terminating in a beveled section 40. As is known by those skilled in the art, the shank portion 26 is the portion of the cutting tool body 22 that carries a retainer 42. The retainer 42 rotatably retains the rotatable cutting tool 10 in the bore of a tool holder (not shown) or the bore of the sleeve carried by a holder.

[0023] Still referring to FIGS. 1 and 2, the head portion 22 includes a base portion 44 that is affixed to the collar portion 24. As illustrated in FIGS. 1 and 2, the base portion 44 of the head portion 22 is formed with a pocket, shown generally at 48. In one aspect, the pocket 48 extends axially along axis X-X from an axial forward end 50 of the base portion 44 rearwardly toward the collar portion 24.

[0024] A bolster 46 is at least partially received in the pocket 48 of the base portion 44. The bolster 46 is made of a suitable material, such as cemented metal carbide material comprising about 1 to 40 percent concentration of cobalt by weight, preferably 5 to 10 percent. In one aspect of the invention, the cutting insert 18 is affixed to the bolster 46.

[0025] Referring now to FIGS. 3-7, the bolster 46 is shown according to an embodiment of the invention. The bolster 46 has an axial forward end 52 and an axial rearward end 54. The bolster 46 is divided into three principal portions; namely, a convex-shaped head portion 56, a collar portion 58 and a tapered shank portion 60 that terminates in a beveled section 62. The most axial forward portion is the convex-shaped head portion 56 that begins at the axial forward end 52 and extends along longitudinal axis Y-Y in the axial rearward direction. In one embodiment, the convex head portion 56 is formed with a radius, R1, of about 0.54 in (13.8 mm). The mediate portion is the collar portion 58 that begins at the juncture with the head portion 56 and extends along the longitudinal axis Y-Y in the axial rearward direction to the tapered shank portion 60. In one embodiment, a portion the tapered shank portion 60 proximate the collar portion 58 is formed with an angle, A1, of about thirty-five (35) degrees with respect to the longitudinal axis Y-Y.

[0026] As shown in FIG. 5, the convex-shaped head portion 56 of the bolster 46 includes the socket 20 for receiving the cutting insert 18. The socket 20 is formed with a substantially planar side wall 20a, a substantially planar bottom wall 20b, and a radius blend 20c extending between the side wall 20a and the bottom wall 20b. In one embodiment, the radius blend 20c is formed with a radius, R2, of about 0.157 in (4.00 mm).

[0027] Referring now to FIGS. 3 and 4, the bolster 46 is movably connected to the base portion 44 when initially installed within the pocket 48 of the head portion 22. This movable connection is provided by a plurality of dimples 64 formed in the tapered shank portion 60 that engage the pocket 48 of the base portion 44 of the head portion 22. As shown in FIG. 4, the dimples 64 lie in two circumferential rows about the tapered shank portion 60, each row having six (6) equidistantly-spaced dimples 64 at an angle, A2, of about sixty (60) degrees such that the dimples 64 in one row is circumferentially spaced from the dimples 64 in the other row by an angle, A3, of about thirty (30) degrees.

[0028] As shown in FIGS. 6 and 7, each dimple 64 is substantially identical and have a semi-spherical shape with a height, H, of about 0.015 in (0.37 mm) and a width, W, of about 0.093 in (2.36 mm). After positioned at the desired position within the pocket 48, the bolster 46 is then fixedly attached to the pocket 48 by brazing, and the like. In one embodiment, the bolster 46 is affixed to the pocket 48 by brazing at a location 66 formed between each dimple 64 and the collar portion 58, as shown in FIG. 6. It will be appreciated that other means for fixedly attaching the bolster 46 to the base portion 44 may be provided in accordance with the scope of the invention.

[0029] Referring now to FIGS. 8-10, the hard tip or cutting insert 18 is shown according to an embodiment of the invention. The hard tip or cutting insert 18 has an axial forward end 68 and an axial rearward end 70. The cutting insert 18 is divided into three principal portions; namely, a convex-shaped conical head portion 72, a collar portion 74 and an axially-rearward portion 76 that terminates in a beveled section 62. The most axial forward portion is the convex-shaped head portion 72 that begins at the axial forward end 68 and extends along longitudinal axis Z-Z in the axial rearward direction. The mediate portion is the collar portion 74 that begins at the juncture with the head portion 72 and extends along the longitudinal axis Z-Z in the axial rearward direction to the axially-rearward portion 76.

[0030] As shown in FIG. 8, the axially-rearward portion 76 includes three sections: a forward cylindrical section 84 proximate the collar portion 74, a radius blend 86 formed with a radius, R5, and a substantially planar rearward section 88. In one embodiment, the radius, R5, is between about 0.14 in (3.556 mm) to about 0.18 in (4.572 mm). For example, the radius, R5, can be about 0.157 in (4.00 mm). It is noted that the radius, R5, of the radius blend 86 of the cutting insert 18 is approximately equal to the radius, R2, of the radius blend 20c of the socket 20. The substantially planar rearward section 88 has a width, W1, of about between about 0.21 in (5.334 mm) to about 0.41 in (10.414 mm). For example, the substantially planar rearward section 88 can have a width, W1, of about 0.31 in (7.88 mm). In cases where the substantially planar rearward section 88 is circular, then the width, W1, is substantially equal to the diameter of the rearward section 88. It is noted that the geometry of the planar rearward section 88 substantially conforms to the geometry of the bottom wall 20b of the socket 20.

[0031] In the illustrated embodiment, the rearward section 88 is substantially planar. However, it will be appreciated that the invention is not limited by the rearward section 88 being planar, and that the invention can be practiced with any desirable geometry, such as tapered, non-planar, and the like, so long as the geometry of the rearward section 88 generally conforms to the geometry of the bottom wall 20b of the socket 20 of the bolster 46.

[0032] The cutting insert 18 comprises a super hard material 78 bonded to a cemented metal carbide substrate 80. The super hard material may be bonded to the substrate through a high temperature, high pressure process. The super hard material 78 may comprise diamond, polycrystalline diamond (PCD), natural diamond, synthetic diamond, vapor deposited diamond, silicon bonded diamond, cobalt bonded diamond, thermally stable diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, infiltrated diamond, layered diamond, monolithic diamond, polished diamond, course diamond, fine diamond, cubic boron nitride, diamond impregnated matrix, diamond impregnated carbide, non-metal catalyzed diamond, or combinations thereof. The super hard material 78 may have a thickness of at least 0.100 in (2.54 mm). As shown in FIG. 10, the super hard material 78 is bonded only to the head portion 72 and the collar portion 74 of the cutting insert 18.

[0033] In the illustrated embodiment, the head portion 72 of the cutting insert 18 has a substantially pointed geometry with an apex 82 having a radius, R3, of between about 0.050 in (1.27 mm) to about 0.125 in (3.175 mm). For example, the apex 82 may have a radius, R3, of about 0.090 in (2.40 mm). The head portion 72 is also formed with a radius, R4, of between about 0.25 in (6.35 mm) to about 0.75 in (19.05 mm). For example, the head portion 72 may be formed with a radius, R4, of about 0.50 in (12.7 mm).

[0034] As shown in FIG. 8, the head portion 72 can have a length, L1, of between about 0.30 in (76.2 mm) to about 0.35 in (88.9 mm). For example, the head portion 72 can have a length, L1, of about 0.325 in (8.27 mm). The collar portion 74 has a length, L2, of between about 0.03 in (0.762 mm) to about 0.045 in (1.143 mm). For example, the collar portion 74 can have a length of about 0.038 in (0.95 mm). The axially-rearward portion 76 can have a length, L3, of between about 0.22 in (5.588 mm) to about 0.26 in (6.604 mm). That is, the length, L3, of the axially-rearward portion 76 can be between about sixty percent (60%) and about ninety percent (90%) of the length, L1, of the head portion 72. In one embodiment, the length, L3, is about seventy-five percent (75%) of the length, L1, of the head portion 72. For example, the axially-rearward portion 76 can have a length, L3, of about 0.24 in (6.10 mm). Thus, the cutting insert 18 can have a total overall length, L4, of between about 0.55 in (13.97 mm) and about 0.655 in (16.637 mm). For example, the total overall length, L4 of the cutting insert 18 is about 0.603 in (15.32 mm).

[0035] Referring now to FIG. 11, a cutting insert 18 is shown according to an alternative embodiment of the invention. In this embodiment, the cutting insert 18 is substantially identical to the cutting insert 18 shown in FIGS. 8-10, except the cutting insert 18 shown in FIG. 11 includes dimples 64 on the axially-rearward portion 76. The dimples 64 on the cutting insert 18 can be substantially identical to the dimples 64 on the bolster 46 and perform the same function when affixing the cutting insert 18 to the bolster 46 by brazing at a location 66 formed between each dimple 64 and the collar portion 74.

[0036] As mentioned above, the cutting insert 18 is affixed to the socket 20 of the bolster 46 by brazing, and the like. Because the geometry of the cutting insert 18 generally conforms to the geometry of the socket 20 of the bolster 46, the cutting insert 18 is affixed to the side wall 20a of the socket 20 with a tolerance of about 0.005 in (0.13 mm) and affixed to the bottom wall 20b of the socket 20 with a tolerance of about 0.003 in (0.08 mm). However, it will be appreciated that the geometry of the cutting insert 18 can vary depending upon the specific application, so long as the collar portion 74 and the axially-rearward portion 76 conforms to the geometry of the socket 20 of the bolster 46. For example, the bottom wall 20b of the socket 20 and the rearward section 88 of the cutting insert 18 can be non-planar, tapered, and the like.

[0037] As shown in FIG. 2, the collar portion 74 and the axially rearward portion 76 of the cutting insert 18 is disposed within the socket 20 of the bolster 46. In other words, only the head portion 72 of the cutting insert 18 extends from the axial forward end 52 of the bolster 46. Thus, between about sixty percent (60%) and about ninety percent (90%) of the cutting insert 18 is received in the socket 20 of the bolster 46. As a result, the geometry of the cutting insert 18 and the conforming geometry of the socket 20 of the bolster 46 is such that a relatively large percentage of the cutting insert 18 is received in the socket 20 of the bolster, thereby reducing the transmission of forces and stresses to the cutting tool 10 during a machining operation more effectively and reducing tool failure, as compared to conventional cutting tips with shanks that extend a greater distance from the axial forward end of the cutting tool.

[0038] The patents and publications referred to herein are hereby incorporated by reference.

[0039] Having described presently preferred embodiments the invention may be otherwise embodied within the scope of the appended claims.