CA2553354A1 - Cutting tool for drilling concrete, aggregate or masonry - Google Patents

Abstract

A cutting tool has a longitudinally extending shaft portion with a chucking part and a cutting head. A pressed powder cutting insert with a cutting edge is on the cutting head. The cutting edge includes at least one cutting portion. A rake surface is formed adjacent to at least one of the cutting portions with the rake face being at a rake angle from about 0° to 10°. A clearance face is formed adjacent to the at least one cutting portion opposite the rake face. The clearance face is at a clearance angle from about 10° to 50°. An edge radius between the rake face and the clearance face is at a radius of from about 0.0015 to about 0.004 inch. The edge radius is formed during pressing of the powder to form the insert, thus, enabling the insert to be directly braised into the cutting head.

Description

CUTTING TOOL FOR DRILLING CONCRETE, AGGREGATE OR MASONRY
This is a divisional of application serial no.

2,228,652 filed December 15, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to cutting tools or drill bits, and more particularly, to cutting tools which are used in hammering, percussive, or rotary boring or drilling applications in concrete, aggregate, masonry or the like material.
When drilling concrete, aggregate or the like materials, generally three different types of cutting tools or bits are used. These bits can be defined as hammer bits, percussive bits, and rotary masonry bits. In a true hammer bit, the bit is placed into a driver which includes a hammer which is sea-uentially and repetitiously moved toward and away from the bit. This hammering action hammers the bit. While the bit is being hammered, the bit continues to either passively or actively rotate. Thus, this type of cutting would be synonymous with using a chisel and hitting it with a hammer. Also, the driver may include a rotational feature where the bit is hammered and actively rotated.
In percussive drilling, the drive includes a chug: whi ch is associated ~nith stepping cam surfaces on nears z~:hic~. aT-a rotated and, at the same time, moved up and do~::n within the dri ~rer .
Thus, the entire chuck mechanism rotates ~.nd moves u~ ar:d do~~:n during th~' cutting prccess.

A rotary masonry bit is positioned into a driver which provides only a rotary movement. Thus, the rotary masonry bit does not move up and down and just rotates to cut at the concrete or aggregate.
Cutting tools in these three fields require different parameters for each type of application. In hammer and.
percussive bits, which utilize a chiseling action, the tip cutting angle, which provides tip strength, debris elimination and a cutting or rake face are a primary concern. Likewise, in rotary masonry drilling, which uses purely rotary movement, the cutting or rake face, debris clean out and cutting angle are also of primary importance. However, all of these elements are interrelated to provide an optimum cutting tool or drill bit to drill concrete, aggregate and the like materials.
Existing hammer and percussive cutting tools ordinarily include carbide insert tips with cutting edges which have large obtuse included angles as well as a negative rake face at large acute angles. Thus, the tip has been utilized to chisel and rotate to drill or bore into the concrete material. The rotary masonry bits ordinarily use a rake face on the bit so that when it is rotated, it will bore through the concrete material.
Further, when the carbide tips are formed, the carbide powder is laterally pressed into a mold to form the tip. This tip is inserted directly and welded or brazed onto a tool shank.
Thus, this is the art accepted way to form current design tools or bits.

,3 SUMMARY OF THE INVENTION
The parent of this divisional describes and claims a cutting tool or bit which will reduce the time to drill holes into concrete, aggregate or the like material and improve the quality of the hole. The cutting tool has an improved cutting tip with a rake face which is slightly negative, zero or positive. The tip cutting angle, which is the angle between the rake face and clearance face, is smaller than current designs to provide better chiseling action. Also, the insert can be formed from pressed powder and maintain the desired tip cutting angle. The debris recess of the cutting tool rapidly ejects debris from the tip into the helical flutes. A rake face on the cutting tools increases cutting action during rotation of the cutting tools in the hole.
In accordance with one aspect of the invention there is provided a method of forming an insert comprising: providing a mold with an insert cavity defining a longitudinal axis and having an opening along the longitudinal axis; adding powder material into the mold; compressing the material in the direction of the longitudinal axis; forming the insert with a positive rake face.
The method of forming the insert preferably uses a V-shaped punch for compressing said powder material.

,4 The method of forming the insert preferably includes the step of forming a land on a face of said insert, said land being at an acute angle and counter clockwise with respect to an axis of the insert.
The method of forming the insert provides said insert with a desired rake face, clearance face and edge radius.
The method of forming the insert includes the step of ejecting the insert from the mold.
Additional objects and advantages of the invention will be apparent from the detailed description of the preferred embodiment, the appended claims and the accompanying drawings, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate two embodiments of the present invention and together, with the description, serve to explain the principles of the invention. In the drawings, the same reference numeral indicates the same parts.
Figure 1 is a perspective view of a prior art cutting tool.

Figure 2 is a side plan view of the cutting tool of Figure 1.
Figure 3 is a side plan view, rotated 90°; of the cutting tool of Figure 1.
Figure 4 is a top plan view of the cutting tool of Figure 1.
Figure 5 is an auxiliary view along the cutting edge of the cutting tool of Figure 2 illustrating the rake surface.
Figure 6 is a perspective view of another prior art cutting tool.
Figure 7 is a side plan view of the cutting tool of Figure 6.
Figure 8 is a side plan view, rotated 90°, of the cutting tool of Figure 6.
Figure 9 is a top plan view of the cutting tool of Figure 6.
Figure 10 is an auxiliary view along the cutting edge of the cutting tool of Figure 7 illustrating the rake surface Figure l0A is an enlarged side view of the insert tip of Figure 10.
Figure 11 is an enlarged side plan view of a cutting radius of Figures 5 and 10 in circle 11.
Figure 12 is a perspective view of a cutting tool in accordance with the present invention.
Ficrure 13 is a side plan view of the cutting tool of Figure 12.
Figure 1 ~ is a side plan vie~~~, rotated 90 ° , of the cutting tool cf Figure 12.
Figure 15 is a top plan view of the cutting tool of Figure 12.

a Figure 16 is an auxiliary view along the cutting edge of the cutting tool of Figure 12 illustrating the rake surface.
Figure 17 is a perspective view of an alternate embodiment of the present invention.
Figure 18 is a side plan view of the cutting tool of Figure 17.
Figure 19 is a side plan view, rotated 90°, of the cutting tool of Figure 17.
Figure 20 is a top plan view of the cutting tool of Figure 17.
Figure 21 is an auxiliary view along the cutting edge of the cutting tool of Figure 17 illustrating the rake surface.
Figure 21A is an enlarged side view of the tip of Figure 21.
Figure 22 is an enlarged view of the edge radius of Figures 16 and 21 within circle 22.
Figure 23 is a side plan view, partially in section, of the cutting tool of Figure 12 rotating within a material.
Figure 24 is a view like Figure 23 with the cutting tool impacting or chiseling the material.
Figure 25 is a partial cross section of a side plan view of the cutting tool of Figure 17 in the material during rotary boring.
Figure 26 is a figure like that of Figure 25 ~,~ith the cutting tool impacting or chiseling the nGterial.
Figure 27 is a figure li~:e that ef Figure 25 with the cutting tool rotating and impacting or ci:ise 1 ing t~:e ,;,ater i al .
Figure 28 is an auxiliary vie~~: along the cutting adore of a cutting tool of an alternate embodiment i';lustratinc a-: arcuate first egress surface and area.

Figure 29 is a side glan view of another embodiment of a cutting tool with a 180° included angle.
Figure 30 is a side plan view like Figure 29 rotated 9 Figure 31 is a perspective view of an alternate embodiment of the present invention.
Figure 32 is aside plan view of the cutting tool of Figure 31.
Figure 33 is a side plan view, rotated 90°, of the cutting tool of Figure 31.
Figure 34 is an auxiliary view along the cutting edge of the cutting tool of Figure 31 illustrating the rake surface.
Figure 35 is a top plan view of the cutting tool of Figure 31.
Figure 36 is an enlarged view of the edge radius of Figure 34.
Figure 37 is an enlarged auxiliary view like that of Figure 34.
Figure 38 is a plan view of an insert in accordance with the present invention.
Figure 39 is- a schematic elevation view of a mold in accordance with the invention.
Figure 40 is a section view along line 40-40 of Figure 39.
Figure 41 is a section view alone line ~1-~~ of Figure 3°.
DESCRIPTION OF PRIOR PRT DRAPTINGS
Turning to Figures 1 through 11, two prier art cutting tools are illustrated. Figures 1 through 5 ill~~st~~ate ~" ball head single flute cutting tool, while Figures 6 through 10 ,illustrate a double helix cutting tool. Figure 11 illustrates the edge radius of both the cutting tools.
The ball head single helix cutting tool is designated with the reference numeral 100 and the double helix reference tool is designated with the reference numeral 102, The single flute cutting tool 100 has a chucking end 104 for a hammer_driver and a ball cutting head 106. The shank 108 has the single helix 110 defining a flute 112. The flute 1.12 ends at the cutting head 106 at a debris channel 114. Also, an additional debris channel 116 is on the opposing side of the head, which dumps directly into the flute 112, as seen in Figure 3.
The cutting head 106 includes an insert 118, which includes a cutting edge 120, either brazed or welded or the like into a slot 122 in the cutting head 106. The insert is formed by placing powdered carbide into a mold and compressing it. The insert is directly welded or brazed as described.
The cutting edge 120 is defined by rake faces 124, edge radius 125, and clearance faces 126. Ordinarily, first egress faces 128 are directly adjacent to the rake faces and egress area 129 forms the remainder of the egress portion. The egress area 129 may be on the same angle as the rake faces 124. The rake angle is negative and is about -30° to about -40°. The egress faces 128 lead into the debris channel 114, 1i6. The rake faces 124 have a substantial negative rake angle ~~rith the exception of some percussive bits which are at 0°. The edge radius 125, as can best be seen in Figure 11, is betvreen the ~-a~:e faces 124 and clearance faces 126 and, as can be seen, is relatit:el~~ dull and is on the order of 0.004 to 0.008 inch as measu=~ed on some prior art examples. However, in rotary only bits, while these bits may have 0° rake angles, the edge radius is in the mentioned range.
Also, the rake face 124 and clearance face 126 define a cutting angle between the two surfaces. The cutting angle is important for chiseling action and is about 45° to 110°. Thus, with the negative rake angle and the dull edge radius, the cutting tool 100, 102, as it rotates, glides inside the hole, synonymous to spreading butter with a knife, smoothing away debris within the hole. This requires substantial force to initiate cutting of the hole in the concrete, aggregate or the like material.
In the double helix cutting tool 102, the chucking end 104' is different from that of the single flute cutting tool 100 to illustrate a rotary or percussive type chucking end. The tool includes helixes 111 and 113 as well as flutes 115 and 117. As the flutes end at the cutting head 106, the debris channels 114 and 116 are formed at the end of each of the flutes.
The cutting tip insert 118 is the same as that previously described and the rake faces 124, cutting edge 120, clearance surfaces 126 and first egress surface 128' and egress area 129' are identified with the same numbers. However, the egress area 129' is different than that in the single flute design. Here, the egress area is parallel to the rake face. ~:lso, the debris channels 11~', 116' are substantially identical.
Both of these cutting tools illustrate a cutting tip having a large obtuse included angle betcaeen the t~~:o cutting edges on the order of 120° to 130°. Also, the egress angle, ordinaril~,~
about 30° to 35°, defining the plane a' the caress area is a relatively shallow. Likewise, the clearance angle, ordinarily about 20° to 30°, which defines the plane of the clearance surface is also shallow. Also a cutting angle, between the rake face and clearance face, is ordinarily about 90 to 110.
When defining angle measurement, the angles are true angles.
True angles are taken by,defining a plane parallel to the center line of the tool and through the cutting edge in an auxiliary view with the cutting edge as~a point. See Figures 5, 10, 16, 21. The rake angle, designated by a, is the angle measured from the defined plane to the rake face. The clearance angle, designated by CA, is the complement of the angle measured from the deffined plane to the clearance face. The cutting angle, designated by i3, is the angle between the clearance face and rake face. The cutting angle f3 is equal to a + (90 - CA) . The egress angle, designated by ~, is the angle from the defined plane to the egress face. Positive rake angles are defined by clockwise rotation from a point on the defined plane at the cutting edge to the rake face, when viewed along the cutting edge from the outside diameter of the bit. Negative rake angles are defined by counterclockwise rotation from a point on the defined plane at the cutting edge to the rake face, when viewed along the cutting edge from the outside diameter of the bit.
DETAILED DESCRIPTION OF THE PREFERRED Ei~;BODIMErTt Turning to Figures 12 through 26 , embodiments or the present invention are shown. Figures 12 through lc illustrate a single helix: design, designated ~.~ith the reference numeral 200, and Figures 17 through 21 illustrate G aouble heii:; design, desicnated ~~.~ith the ~~efez~ence numerz'_ 300, :~espectivel_,~, a The single helix cutting tool 200 includes a chucking end 204 , in this particular case illustrated as a spline for a hammer driver, however, a percussive and/or a cylindrical rotary end or other attachment and drive means could be used. A cutting head 206 is at the other end of the cutting tool 200 and a shank 208 is between the two ends . The helix 210 defines a f lute 212 . The flute 212 ends at the cutting head 206 into a debris channel or recess 214. Likewise, a second debris channel or recess 216 is cut into the cutting head 206 opposing the recess 214.
The cutting head 206 includes an insert 218 which includes cutting edge 220, rake faces 224, and clearance faces 226.
Likewise, egress faces 228 are immediately adjacent the rake faces 224.
The insert 218 has an overall pentagonal shape of a house with the cutting edge 220 defining the roof, sides 230 and 232, and a base 234 which is substantially perpendicular to the two parallel sides 230 and 232. Also, the cutting edge could be along a straight line to provide a rectangular insert, as seen in Figure 29 and 30. Here corresponding reference numerals are increased by 200. Thus, the cutting tool is designated with the reference numeral 400. The insert 218 is brazed, welded or the like into the slot 222 in the cutting head 206. The insert 218 is generally manufactured from G carbide material, such as carbide or tungsten carbide, howe~~er, ceramics, ceramic composites, diamond dust, metal ceramic composites or G unitary homogeneous or a deposit of layers ccvald be used. ~:lso, the entire cutting tool could be manufGc~~~r~d from such material or a portion thereof, including the 't~eGd ~i.~~~ manufactured from such a material, eliminating the insert :1~.

The cutting edges 220 are defined by rake faces 224, edge radius 240 and the clearance faces 226. The cutting edges 220 include a primary cutting edge 236 and a secondary cutting edge 238. The primary cutting edge 236 is on an acute angle with respect to the longitudinal axis 242, while the secondary cutting edge 238 is. substantially perpendicular to the longitudinal axis 242.
The cutting edges 220 include edge radius 240 between the rake faces 224 and clearance faces 226 (see Figure 22) . The edge radius 240 defines the sharpness of the cutting tool. An edge radius 240 of the present invention is generally between 0.0003 to 0.004 and preferably between 0.0005 to 0.001. Having a desired edge radius 240 provides a desired sharpness to enable the cutting tool to cut through the concrete, aggregate or the like material during rotation of the cutting tool. The edge radius is formed by working, such as by grinding or the like, the clearance face and the rake face.
The two cutting edges 220 form a tip or point 221 between them. The included angle (IA) between the two cutting edges 220 is from about 90° to 180° and preferably about 100 to 160.
The cutting edges 220 are offset from the longitudinal axis 242 of the cutting tool 200. The rake faces 22~ are worked or ground into the insert and define rake angles a as defined above .
Generall~~, the ral~:e angle a is between 10 ° to '_0 ° , preferably at about 0° for the primary cutting edge port~c~: 2.6. The rake angle is between -SO° to -20° preferably -':0° fc~ the secondary cutting edge portion 238. Thus, the ~~~orl,ed _~.~,~ sur~aces are substantially parallel to the lonqitudinai az:is -:?.

The rake faces 224 are formed by working, such as grinding or the like, into both sides of the insert 218 and extend a desired distance from the cutting edge 220. The distance or depth which the rake faces 224, which are worked or ground into the insert, extend from the cutting edge is known as the length of relief. The depth of the length of relief is measured from the cutting edge 220 along the longitudinal axis 242 to a first egress surface 244. The length of relief of the rake faces 224 has a depth of about 0.08 to about 0.25 inch for a 3/4 inch diameter bit. Preferably, the depth is from about 0.15 to about 0.25 inch. The length of relief can be defined as a ratio with respect to the diameter of the tool. Thus, the length of relief ratio is about. 0.10 to about 0.32 inches per inch diameter of the tool.
The first egress surface 244 angles from the terminus or end of the length of relief. The first egress surface 244 is generally angled with respect to the rake face 224, providing an overall stepped cutting head, as seen in Figures 16 and 21. The angle of the first egress surface 244 is from about 30° to 90°
and preferably 55° to 60° and may be continuous with and at the same angle as the egress area 228.
The clearance surface 226, which includes a portion of the insert 218 and the cutting head 206 define a clearance angle CA.
The clearance angle CA is defined as r-:entione~ above. This clearance angle is from about 10° to abou~. SO° and preferably about 20° to 40° for hammer and percussive tool= and 30°
to 50°
for rotary only tools.

A cutting angle f3, as defined above, is defined between the clearance face 226 and rake face 224. The cutting angle i3 is from about 30° to 90° and preferably from about 40° to 60° for the primary cutting edge portion. The cutting angle for the secondary cutting edge portion varies from 6~0° to 120°
preferably from 80° to 100°. These cutting angles define a primary cutting edge.portion which enhances cutting action, while the cutting angle defined for the secondary cutting edge portion enhances the chiseling action of the cutting tool.
The egress area 228 defines an egress angle ~ which is measured as mentioned above. The egress area 228 is adjacent to the first egress surface 244. The angle is at least 0° and preferably from about 30° to 60° for hammer and percussive tools and at about -20° to 90° for rotary only tools, preferably about -20° to 20° for hammer and percussive tools and 45° to 105° for rotary only tools. Also, the first egress surface 244' and egress area 228' may be arcuate as seen in Figure 28. Here they are shown on the same arc, however, they could be on different arcs. This egress angle and surface enhance the transport of debris from the tool tip into the flute 212 of the shank 208.
Thus, by providing a desired egress angle, choking is prohibited at the cutting head 206. As seen in :figures 12 through 16, a larger volume of material i s removed from the bal 1 head enabling better debris removal.
Turning to Figures 17 to 21 , the doubt a heli:=; er~,ouiment of the present invention is shown. The cutting tco~_ ~C~O includes a chug: end 304 which is a rotary o_~ percuss,~~~e t~s-pe o= cutting tool end. Also, the helixes 307 and 309 and flutes 310 and 312 are different from those previously described. The helixes 310 and 312 end at the cutting head 306, thus enabling the debris recesses 314 and 316 to include a larger volume of debris. The remaining portions of the cutting head 306 are designated with reference numerals increased by a hundred and the description is the same as in the first embodiment since these elements are the same. The difference in the head 306 in the egress area 328 and clearance surface 326 is due to a reduced amount of material present in the double helix design than is present iri the single helix design. Otherwise, the angle parameters previously described are the same with the double helix design as they are with the single helix design.
Turning to Figures 23 through 27, the cutting tools of the present invention are illustrated in concrete, aggregate or the like material, boring a hole. When the terms concrete, aggregate or the like material are used, the cutting tools may be used to bore, but are not limited to, cap block, brick, stone, ceramic materials, concrete, aggregate, black top, rock, cement, masonry or the like materials. In drilling a hole using rotary only motion, the bit of the present invention contacts the concrete, aggregate or the like material. The cutting tool may be rotated only where the rake face of the cutting tool cuts and bores a ho 1 ~ into the material . Flternativel zr, the cutting tool contacts the concrete, aggregate or the like material and impacts or chisels the material to form a hole. Further, the cuttincr tool ma..~ contact the material and impact~.n~ and rotati ng movement utilized together to bore G i~:oie as seen in Figure 27.
Generally, the impactinc is seaue:ntiGl and repetit,~.ous so that a constant repeating force is applied onto the cutting tool.
Also, when the cutting tool is purely rotational, a constant force may be applied to the driver.
Figures 31 through 37 illustrate a double helix embodiment of the present invention. Cutting tool 500 includes a chuck end 504 which is a rotary or percussive type of cutting tool end.
Also, the helixes 507 and 509 and the flutes 510 and 512 are like those previously described with respect to Figures 17 through 21.
The helixes 510 and 512 end at the cutting head 506, thus enabling the debris recesses 514 and 516 to include a larger volume of debris.
The cutting head 506 includes an insert 518 which includes cutting edges 520, rake faces 524 and clearance faces 526.
Likewise, egress faces 528 are immediately adjacent the rake face 524.
The insert 518 has an overall pentagonal shape of a house with the cutting edge 520 defining the roof, sides 530 and 532, and a base 534, which is substantially perpendicular to the two parallel sides 530 and 532. Also the cutting edges 520 could be along a straight line to provide a rectangular insert as seen in Figures 29 and 30.
The insert 518 is braised, welded or the like into the slot 522 on the cutting head 506. The insert 518 is generally manufactured from a carbide material such as a cobalt carbide mixture however, ceramic, ceramic composites, dia:;;ond dust, metal ceramic composites or a unitar~~ homogeneous or a deposit of layers could be used.
Cutting edges 520 are defined by ra~:e paces ~2~.~ , edge radii 5~0 and cleazance faces 526. The cutting edae~ 520 include a primary cutting edge 536 and a secondary cutting edge 538. The primary cutting edge 536 is on an acute angle with respect to a longitudinal axis 542, while the secondary cutting edge 538 is substantially perpendicular to the longitudinal axis 542. The cutting edges 520 include edge radius 540 between the rake faces 524 and clearance faces 526 as seen in Figure 36.
The edge radius 540 defines a sharpness of the cutting tool.
An edge radius 540 of the present invention is between 0.0015 to 0.004 and preferably between 0.002 to 0.003. Having a desired edge radius 540 provides a desired sharpness to enable the cutting tool to cut through the concrete, aggregate or the like material during rotation of the cutting tool. The edge radius as mentioned above is formed during the powder pressing operation.
The included angle between the two cutting edges is like those previously described. Also, the rake face angle a is between 10° and 0° preferably at about 5°. However, these angles are formed during the pressing operation. Also, the angles of the primary and secondary cutting edge are similar to those described above. The clearance angle CA as well as the cutting angle i~ are the same as those described above.
In this embodiment, a first egress surface is eliminated and an egress area 528 is defined b}' an egress angle ~ c~.hich is measured as mentioned above. The egress area 528 is adjacent to the rake face 524 . The anctle is betu;een 80 ° Gnd 100 ° and is preferably about 90°
For a better understanding of m:~ldi: _ th= ,insert, refer to Figure 38 through 41.

a The insert 518 is illustrated with a clearance face 526, rake faces 524 and a trailing face 525. The land 533 is formed between the clearance face 524 and the trailing face 525. The width (X) of the rake face 524, at the bottom of the insert, along the base 534 is wider than the width (Y) of the trailing face 525 such that an angle B is formed along the land 533 with respect to the central axis 559. The line extending from the land 533 is on an angle which is counter clockwise away from the central axis. This angle enables the insert to be removed from the mold.
Turning to Figure 39, a mold and punch is illustrated. A
V-shaped punch 560 forms the roof of the insert 518 and an ejector pin 562, in the mold 564, ejects the insert after it has been molded. Powdered metal is poured into the mold 564 and the punch 560 is inserted compressing the powder metal within the mold 564. Upon compressing the powdered metal, as seen in Figure 40, at the bottom of the mold 564, the portion 568 of the mold 564 forming the rake face 524 extends inward from the portion 570 of the mold 564 that forms the trailing face 525. At the top of the mold 564, the width of the molds are substantially the same as seen in Figure 41. Thus, when the insert 518 is ejected from the mold 564, since the bottom portion of the rake face 524 is in an area as it exits the mold which i s a:ider than the rake face base portion of the insert 518, the insert 518 is easily ejected i I. from the mold 564. However, if the angle B was clocl~:u:ise ~nith respect to the central axis 559, the land ~~:ould ba formed in the opposite direction anti the insert caould be jGmmed ~~:ithin the mold since the bottom of the insert ~~:oulci be :~:id~r than, tt-:a ~~idth of the too ef the mold.

r By having the punch 560 move axially with respect to the insert, the desired rake faces 524 and clearance faces 526 as well as the edge radii 540 are formed on the insert 518. The above identified insert 518 forming is contrary to conventional molding of positive rake carbide inserts, which moves a punch laterally or perpendicular to the axis of the insert, to form the insert.
To manufacture a cutting tool in accordance, with the invention, ordinarily the tool would be made in methods consistent with those in the art. To provide a tip with surfaces like those disclosed, ordinarily the rake surfaces, egress surfaces and clearance surfaces would be ground or formed by other conventional means into the cutting tool to form the desired surfaces with desired angles.
While the above detailed description describes the preferred embodiment of the present invention, the invention is susceptible to modification, variation, and alteration without deviating from the scope and fair meaning of the subjoined claims.

Claims (5)

1. A method of forming an insert comprising:
providing a mold with an insert cavity defining a longitudinal axis and having an opening along the longitudinal axis;
adding powder material into the mold;
compressing the material in the direction of the longitudinal axis;
forming the insert with a positive rake face.

2. The method of forming an insert according to claim 1 further comprising a V-shaped punch compressing said powder material.

3. The method of forming an insert according to claim 1 and forming a land on a face of said insert, said land being at an acute angle and counter clockwise with respect to an axis of the insert.

4. The method of forming an insert according to claim 1, wherein said insert has a desired rake face, clearance face and edge radius.

5. The method of forming an insert according to claim 1 and ejecting the insert from the mold.