AU619216B2 - Cutting insert with chip control - Google Patents

Description

TW4 1 (51) (43) WOUP NTLAL PERKTi ORG ZATIO PCT I IE ntL Bul1 INTERNTIONA APLCTO~J L U T~ EPTNT COOPERATION TREATY

(PCT)

(59) International- Patent Classification 4. (11) International Publication Number: WO 89/ 01836 B23B 271Z2 Al (43) International. Publication Date: 9 March 19$9 (09.03,89) (21) International Applicsk~lon Number; PCT/US88/0253 1 (81) Designated States- AT (European patent), AU, 13E (Eu-, ropean patent), CH (European patent), DE (Euro- (22) International Filing Date; 26 July 1988 (26,07,88) pean Ipatent), FR (European patent), GB (European patent), IT (European patent), JP, KR, LI) (European patent), NL (lFurope4n patent), SE (European pa- (31) Priority Application Number: 093,34$ tent), (32) Priority Date: 4 Septemrber IM87 (04,09,87) Published (33) Priority Country;- us With intern adolyI garch report, Before the expiration of the time limnit for amnending the claims and to be republished In the event of the receipt (71YAppllcant; KENNAMyeTAL INC, LUS/USI;, P.0, Boxt of antendinen is, 2 1 Latrobe, PA 15050 (US), (72) Inyentors; NIE13AUER, Kenneth, L. 327 Colllng.

wood Drive, Raleigh, NC 27609 LOCKART), Thomas, A, 501 Qq4ir Hilt Laine, Raleigh, NC 27609 (74) Ageolls TREMPUS, 'Thomas, K. et alk Kortarnwtal 1U 11, I AY 1989 le,, PQO 13ox 2311 Latrobe,, PA I' 6 Q (US)

AUSTRALIAN

31 MAR 1989 FPAUhNT OFFICk (54)Tltlv* CUTTING IN$ERT WITH Cl-UP CONRL (57)Aberact Ali kmproVed cutting Iti1'ri (10) wvith chip c~rtm'l reituees atidt a fethod for ni toa~tutdn thle tine An iruert body (11 having wall rt1gow (14,f 16), sides (18, 20)anid top urid bottom~ Nwal1 j22, 24) k~ adated for mounting ill a paoct (746 in itholder Tile iniert body (12)1 hue ctitting edges u ntd diagonal ilotch I h o ~tdbto ie ('421 24), A land regiont (34, 36) extimn-is Wrcitl~y fran the' etd wall (14, 16) region toward the r0e ,ective top or bottoni wval 1 (12 24) and dtlelT a mirface regiont or tetemed wvidth. A descen~ding will (40) nitlatei i it portiotn of the land (14, 36) and tcrininate itt a planat lr lotregiont (44 hav1ig a rprwrtrd a reoaa 0$4) and opposed side cdges A Wck ramp (60) etends upwardly rrot the planar tiloor rearward edge (14) anld erintillwie at the reipcctive top or botton Wlli (22, 24),

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S wo 89/01 836 PCT/US88/02531 -1- CUTTING INSERT WITH CHIP CONTROL FIELD OF THE INVENTION The invention is directed to cutting inserts, especially metal cutting inserts with chip control.

The invention also provides a method for the manufacture of such cutting inserts.

BACKGROUND OF THE INVENTION cutting inserts are well I known and a large percentage of the% are of the throw away design. Such inserts are detachably clamped on a holder and then are discarded whet th* beome ~X5a: ht~d discarded when they become dull or chipped, Throw away inserts are usually indexable and often are reversible so that an insert can be provided with at least two cutting edges for selective presentation to the cutting 1L position.

The provision of two or more cutting edges on the insert makes it economical to use and is particularly important with respect to throw away inserts because of the high cost of the materials from which the inserts are ptoduced, especially when the material is, for example, a cemented metal carbide.

The inserts must be securely and accuratkely held in place within an insert holder during the cutting operation, This is especially true when the inzerts are amployed with numerically controlled zachines which depend for accuracy upon an accurately lociatd and firmly vupported inmart, When the inserts are of a oubstantial area, it is possible to fix the Ti ii 11 n, i, II- WO89/01836 PCT/US88/02531 -2insert both accurately and firmly within the pocket of a toolholder by providing the insert with a central hole and the toolholder with a pin-type clamping device. In other cases, such inserts may be held in place by a top clamp. Examples of such holders are found in U. S. Patents No. 3,754,309; 3,399,442 and 3,762,005 and British Patent Specification 1,363,542.

The main object of metal machining is the shaping of the new work surface. Much attention is paid to the formation of the chip during the machining process, even though the chip is a waste product. This is because the consumption of energy occurs mainly in the formation and movement of the chip. Thus an essential feature of any metalcutting operation is effective chip control. A principal class of chips is the discontinuous chip which has the practical advantage of being easily cleared fcom the cutting area. While some metals and alloys generate discontinuous chips during cutting operations, many do not, It is therefore very desirable to produce discontinuous chips during a cutting operation, regardless o the meta o h or alloy of the workpiece It has been a common practice to place a mechanical chip breaking member between the insert and the clamp securing the insert to the tool in order to provide at least a degree of chip control during the cutting operation. This arrangement presents the obvious drawback of increasing the atfective area necessary for metal cutting operations with a given tool.

Bfcause chip control is an important consideration in metal cutting operations, it has been a long standing objective in the art of metal cutting to develop improvQd chip breaking members for use with tools as well as improved designs for the cutting inserts, One example of a cutting insert with chip breaking capailitis is the aut-grip insm erts IG'p 1 *i T WO 89/01836 WO 8901836PCT/US88/0253 I -3available from ISCAR. The ISCAR insert has a land with a paIr of generally parallel, elongated and elevated members which deform the metal chips as they are removed1 from the workpiece. Another example of a cutting insert with features designed to provide chip control is the Econ-o-groVe insert manufactured by Valenite, Corporation. This insert has par~allel side walls extending along a continuous descending wall, floor and back~ wall of constant radius. Another example of a cutting inisert with a chipbreajer style is commercially available from Sandvilt. and is characterized by a non-continuous front face which may not provide a flat finish to the cut groove in a worxcpieoe.

Xt is an object ot the invention to provide an insert with improved chip control characteristics.

It i provide a method of. ianuf aetUi;nq an insert Wit improved chip contr~ol.

It is yet another object be this inventi n to providqe an improved chip control insert oortfig ed to coopezratO with a clamping etemant of an insAt T T The invention provides~ Jth a cutting~ insert 2$ with a tinlitie configuration t atE results in improved chip control and a method fr manufacturing an insert.

Tha improved cu~tting in prt with chip control ifetures oompris*os an insert cW.~d having end wall regions and sie nd~ top ando6ttom wIalls sustntially prppendicujar-to the sides. The inser't body is adaptad for mount~m in a pocket in an holderz with one Onct reqio~ xpo.dT, insert body is invertible about art a4 p ndiolarto tho Sidez theroo and the insert kody has, cutting odges at the thje end wall rgiong, S whereby in each inverted position of the inmert body a respactivO cuttingt edqe is presented uppermost At the SUMMARY OF THE INVENTIOQN According to the invention there is provided a cutting insert with chip control features for grooving applications comprising an insert body having end wall regions having a predetermined width and defining in part a cutting edge and sides and top and. bottom walls generally perpendicular to said sides, said insert body being invertible about an axis perpendicular to said sides thereof, said Insert body having cutting edges at said end wall regions, whereby in each inverted position of said insert body a respective cutting edge is presented uppermost at the same end of said Insert body, said top and bottom. walls of said insert body defining -a notch therein; a land region extending rearwardly from each said end, wall region cutting edge toward said respective top or bottom. wall and deinin a urface region of a _predetermined Width, a descending wail having a forwa7d, poton and opposed side portions, InItiin inaprio :~20 of~ said land and terminating in a planar floor r:^ion too# h~aving a forward, a rearward and opposed side edger, and whezein, said dosedngwl terminates at said planar florsfQW0dan pposed side cdges; and a back ramp eXtending upwardly from said planar floor rerward edqe,, intersecting said descending wall opposed pide portions *and termrinatingte sai esective top or bottom wall.

Furherthepreentinvention provides an improved cutti.ng insert with chip control features comprising: an insert body having. end wall regions and aO sides and top- and bottom walls perpendicular to gaaid sides ndadapted for moointing in a pocket in 4 holder with e end region exposedI, said insert body being invertible Pbout an axcis perpendicu~lar to said sides thereof, said insert having cutting edges ait the Juinctures of said top and bottom walla and respective ones of said end wall regions, whereby In each Inverted position of said insert bodly a respective cutting edge is presented uppermost at the sam and of the insaert, said top and bottom walls of the insert defining n notch thetein; ai land reqiOn a Mr extending rearwardly from said end wall region toward said respective top or bottom wall and defining a surface region of a predetermined width proximate thereto; a descending wall initiating in a portion of sai~d land and terminating in a planar floor region having a forward, a rearward and opposed side edges and wherein said descending wall terminates at said, planar floor's forward and opposed side edges, said land region being asymmetrically disposed :in the end wall region re;lative to said descending wall forward portioM, and said end wall region further including at least one flat land region adjacent said land region; said flat land region defining in part at least one 5oe ct-Lvely disposable Portion of said end wall region, whereby the overall width- of said end wall regio.n, is reducible by the selective removal of at least; a portion of the selectively disposable portion of said end wall region; and a back ramp xedn upwardly troM said planar floor rearward edge and at, said respective top or bottom, wall.

the present, inventioa provides in1 combination With a cutting tool holder adapted to retain a cutting insert therein by, means of insert retaining means, a cutting insert with chip control teattxres for grooving applications comprising an, insert body having end wall rein.0 iga rdtrie widthi and defining in part a cutting edge and aides and top and bottom walls ganerally perpendicular to) said sidos, said insert body being invertible about an, axis petpondcla IQ si sieq *thoro and adapted for mounting in the CLILting tool holder With one end region exposed, said insert body having ctting edges at siaid end wall regions, thereby~ in each inverted position of said insert body a reispective cutting edge is presented uppermost at the same Ond of said insert body, said top and bottom walls of smaid Insert 3 body defining thorein a notch, said notch Cooporating with shid insert retaining means for thej pos LLivc- retention of ,,ad insert in said cutting tti-, holder-i land rengion extending rearwardly from each said end wall region cuttinq Odge toward s;aid rospaCtiVO too or bottoml wall and ~3 3b 9. 9 9 9* .9r 4f 99- 99 9: 99 9: I 9 9c 99 9 9I 4.

9 9 defining a surface region of a predetermined width; a descending wall having a forward portion and opposed side portions, initiating in a portion of said land and terminating in a planar floor region having a forward, a rearward and opposed side edges and wherein said descending wall terminates at said planar floor's forward and opposed side edges; and a back ramp extending upwardly Efrom said planar sfloor rearward edge, intersecting said descending wall opposed side portions and terminating at 1O said respective top or bottom wall, Still further the present invention provides an improved cutting insert with chip control features for groov'ing applications comprising an insert body having eand wall regions having a predetermined width and deftinig in part a cutting edge and sides and top and bottom walls generally perpendicular to said sides, said insert body being invertible about an axis perpendtcular to said sides thereof, said insert body having cutting odgqe at sid end wall regions, whereby in each invertod position of said insert body, a respective cutting edge is presented uppermost at the same end of said insert body, a land region extending toward said respective top or bottom wall and dOefining a aurEace region of a predetermined width; a descending wall having a forward portion and opposed side portions, initiating in a portion of said land and terminating in a planar Efloor region having a forward, a rearward and opposed side edges and wherein said descending wall terminates at siaid planar floor's forward and opposed aside edges; and a back tamp extending upwardly 3 from said planar floor rearward edge, i snteracting said descending wall opposed aside portion and terminating at tsaid r peoctive top or bottomt wall.

In one embodiment the invention providos both a cutting insert with a unique confiqgraton that rosults in improved chip control and a method for manufacturing an insort. The improved cutting insert with chip Control toature comprison ain insert body having end wall regions and P1o 115 Find top and bottom walls zubstnttially porpondkular to the zids. The inzert body io oDated It cl--~ 4' *1 for mounting in a pocket in an holder with one end region exposed. The insert body is invertible about an axis perpendicular to the sides thereof and the insert body has cutting edges at the the end wall regions, whereby in each inverted position of the insert body a respective cutting edge is presented uppermost at the same end of the insert body.

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r lir /g i- WO 89/01836 PCT/US88/02531 -4- The top and bottom walls or seating surfaces of the insert body define therein a diagonal notch, which extends thereacross at an angle such that each notch when uppermost forms substantially the same angle with the sides of the insert.

Each of the end wall regions of the insert defines at least in part a cutting edge for presentation to a workpiece. A land region extends rearwardly from the end wall region toward the respective top or bottom wall and defines a surface region of a predetermined width and area, A descending wall initiates in a portion of the land and terminates in a planar floor region having a forward, a rearward and opposed side edges. The descending wall terminates IS at the planar floor's forward and opposed side edges and a back ramp extends upwardly from the planar floor reward edge and terminates at the respective top or bottom wall, In an alternative embodiment, the land, descending walls, back ramp and planar floor define a region which can be asymnmetricallXy disposed in the end wall region and the end wall region also incltudes at least one flat land region. With this configuration, an improved method of manufactwuring inserts is made possible, The flat land region or the insert body end wall region preferably defines at least in part a selectively disposabte portion of the end wall region.

As a result, the overall width of the end wall region is rQducible by the selactive removal of at least a portion o0 the disposable portion.

B-IE FDE C1TIPTO 10 QO THE DRAWtTNGs The above as well as other features and advantag.m of the invention will beomwe apparent through eonsideration 6f the detailed dascription in S- connaeotion with the smvQral drawings in which: i WO 89/01836 PCT/US88/02531 Figure 1 is an isometric view of a cutting insert configured for chip control, all according to the present invention.

Figure 2 is an exploded perspective view illustrating a typical holder and clamping arrangement for use in combination with the cutting insert this invention.

Figure 3 is a plan view of the cutting insert of this invention.

Figure 4 is a side view of the insert of this invention.

Figure 5 is a an e'.arged fragment plan view illustration the end region of the insert of Figure Figure 6 is a section along lines VI-VX of Is Figure Figure 7 is a section along lines VII-VIt of Figure Figure 8 is an enlarged fragment plan view illustrating the end region of an insert of this invention, which insert has an enlarged and extended land which can be selectively removed to provide inserts of a variety of sizes, all aecordingly to a process of this invention, Figure 9 is a section along lines XX-IX of 2$ Figure a8.

Figurea 10 is a section along ilnes X-X of Figure s.

Figure 11 is an enlarged fragment plan vi.w illustrating the end region o an alternative ebodiment of the insert otf this invention which insert has an aymmetrically disposed land in combination with an enlarged and extended flat land which can be s.lectively removed to provide inserts of a variety of sizes, all aceoringly to a proaess of S3 this invention. i WO 8/01836 PCT/US88/02531 -6- DETAILED DESCRIPTION OF THE INVENTION An improved cutting insert with. chip control features is isometrically shown in Figure 1. and generally indicated by the reference character 10. The insert 10 comprises an insert body 12 having a first alahc, or end wall 14, A second opposed, flanc or rand, wall 16, first apd seoond sides 18 and 2 0 anOc cOp nd Ibottom seating surfaces or walls 22 and 24, TheiInsert body 12 is preferably made from a hard cemented carbide such as tungsten or titanium carbide or tungsten titanium carbide or, TIC-Tit. At the uoqture of one end part 14 and top Wa41 22 there is one- ctitting edge 26. At the j.nctte Of the Other end wall ;region. 16 and the bottom wall 24 there is a second cutting The insert body 12 of the insert 10 is formed, with a diagonal groove 30 in the top wall 22 and a diagonal groove 32 in the bottom wall 24 of the insert.

Eoh q.c/e 30 and 32 Is preferably OV$ shapedI in cross nection and Adapted for nraJement by the, toolholdqr ansembty which will be descrbed below. With the, inaert oonfiguration as or )ibed above, in each inverted position of the insert bodXy 12, a respective cuttingi edge is preseted uppermost at the same end of 2$ the insert body. The diagoAl't notch or grove.-, 30 and 12 extending across the Iniart body are disposed at an angle such that eAch notchi when uppermost, forms ou~bstntially the mama angle with the sids 18 and 2O of the insert body 12, Alool In each i nverted position, the insert body 12 prexento an enid wall raqp o of thie insert defining at loamt In part the cutting edge 26 or 20 to a workpiec,.

Am can be soon more cl4ary through considration or Figure% 3 4 and 5, in conjunction IS with riqure 1, the inzert bodY 12 itioluide. at each end region theareoo, a and region $4 and $6 extanding reawardly from the rogpacti. etond wad ?egiPtojh Xf t and 4 WO 89/01836 PCT/US88/02531 -7- 16 toward the respective top or bottom wall 22 and 24.

Each land region defines a surface region 38 of a predetermined width and area, It is to be appreciated that the insert 10 of this invention is reversible, and therefore the detailed features described in conjunction with one side or end region of the insert are present in the other side or end region thereof, Considering the end wall region 14, a descending wall initiates in a portion 42 of the land 34 and terminates in a planar floor region 44. The descending wall 40 has a forward portion 46 and opposed side portions 48 and 50. The planar floor region 44 has a forward edge 52, a rearward edge 54 and opposed side edges 56 and 58. The descending wall 40 terminates at the planar floors forward edge 52 and opposed side edges 56 and 58. A back ramp 60 extends upwardly from the planar floor rearward edge 54 and terminates at the top wall 22.

The bac* ramp 60 ascends from the rearward edge 54 of the planar floor 44 toward the top Wall 22 at an angle of approximately 35 to 45 degrees and, preferably, 40 degrees relative to the top wall 22.

As can be seen in Figure 6, the descending wall 40 portion proximate the folward edge 52 of the 2$ planar floor 44 descends toward the floor 44 at an angle of approximately 15 to 21 deqrees And, preferably, 18 dogreev with respect to the planar floor 44. The land region 34 proximate the cutting edge 24 olopes downwardly toward the dscoending wall juncture 42 at an angle of approximately between aboiut 5 to degees, preferably, 0 to 12 degrees, and mor specifically about 10 daeq;. es with respect to the top wall 22 of the insert body 12. The cutting odge 24 it of a IQ5s5r elevAotin than the top wall 22.

As can be soon in Figure 7, the side wall of the dexcending wall 0, descends trom the land 34 toward the planar fl1or 44 at an angle of between about W0 89/01836 PCT/US8$/0253I -8to 21 degrees and, preferably at an angle of about 18 degrees. Generally the side wall has an angle wxth a slXope selected to facilitate the pressing operation of the manufacturing process.

It has been found when cu.ttin metal, with the insert of the present Invention that a chip coming o~f a wcrjpiece in a light feed comes off the lAnd area of the insert And sptries the raIMP $0 wherein breakage is qaused by the force of the chip's impact with either 1Q the back ramp or the chip Itself as the Phip is directed back tcward the workjplece In a heavier feed rate, breakage appears to be the result of a combination of the chip strking thei floor 44 and the back ramp 6O as Well as the chip turninq back in on I$ itself The chip comning from the Workpidce forms a qeneraly "t'ill shaped cross section As a result of the chip control feature pf the insert l0.* While as shown in 4gure 71 the land region disposed between the side 2Q and the descencioq side Wal, 42 descends toward the dcnding side w&al 50 at a slight angle, It is believed that tho lack of such a deaoendinq angle would not adversely impact chip control, However, -this descending angle is believed to contribute to a rduction in cUtting forcez 4nd thus is 4prpaaable feature.

Trning now to Figure 2, thres li shown a toolholder 70 which is Ideally suited for use in combination with the insert 10 of this invention. The toolholder 70 is in the form of a bar-liko otel metbler 72 adaptd for being clamnped In a tool Oupport of any ouita l~e t At one end of the niber 72 there Is 4n insert pocket 74 having a bottom wall 74, a OldO wall 7& and 4 back wall 00. AdVantaJeoUsly, an undoreut Is Providoa at tho juncture at the bottom and back walls% 3! am 1ndicatod at a2 in arder to protet the cutting vdgeq 26 6ot the invert 10 which im dispoood in that rocjion In each a~mpld posItion of thE inart at said respective top or bottom wall. i

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WO 89/01836 PCT/US88/02531 -9- It will be noted that bottom and side walls 76 and 78 of the pocket are at right angles to each other whereas back wall 80 may be at a right angle to side wall 78 but converges with bottom wall 80 in the direction toward the back of the pocket. This pocket 74 is adapted for receiving an insert 10 therein. As described above, the insert 10 is provided with "V" shaped notches or grooves 30 and 32. These grooves and 32 are adapted for engagement by the rounded nose 84 on the one end of one leg of a clamp member 86 which is in the form of an inverted shaped member.

Clamping member 86 has a further leg 88 adapted for being received in a recess 90 formed in the top of the holder 70. A clamp screw 92 extends through a hole in the clamp member 86 between the legs thereof and into a threaded hole 94 provided in the top wall of the holder, When the insert is placed in the pocket, the clamp member is put in position, and screw 92 is tightened up, and the insert is pressed firmly against the bottom wall 76 of the pocket while simultaneously being drawn toward walls 78 and 804 The insert is thus fixedly alamped in the pocket in the holder and is accurately located therein by being forced against the side walls of the pocket.

The side Wall 78 of the pocket is preferably at a slight angle, approximately about 3 degrees, to the longitudinal axis of the holder 70. Foe this reason, the opposite ends of the insert are shaped in such a manner as to compensate for the small angularity of the wall 78 to the longitudinal axis of the holder A more detailed description of this as well ae several other clamping arangements and toolholdrs 3, which can be advantagaus!y utilizd with the mubj~ot cutting insert can b~ had through a review of u. S.

Pattnt No. 3,S84,S301 antitlqd "Cutting Insert and WO 89/01836 PCT/US88/02531 Clamping Arrangement Therefor," which patent is assigned to the aysignee of the present invention and incorporated by reference herein.

The present invention is also directed to an improved method for manufacturing a cutting insert with chip control features. Turning to Figures 8, 9 and there is shown in Figure 8 an enlarged fragment plan view illustrating the end region of an insert generally indicated by the reference character 110 which, has an enlarged and extended land which can be selectively removed to provide inserts of a variety of sizes, all accordingly to a process of this invention. The insert 110 has an enlarged and extended land which can be selectively removed to provide inserts of a variety of sizes. In all other respects, the insert 110 has the same features as the insert 10, and therefore these features will not be set forth again in detail, but reference is invited to that portion of the specification which describes the insert 10. The insert body 112 of the insert 110 has a land 134 with an extended or flat land portion 135. The insert body 110 has an end wall region 114, sides 118 and 120 and a outting edge 126. The land region 134 extends rearwardly from the and wall region cutting edge 126 toward the top wall 122 and defines a surface region of a predetermined area 138 and 139. The area 138 of the land 134 has a descending slope which is at an angle as described in conjlunction with the embodiment of the insert as shown in Figures 6 and 7. The area 139 of the land 135 is generally flat and defines a cutting height surface while the edge of the land opposite the area 139, adjacent the insert side 120, defines a.

cutting height line -he features of the descending wall 140, the planar floor 144 and the back ramp 160 are substantially similar to the wall 40, the planar floor 44 and the back ramp o0, which are desribed alsewhere heein.

W089/01836 PCT/US88/0253F -11- As can be seen in Figure 8, the land area 138 and land area 139 combine to define an overall width of the end region 114. The land area 138 represents approximately two-thirds of the overall width as indicated at while the land area 139 represents approximately one-third of the width of the end regicn as indicated at Preferably, the flat land region 139 is no more than one-third of the total width of the end region of the insert after the grinding process which produces an insert with the desired final dimension. If the flat-land region 139 is larger than this preferred ratio, then during cutting operations the chip may not be adequately deformed and the advantages of the improved chip breaking feature of this invention not fully exploited, In this embodiment, the flat land 135 defines, in part, a selectively disposable portion of the end wall region 114 of the insert body 112, While the land region 134 is shown in Figure 8 to be located adjacent the cutting height line L, it is to be appreciated that the land 134, and associated descending wall, floor and back ramp can be disposed in a more central location or adjacent the opposite side 118 of the insert body 112. As illustrated in Figure 11 an insert 200 inacludes a land 234 which is more centrally disposed in the end wall region 214 of the insert body 212. Accordingly, the flat-land region 235 now comprises two separate regions on opposite sides of the land 234, with either one or both of the separate regions being modified through grinding operations during manufacture, In a configuration in which the land area 234 is disposed in the and region 214, the ratio of the width of land area 238 to tthe total width of the combined land areas 239 is preferably maintained as described above, so that the combined width of the two separate flat land regions 23$ in the fully manufactured cutting insert mod WO89/01836 PCT/US88/02531 -12- 200 of this invention represents no more than approximately one-third of the width of the end region 214. The remaining portion or approximately to-thirds of the end wall region consists of the land 234.

It has been found that a portion of the at least one flat land region can be selectively removed by grinding whereby the overall width of the cutting edge is selectively reduced to a predetermined dimension, This extended width land area comprising the land and the flat land regions of the insert body as shown in Figures 8 and 11, permits the manufacture of a lesser number of unique individual insert sizes and the selective grinding of a portion of the flat land regions in order to achieve the desired dimensions for a particular insert style. As a result, fewer dies are necessary to manufacture a greater number of inserts having differing dimensions.

It has been found that a metal cutting insert incorporating the chip control features described herein provides significantly improved chip control over a wide variety of metalcutting conditions.

Additionally, the new insert configuration facilitates the manufaacturing process. What has been described is an improved cutting insert with chip control features and a method for the manufacture of such cutting inserts.

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Claims (9)

1. A cutting insert with chip control features for groobvitng app~lawoxit Oompr Sing an insert body having end Wall regions S hvinc-[ a predetermined width and defining in part a cuttinq 0dge and sides and top and bottom walls S:generailly pe pedicu:ar to said $idea, said insert body being invertible about an axis perpQndiuular to said sidps thtereoft saI insert body aving cutting edges At IQ said end wall regions, whereby in each inverted P osition of said insert body a respective' cutting edge is prasned i~peost_0 aMt the same end of said insert -1aprscitd ip boy, said top and botto% walls of said insort body dcofining a notch therein; a land region oxtending 9 i s9re d 1$ from eacn haid end wall regin cuttng odge toward said resoCoive top or bottom wall and defining a srface region of a predetermined width; a descending wall having a forward portion and opposed side 9poriions, initiating in. a portion of said land and o torminating in a planar floor region having a forWard, a vaarward and opposod s;ide edges and whorein said cmsconding wall teriminates at said 1 a"ar I O~r 's forward and opposd side edgqen.; and a back ramp extending upwardly from s-aid planar floor rearwa cte intersecting said descending wall opposed side potions, Ad terminating at siiid respctive top or bottomn wall. he inmproved cutting insort kccording to Olaim I whoruin the and w411 region ftirther incltider at MV 1 i' -14- i least one flat land region adjacent said land region and~said land region has a surface of a pr'ede-termined width and said at least, one flat land region is of a predetermined width which define in combination the width of the end wall. region and wherein the fClat land. region width is no inore than approximately one-third of said end wall region width. T 'he improved cutting insert according to claimu wherein the end wall region further Inpludes a second flat land region adjacent said land region and said land region is asymmetrically disposed in the end wall region relative to the descending wall forward portion such that the portion of the flat land region proximnate one opposed side edge Of said land region is of a different dimension thnte otono he land region prozinate the other opposed side edgje of the 0t land region. 4, The improved cuttinc netacrigt claim, 3 wherein the flat land region proximate o- opposed side of the land ~egqion Which is of a g~reater O imension than thle region proximato the other opposed, side defines in part zit least one0 solotively disposakle, porti of said eind wall region, werey the overall widtq, of the end wall roqion Is, reducible )a~y the solectiVo removal of tit least a portion of the at least Ono 8elec~ively disposaIble portion. The imprvod cutting in:eirt acoordinq to anfy one, 04, 01iiLnsi I to 4, Wbertln Lbe backtrarp ascuiidk foithe roitanr v~dg2 of 01o floor tLotwir4l tzhe renpoctvC top or bottoo wiIL- at an miyoof opproximatety~ bviLW(ou 4hbt 35 to, 4!i 4aere.* trehit(vo. -iiiW rv p LVv top or~ hoUtom wi1I. The- iimprovocl mit-tingj iinirt aoorlII~j to clailn S whorein, the barokvaip ascends from~ the reasrwktrd Qedge of tho floor~ towards tho rosIpective top or bottom wall at nn 111(Jl' O~f approximately 40 dogro(ee I ro"tIvo to znId rospotIvo top or hoton Wall,

7. The improved cutting insert according to any one of claims 1 to 6 wherein the descending wall portion proximate the forward edge of the planar floor descends thereto at an angle of approximately between about 15 to 21 degrees with respect to the planar floor.

8. The improved cutting insert according to claim 7 wherein the descending wall portion proximate the forward edge of the planar floor descends thereto at an angle of approximately 18 degrees with respect to the planar floor. 9, The improved cutting insert according to any one of claims 1 to 8 wherein the land region proximate the cutting edge slopes downwardly toward the descending wall at an angle of approximately between about 5 to 15 degrees with respect to the top wall of said insert body, 10, The improved cutting insert according to claim 9 wherein the land region proximate the cutting edge slopes downwardly toward the descending wall at an angle of approximately 10 degrees with respect to the top wall of said insert body. 20Q 11. The improved Outting insert according to any one o£ claims 1 to 10 wherein each said notch extends b* thereacross at an angle such that each notch when upperniost forms subEstantially the same angle with said '4" sides of the insert and is substantially shaped in 0W 2S cross section. 12, The improved cutting insert according to any one .of claims I to 11 wherein the cutting edge is of a lesser elevation than the respective top or bottom wall. 9 13, An improved cutting insert with chip control features comprising* an insert body having end wall regions and sides and top and bottOm walls perpendicular to said sides and adapted for mounting in a pocket in a holder with one end region exposed, said inert body being invertible about an axis perpendicular to said sides thereofr said inert having cutting edges at the 4 1 1 1 1 junctures; of said top and bottom walls and respecti've ones of said. end wall regions, whereby in each inverted position of said insert body a respective cutting edge is presented uppermost at the same end of the insert, said t~Q and bottom walls of the insert defining a notch therein; a land region oztcndinq rearwardly from said end wall region toward said respective top or bottomu Wall and defining a surface region or a predetermined width proximate thereto;~ a deswending wall initiating, in a portion of said land and terminating in, a, pUiinnv Lloar region having a forward,, a rearward and opposed side edges and wherein said descending wall tormnInates at said pIlour floOVI$ forwwad and opposed CJ~ de, adln region being

11- asymmetrically disposedI in the endl Wall region relative to said descending wall forward portion, and said end wall region further including at le~ast one flat land region adjacent said land region; said flat land region defining in part at leakot one selectively disposable portion of said end Wall region, wherb the overal:L width of said end wall region is, reducible by the selective removal of at least a portion of the selectively disposable portion of: said enld wall regionl; a~nd a IbaCI, rarap Otending UpWatdly from sa id pAlnar top or Jbotton wall.

14. The Improved votinrq insor,1t ACco ngt claim 13 whorein the land region ha-, a turface of a prodoteermined width cind said at lelas t one flat land region is of a. predetermined width which define in 000mbinationl thte width.I of the en wal'l r~egion andl wherein the 1fla-t Iatid region width if, no miore thanl approximately one-L'hird of said end wall region widith 9 ho Improved cuttting inttert accordintg to olaiiu 14 whoreAi thoe nd Wall reqion further includes' A slconld flat land rencll adacent the land region kindj maid land reqgion ir, Oyllmmtrically dJ1-po.,d in the and, )A4 f -17- wall'region relative to the descending wall forward, portion such that the portion of the flat land region Proximate one opposed side edge of said land region is of a different dimension than the portion of the land region proximate the other opposed side edge of the land region.

16. Thq improved cutting insert acording to cl1aim 14 or claimn 15 wlierceIn the backrarnp acoids frorq the rearwaird edg4 QX the floor towards the respoqtivo top or bet jom wall at oni ongle of opproximate~y betwoon about tQ 45 dogrpoe% relative to oiaid rospective top, or bottom wall,

17. The improved oudtn insert according -to claim 16 wher'ein the )Dackramp, ascnds fioin thQ rearward d~ g~ od of the floor towards~ the respective top or )botton1. Wall at jn tingle of approximately 40 degjree rative to said roope~tive top or bottopf waIlt. t.Tile irpproved cluttira, in,-ert #ceordting to. any: ono of Claimmi 14 to. 1,7 Wh~ere in the denconding Witt portion~ vroxirnato the fo~wjir4 edgt-, of the plainar floo~r bevtQ ~t n angileof ap~proxiwnately betwe abotltt I2$ to 21 dogrooe W101 renpe)CC to the ptI'lir cor. 2o Vw~ IIJuproved etittt$Ang firiset aecordtti to, aly Ile of clhii~ 14 to 19 wlrin weli la4In rogtneter-Xln 301 theo ~Otiwn edge noptes downwardl rowae d 0m doticnt.n ata anl o( apjox'mtetm, 1$l 4betwo wtlt 5a t(1.

21. The imriovd O-tIii' I nsrt iiiodt( to nrI'i 20e orvi c1the land tr 19 tolltt the lmato th otiir $0 theo !uttInges g e downwrdty toward t hAi donzhIln al a. 1 angl, o tanpoaitl 4 0 doqvenl wioel r eott O top wall oft fpeid tnvorth btpwI ot1I4y~rth~ 4v Th mlO de3iig A~~~crti t

22. The improved cutting insert ac~i~ o any one of claims 13 to 21 w.hrein cacbi said -notch exteinds 4hereacroso at gt arwglP 'Suh -that eachi .notqh whon uppqr- most forms subst4,ntiatly tbe same angle, wtih said side$ of the inser and is substantily""s~e in~ 0rs 23, The improved Cutting insert aocQr4tug to. Roy one of Plailms 0, to 22 whercin Ohe cutt~tng 0040 is of I A Loetr ce ~ion thon (110 respective top or 6hattom, wall,~ 24, 1 4~bfat With a Q-Uttincj toOi hoidr adan~tacd to re~tain it cuttinqg insert therein by Meoan,% of imnse't re~taining means, a ctlttin Wns i th ohip oontrol featurecs for grfooving applications ccnmpri.,4nq an in,;ot boly htvingi en~d wa 11 toqreions lizvinq a p de~otzormirwcl width andl defining in Spart a ctilng and sdct- arwl to[) andI botton wiln. tlralaly pe pendimilar to nidl sides, saidl iwjort, hody Ionqj invertble abouit an axis Ivoperdicu4a to paid ~der ~ot n adaiptuc for miounting in the otttinq tool holder with one otil rogion eposed, si it),t bodly having utiqodqJo at "maid onld Wal. ro( 'i thereby in each inverteod i,0 of 's1aid insoWrt body 4 re! tspoctvo cuttinq to~4lJo twoTh'n1to( lUj~-~"t iiot, tho ellu on of ,;aIdktr bodly, paiid top and botot. woll's o~sidIhw ody definlinq thoroiln I IotAII, saEidI inolchoorwrtatinq wit'lh slid iwwrt, retidrinlq foraw tool ll1lor,, it land1 reqtlon oxtondIIIIq zoa 7wau-ly ftoinl 1"wh sadond( Wall roqion rV ("ttil odgjo toward "lidd I0 rowctvo hup or~ Iot'-on wolt and doftzing a itz troqtior of a t~tritdsd a dosoonwIding(I Will jiaVinq it foi'Word portiort andI opposoct sidoe lpottiolvif itlitvhtinq in at portion of ,-aid land awld tonlinatinq tn a pdallar daor roqioyn havinlq a rorwatd 1 at raITwil- and opposowd tsido ndqo~rn and whoroio tsaid dowlemidinq wil. tnM lt tw at s-aid planlav Clooel fovword and opposoed rilda odq~its: and a Nick r*1nIN oixtteiig vjUwatdly frol. said planar floor rearward odger interseotiig said, descend~ing .wall oppQo3ed side portions and terminating at said zrspeotivo top or b~ottomn wall, An impr~oved ctuttitiq insqrt with chiP ~qntrQ1 reAturos for grooving applcatonscompsin aninsert, body having end wall r'egIona having 4 pr etrminod Width and, dqflning Jn PazI a Outtinq edge and sides ald top an14 boto walS cjge-0rlY PerPendJic11Ia to -,IAid Sidefl, Saitd insert bodly ein VGh1~about an alxif porpcndicoUlar to said I os thoeoof said inlsozt tbody havinqj Ctting edges at sidi( Cnd wall treWojiorfl5 wh(-Ij-ohy in O(Chinv(to po.- tiofl of szAid innwOt bodY, ia r0,5[Wotiveo cutting edqje Spreseilted up~pEotlThOE' at, t1he s'anc( (!nd of' iaid insert bokdy, a land r'egion e4~onainq to~jard( saidl venpective 99top or b~ottomu 1a an~ doilning i a srfaco region of a 99 9 predeterminedj viddthj; aj snedin waL ing a forwr 9portion and cnpoed slidn port.ions-, inlitiat'ing ill a too potion of said land and Vermiiting in )0 reqion haiiinq a fforward, at rearwalrd a~nd opposed.I side odcjoi and Werin i dos(endinq vwall tetpinilte!7 at tjii4 plaliar Cloor',- forvlardl ondl opp d side odqesL; anld *x ati raKiampy ntfenli tipwardly uoni !s.vtd planar Cloor 4400t: 41 (qpw;(ed ,-det portinns andl t xiuinIAt11tqM a'said 9*o~wtif top or hot.Leu11 w11 (I r Wni 4it h1tv~ wii*t ~lsi rvfervfict (0 ~lly Olf ofh~x faiLe VIIIdIIIo ORMONDF,~i FtTZATMU~ AtLteullyn foyjt 4