JP2008509822A - Indexable cutting insert and method for manufacturing the same - Google Patents

Abstract

  A method for manufacturing a cutting insert includes the steps of: (i) forming a blank having a substrate having four or more pockets and a super-hard material disposed in the pocket; and (ii) along a cutting line. Removing a cutting tip from the blank by cutting the blank; (iii) providing a cutting insert body having a plurality of cavities for receiving a corresponding number of cutting tips; (iv) a plurality of cavities Inserting a cutting tip into each of the above, and (v) brazing the cutting tip to the cutting insert body. The related cutting insert includes a cutting insert body having a plurality of cavities formed therein, and a plurality of cutting tips, each of the plurality of cutting tips being disposed in the respective cavity, and the cutting tips are disposed in the cutting insert body. Having a shape that provides mechanical retention or locking when inserted into the cavity, the shape including a generally trapezoidal anchor portion, the base of the anchor portion being substantially flat and spaced from the cutting edge of the body A plurality of cutting tips, wherein the cutting tips are further brazed to the cutting insert body.

Description

  The present invention relates to a cutting insert having a cutting edge formed from an ultra-hard abrasive material and a method for manufacturing the cutting insert.

Description of Related Applications This application is a continuation-in-part of US patent application Ser. No. 10 / 918,391 (Lawyer Docket No. 024445-308) filed on August 16, 2004.

  While the description of the background art refers to particular structures and methods, such references acknowledge that these structures and methods are considered prior art under applicable legal provisions. It should not necessarily be interpreted as a thing. Applicants reserve the right to explain that none of the cited subject matter constitutes prior art with respect to the present invention.

  Indexable cutting inserts typically have a polygon in which an ultra-hard material is generally located at the corner. Superhard materials, often cubic boron nitride or polycrystalline diamond, are useful for cutting hard workpieces such as metals. These cutting inserts are typically mounted in a fixed position on the cutting tool so as to provide one of the corners or areas containing the superhard material on the surface of the workpiece. After a certain period of use, the area of superhard material wears. The cutting insert can then be removed from the cutting tool and rotated to provide a new unused corner or area of superhard material on the surface of the workpiece.

  There are two main ways to make such an insert. According to one method, a stack structure is formed comprising a first layer of hard substrate and a layer of ultra-hard cutting material superimposed on this layer. Next, the cutting tip is cut from this stack structure and brazed to the cutting insert body, typically at the corner. US Pat. No. 5,183,362 to Kuroyama et al., The entire disclosure of which is incorporated herein by reference, describes such techniques.

  However, there are several problems associated with such techniques. The braze joint that connects the cutting tip to the body of the cutting insert results in an inherently weak portion in the structure. In particular, this is due to the high temperatures that tend to occur during the use of such cutting inserts, which are close to the brazed joint. Another problem posed by such techniques is that the range of superhard materials provided to the workpiece and effective for wear is limited, thus limiting the effective use period of special cutting edges. It is.

  A second technique for forming indexable cutting inserts provides a blank or substrate in which superhard material is placed and pockets are formed, and then a sintering process that bonds the superhard material to the substrate. Is applied to the blank. Next, the blank is substantially machined to give the cutting insert a final shape, i.e. a generally polygonal body in which the superhard material is placed in the corners of the blank. US Pat. No. 5,676,496, the entire disclosure of which is incorporated herein by reference, describes such techniques.

  Such technology also raises certain difficulties. The process by which ultra-hard material is bonded to a blank or substrate is difficult and expensive. In this regard, the costs of superhard materials and substrates are relatively low compared to the costs associated with the process cycles required to join them. Therefore, from a manufacturing efficiency point of view, it would be desirable to form an indexable insert with many corners containing ultra-hard material. In this way, the number of expensive joining process cycles can be reduced while producing an insert having a large number of cutting corners. However, while users of such cutting inserts may be eager for cutting inserts having relatively few cutting corners, the cost-based manufacturing costs of cutting inserts using this technology are higher. Most cutting inserts on the market have 2 to 4 cutting corners.

  Another disadvantage associated with this second technique is that if one pocket of super hard material is defective, the entire insert cannot be sold and must be scrapped. Furthermore, another disadvantage or inefficiency is that a single cutting insert is manufactured from an expensive and difficult process cycle, even if it is a single cutting insert.

  French Patent Publication No. 2,691,657 discloses a cutting insert made with a special auto-centering shape made from polycrystalline diamond, CBN or other cutting material. The insert is clamped in the tip by a spring without brazing.

  French Patent Publication No. 2,706,339 discloses an insert of similar material (including fixing protrusions) so that the insert can be fixed in the corresponding hole of the chip by mechanical indentation without brazing. is doing. Therefore, there is a need in the related art to address the above-mentioned problems and other problems.

  The present invention provides an apparatus and method that addresses the above and other problems.

  The present invention provides an improved indexable cutting insert and an improved method of manufacturing the cutting insert.

  According to one aspect, the invention comprises (i) forming a blank having a substrate having four or more pockets and a super-hard material disposed in the pockets, and (ii) along a cutting line. Removing a cutting tip from the blank by cutting the blank, (iii) providing a cutting insert body having a plurality of cavities for receiving a corresponding number of cutting tips; (iv) a plurality of A method of manufacturing a cutting insert is provided that includes inserting a cutting tip into each of the cavities; and (v) brazing the cutting tip to a cutting insert body.

  According to another aspect, the present invention provides a cutting insert body having a plurality of cavities formed therein, and a plurality of cutting tips, each of the plurality of cutting tips being disposed in the respective cavities, Has a shape that provides mechanical retention or locking when inserted into the cavity of the cutting insert body, the shape including a substantially trapezoidal anchor portion, the base of the anchor portion being substantially flat and the body A cutting insert is provided that includes a plurality of cutting tips that are spaced apart from the cutting edge and that further comprises a brazed joint between each of the cutting tips and the cutting insert body.

  Exemplary apparatus and techniques according to the present invention will be described with reference to the drawings.

  According to the invention, the blank is formed from a hard material and an ultra-hard cutting material. The blank has several pockets for receiving a super hard cutting material and a super hard cutting material therein. An exemplary embodiment of such a blank is shown in FIG. As shown in FIG. 1, the blank 10 includes a hard material base 12 having a plurality of pockets 14. Although the blank 10 is shown as having a disk-like shape, other shapes such as polygons are clearly possible. It is also possible to form a through hole in the blank 10 that facilitates handling. Similarly, the pockets 14 can have a different size, location, distribution, and number than the illustrated embodiment. For example, the pocket 14 is shown as having a curved or arched shape. However, other shapes such as oval or polygon are clearly conceivable.

  In the illustrated embodiment, eight pockets 14 are provided in the substrate 12. Other numbers are obviously possible. As previously mentioned, it is an advantage of the present invention to form a blank 10 having as many pockets 14 as possible to receive a super hard cutting material. Thus, according to one embodiment, the substrate has four or more pockets. According to another embodiment, the substrate has at least six pockets. According to another embodiment, the substrate has at least 8 pockets.

  On the other hand, in the illustrated embodiment, an even number of pockets distributed symmetrically are shown. It is within the scope of the present invention to provide an odd number of pockets such as 7 or 9. Similarly, it is conceivable to arrange the pockets in a non-symmetric pattern.

  The substrate 12 is formed from any suitable hard material. Examples of suitable materials include sintered carbides, cermets, and hard alloys. One suitable composition is a sintered carbide of WC—Co having 10-20 wt% Co, preferably 15-17 wt% Co.

  As shown in FIG. 2, superhard material 16 is provided in one or more, preferably all, of the pockets 14. The ultra-hard material can include any suitable material selected for cutting characteristics. The superhard material 16 can initially be provided in powder form. Alternatively, the superhard material 16 can be a pre-sintered body.

  The ultra-hard material can include boron nitride such as cubic boron nitride (CBN) or diamond material such as polycrystalline diamond (PCD). The CBN or PCD may have other material additives such as carbides, nitrides, carbonitrides, oxides and / or borides of metals selected from groups IVa-VIa of the periodic table. . The superhard material 16 is composed of CBN or PCD particles forming the first phase and at least a second phase of a semiconductor (eg, Si), metal (eg, Cu, Ti, Al), metalloid, or an alloy thereof. It can be in the form of an object.

  After the super hard material 16 is placed in the pocket 14, the blank 10 is subjected to an appropriate treatment to integrate the super hard material 16 and the base material 12. The process can include a sintering process performed at high temperatures and pressures. When the ultra-hard material is initially in a soft powder state, a pressing step can be performed before or during the sintering process, for example, as described in US Pat. No. 5,676,496. Examples of suitable processes are described, for example, in US Pat. Nos. 4,991,467 and 5,115,697, the entire disclosure of which is incorporated herein by reference.

  The super-hard material 16 preferably extends continuously from the top surface of the blank 10 (visible in FIGS. 1 and 2) to the bottom surface opposite the top surface of the blank 10 (not visible in FIGS. 1 and 2). Attached to the edge surface of the substrate 12 defined by 14.

  After the above steps of integrating the superhard material 16 into the substrate 12, the material is cut or otherwise removed from the blank. For example, the blank 10 can be cut along a cutting line 18 that defines the contour of the cutting tip 20 there.

  The cutting tip 20 can be removed by any suitable cutting or material removal / separation procedure. Previous such methods are wire cuts such as EDM wire cuts.

  When placed in the body of an indexable cutting insert, the cutting tip is imparted with a shape that provides particularly effective mechanical retention or locking. Mechanical retention or locking provides a degree of stability to the insert in the tip. However, as explained in more detail, much greater stability is provided when the insert is brazed into the body as well. According to the illustrated embodiment, the cutting tip 20 removed from the blank 10 includes a rear portion 21 that is generally shaped as a trapezoid, the base 29 of which is substantially flat and spaced from what will be the cutting edge of the insert. is doing. This shape at the rear of the cutting tip provides a substantial anchor for the cutting tip of the cutting insert.

  A particular exemplary embodiment of this type of cutting tip shape understood by the present invention is shown in FIG. The shape or shape of the cutting tip 20 illustrated in FIG. 3 can be described as follows. A pair of converging front faces 22a and 22b meet at a preferably round front nose 24. The front nose 24 is provided to the workpiece during use of the cutting tip. As shown in FIG. 3, the portions of the surfaces 22 a and 22 b and the nose 24 include the superhard cutting material 16. The range of superhard cutting material 16 that extends rearwardly from the apex of nose 24 and along surfaces 22a and 22b corresponds to dimension "L" and can be referred to as leg length. According to one embodiment of the invention, the dimension L is at least 2 mm. According to other embodiments, the dimension L can be at least 3 mm.

  As it moves away from the front nose 24, a reduced width region or waist 25 follows the converging surfaces 22a and 22b. The waist is defined by a first pair of inclined surfaces 26a and 26b and a second set of surfaces 28a and 28b. Surfaces 26a and 28a and surfaces 26b and 28b meet in a reduced width region to define a trough-like shape. As will be described in more detail below, surfaces 28a and 28b can be the same or different lengths. The cutting tip also includes a substantially flat rear surface 29.

  The particular design of the rear portion, i.e. the substantially trapezoidal shape with a substantially flat rear surface 29 opposite the cutting edge, provides a solid anchor for the cutting insert in the chip.

  FIG. 4 shows three different cutting tip structures 20a, 20b and 20c. The structure of these cutting tips differs with respect to the amount of ultra-hard material contained therein and thus the leg length (L). Otherwise, the shape, in particular each rear part, is the same as in FIG. The amount of superhard material contained in the cutting tip 20 can vary depending on the location of the cutting line 18 (FIG. 2) and the size, structure and / or depth of the pocket 14 of the blank 10. As shown in FIG. 4, the cutting tip 20c can be configured to be entirely formed from a superhard cutting material, or the cutting tip 20a can be configured to have a relatively small component of the superhard material.

  The above-mentioned cutting tip of the present invention is fixed to the main body of the cutting insert. An exemplary embodiment of a suitable cutting insert body is shown in FIG. The illustrated cutting insert body 30 comprises a rigid material body 32 provided with a suitable number of cavities 34, 35 for receiving the cutting tips 20. The cavities 34, 35 are preferably given a shape or shape that is complementary to the shape or shape of the cutting tip disposed therein.

  The body 32 is made of any suitable hard material. Examples of suitable materials include sintered carbides, cermets, and hard alloys. One suitable composition is a sintered carbide of WC—Co having 10-20 wt% Co, preferably 15-17 wt% Co.

  Many variations of the illustrated embodiment are possible. For example, the illustrated blank 30 is generally polygonal or diamond shaped and configured to receive two identical cutting tips. However, the shape of the body can be other polygonal shapes, oval or circular. The central through-hole 36 that can be used for a special kind of attachment can be omitted. The body 30 can be configured to receive more than two chips. For example, a maximum of four chips can be provided at each corner. The chips arranged on the main body 30 do not have to be the same. The cutting tip and / or body 30 can be machined prior to and / or subsequent to attachment of the cutting tip. The cutting insert body 30 and / or one or more cutting tips 20 can be provided with one or more coatings. Further, the body 30 may be provided with a “chip breaker” structure as described in US Pat. No. 5,569,000, the entire disclosure of which is incorporated herein by reference.

  FIG. 6 is an exemplary indexable cutting insert 60 comprising a body having a cutting tip 20 held by a cutting insert body 32. The cutting tip 20 can be secured to the body 32 by any suitable technique. Suitable techniques include soldering or brazing. One such technique is described in US Pat. No. 5,183,362, the entire disclosure of which is incorporated herein by reference. In the illustrated embodiment, the cutting tip is secured to the body 32 by a braze joint 40.

  FIG. 7 is another embodiment of an indexable cutting insert 70 formed in accordance with the principles of the present invention. The cutting insert 70 has a cutting tip 20c configured as described in connection with FIG.

  FIG. 8 is an image comparing a cutting insert 300 formed in accordance with the present invention and a cutting insert 1000 formed as conventional. As shown in FIG. 8, the leg length of the superhard material of the cutting insert 300 of the present invention is considerably longer than the leg length of the superhard material of the conventional cutting insert, which may extend the tool life of the cutting tip. I will provide a.

  FIG. 9A is an embodiment of the present invention of a threaded insert that can be used in a turning process. In this case, the cutting tip 20A is formed and inserted so as to be positioned asymmetrically with respect to the bisector AA of the corner of the insert. For example, in the embodiment of FIGS. 6 and 7, each cutting tip is arranged symmetrically with respect to the bisector of the cutting edge of the insert.

  FIG. 9B is an embodiment of the present invention of a thread milling insert. In this case, the cutting tips are arranged symmetrically along the cutting edge. Similarly, in this case, the cutting tip can be formed from a generally trapezoidal shape with a flat rear face away from the cutting edge, with two anchor portions 21 to provide even greater locking and retention. . Only one such anchor portion 21 is shown in FIG. 9A and is generally required.

  FIG. 10A is another embodiment of the threaded insert of the present invention. Again, it can be seen that the cutting tip is asymmetric with respect to the bisector of the corner of the cutting insert. FIG. 10B shows a similar insert, where each of the substantially flat rear surfaces 29 is a different length. The inclined surfaces 28a and 28b of each cutting tip may be the same or different from each other and may be the same or different from corresponding portions of other cutting tips.

  11A to 11E show another embodiment of the cutting insert of the present invention. FIG. 11A is a substantially square (but can be rectangular) cutting insert, where the cutting tips are asymmetrically arranged with respect to the bisector of the corner of the cutting insert. 11B and 11D are inserts molded into a similar triangle, and the cutting tips are arranged symmetrically (FIG. 11B) and asymmetrically (FIG. 11D) with respect to the bisector of the corner of the insert. . FIGS. 11C and 11E are similar parting-off tools that again have cutting tips arranged symmetrically and asymmetrically with respect to the bisector through the cutting edge.

  FIG. 12 shows another embodiment of the present invention. In this case, the cutting tip 52 is placed on a drill generally indicated as 50. As shown in FIG. 12A, the drill may have a single cutting tip, while the drill shown in FIG. 12B has a cutting tip 52 located on either side of the central axis of the drill. . Although not shown, the drill can have flutes and is otherwise conventional. In FIG. 12A, the cutting tips are arranged substantially parallel to the center axis of the drill, while in FIG. 12B, the cutting tips are arranged substantially perpendicular to the axis.

  FIG. 13 shows a side cross-sectional view of the drill of the present invention. For example, FIG. 13A is a drawing viewed at 90 ° from the left of FIG. 12A. 13B and 13C are also different drawings of the embodiment of FIG. 12B.

  FIG. 14 illustrates another embodiment of the present invention, where the surfaces 28a 'and 28b' are of different lengths and are therefore asymmetric. In this particular embodiment, the insert can be used as a boring bar or for internal turning of a piece.

  FIG. 15A is a side view of the insert of the present invention similar to FIG. 11C, where the insert is used, for example, as a parting-off tool. The insert is held in a cavity generally designated as 60, the shape of which corresponds to the anchor portion of the insert in the holder body 62.

  The present invention and its above-described embodiments provide many advantages over conventional cutting inserts and methods of making them.

  By forming a blank with a relatively large number of pockets of ultra-hard material, a relatively large number of cutting tips can be produced with each expensive and difficult press / sintering process cycle, thereby reducing economics. Provides advantages in terms of perspective. By removing the chips from the blank and securing them to the body of the cutting insert, each cutting insert can have a smaller number of chips than the number removed from the blank. Thus, a cutting insert having a relatively small number of cutting tips, for example 2 to 4 tips, can be manufactured to meet market demand but retain the advantages of economic production. The manufacturing cost of these indexable cutting inserts according to the manufacturing method of the present invention may be on the order of 50-60% lower than the manufacturing cost of the insert according to the second technique described in the background art of the present specification. it can.

  The technique of the present invention also provides the advantage of increased yield when compared to a technique such as the second technique described in the background of the present invention. When utilizing the technique of the present invention, one defective superhard material pocket may result in the scraping of one cutting tip. In comparison, one defective superhard material pocket in the second prior art can result in scraping of the entire cutting insert.

  In accordance with the present invention, the cutting tip is provided with a shape that securely places the tip within the body of the cutting insert during assembly, and thus the need for a complex fixture to hold the insert in place during brazing. Disappears. Furthermore, the shape of the cutting tip allows mechanical retention within the body of the cutting insert in addition to the retention provided by brazing.

  Cutting tips formed in accordance with the principles of the present invention facilitate the formation of cutting tips having leg lengths that are greater than leg lengths (e.g., 2-3 mm or more) that ultra-hard materials can be readily achieved by conventional techniques. The increase in leg length provides more superhard material available for machining the workpiece, thereby extending the useful life of the cutting tip. Furthermore, the superhard material of the cutting tip of the present invention extends from the top surface to the bottom surface of the cutting tip, thereby providing a first cutting edge surface on the top surface and a bottom surface of the cutting tip that can be accessed by turning the cutting insert upside down. A second cutting edge surface is provided.

  Additional advantages will be apparent to those skilled in the art. The described embodiments of the invention are intended to be illustrative rather than restrictive, and are not intended to represent every possible embodiment of the invention. Various modifications may be made to the disclosed embodiments without departing from the spirit and scope of the invention as defined by the following claims, literally and with equivalents recognized by law.

1 is a plan view of a blank or preform constructed in accordance with the principles of the present invention. FIG. 2 is a plan view of the blank of FIG. 1, where the blank pocket is filled with a super-hard material and a cutting line is shown for removing a plurality of cutting tips from the pocket. It is the top view which showed the detail of the shape of the cutting tip formed according to the principle of this invention. 2 is a plan view of various cutting tips formed in accordance with the principles of the present invention. FIG. It is a top view of the cutting insert main body formed according to this invention. 1 is a plan view of an indexable cutting insert formed in accordance with the present invention. FIG. FIG. 6 is a plan view of another form of indexable cutting insert formed in accordance with the present invention. It is the image which compared the cutting insert formed according to this invention with the conventional cutting insert. 1 is a plan view of a threaded insert formed in accordance with the present invention. FIG. 1 is a plan view of a screw milling insert formed in accordance with the present invention. FIG. FIG. 6 is a plan view of another type of threaded insert formed in accordance with the present invention. FIG. 6 is a plan view of another type of threaded insert formed in accordance with the present invention. FIG. 6 is a plan view of another insert formed in accordance with the present invention. FIG. 6 is a plan view of another insert formed in accordance with the present invention. FIG. 6 is a plan view of another insert formed in accordance with the present invention. FIG. 6 is a plan view of another insert formed in accordance with the present invention. FIG. 6 is a plan view of another insert formed in accordance with the present invention. 1 is a side sectional view and a plan view of a drill formed in accordance with the present invention. 1 is a side sectional view and a plan view of a drill formed in accordance with the present invention. 1 is a cross-sectional side view of a drill structure formed in accordance with the present invention. 1 is a cross-sectional side view of a drill structure formed in accordance with the present invention. 1 is a cross-sectional side view of a drill structure formed in accordance with the present invention. FIG. 2 is an illustration of an insert that can be used for internal turning formed in accordance with the present invention. 1 is a side view and plan view of a grooving tool formed in accordance with the present invention. FIG. 1 is a side view and plan view of a boring tool formed in accordance with the present invention. FIG.

Claims (70)

A method of manufacturing a cutting insert comprising:
(I) forming a blank having a substrate having four or more pockets and an ultra-hard material disposed in the pockets;
(Ii) removing a cutting tip from the blank by cutting the blank;
(Iii) providing a cutting insert body having a plurality of cavities for receiving a corresponding number of cutting tips;
(Iv) inserting a cutting tip into each of the plurality of cavities;
(V) brazing the cutting tip to the cutting insert body;
Including methods.   The method of claim 1, wherein the cutting insert is indexable.   The method of claim 1, wherein the blank is substantially disk-shaped.   The method of claim 1, wherein the blank has a polygonal shape.   The method of claim 1, wherein the blank is provided with a through hole.   The method of claim 1, wherein the pocket has an arch shape.   The method of claim 1, wherein the substrate is provided with at least six pockets.   The method of claim 1, wherein the substrate is provided with at least seven pockets.   The method of claim 1, wherein the substrate is provided with at least eight pockets.   The method of claim 1, wherein the substrate is provided with at least nine pockets.   The method of claim 1, wherein the substrate is formed from sintered carbide, cermet, or hard alloy.   The method of claim 11, wherein the substrate is formed from a sintered carbide comprising WC and Co, the sintered carbide comprising 10-20 wt% Co.   The method of claim 1, wherein step (i) further comprises introducing the superhard material in powder form into a pocket.   The method of claim 13, wherein step (i) further comprises pressing and sintering the blank, thereby integrating the substrate and the ultra-hard material.   The method of claim 13, wherein step (i) further comprises introducing the ultrahard material in the form of a pre-sintered body into the pocket.   The method of claim 15, wherein step (i) further comprises sintering the blank, thereby integrating the substrate and the ultra-hard material.   The method of claim 1, wherein the ultra-hard material comprises cubic boron nitride or polycrystalline diamond.   18. The method of claim 17, wherein the ultra-hard material further comprises at least one of a nitride, a carbonitride, a metal oxide or boride selected from groups IVa-VIa of the periodic table.   18. The superhard material comprises a composition having a first phase comprising cubic boron nitride or polycrystalline diamond particles and a second phase comprising a metal, metalloid, or alloy thereof. the method of.   The method of claim 1, wherein the blank comprises a top surface and an opposite bottom surface, and the superhard material extends from the top surface to the bottom surface.   The method of claim 1, wherein step (ii) comprises a wire cutting step to remove the cutting tip from the blank.   Step (ii) includes providing the cutting tip having a shape that provides mechanical retention or locking when the cutting tip is inserted into the body of the cutting insert, wherein the shape of the anchor portion is substantially trapezoidal. The method of claim 1, wherein the base of the anchor portion is substantially flat and spaced from the cutting edge of the body.   The method of claim 1, wherein the cutting tip is provided with a generally dovetail shape.   24. The method of claim 23, wherein the cutting tip is provided with a round front nose and a pair of converging front surfaces that meet at the nose.   25. The method of claim 24, wherein at least the round forward nose portion of the cutting tip comprises the ultra-hard material.   The ultra-hard material is provided with a leg length of at least 2 mm, the leg length being a first point on one of the converging front faces where the hard material is connected to the substrate material and before the converging. 26. The method of claim 25, defined as a distance between a second point defined by an intersection between two imaginary lines drawn along each of the directions.   27. The method of claim 26, wherein the leg length is at least 3 mm.   25. The method according to claim 24, wherein the cutting tip is provided with a reduced waist.   29. The method of claim 28, wherein the waist comprises a first pair of inclined surfaces and a second pair of surfaces that meet at a reduced width portion.   30. The method of claim 29, wherein the length of one surface of the second pair of surfaces is different from the other surface of the surface.   The method of claim 1, wherein the cutting insert body is formed from sintered carbide, cermet, or hard alloy.   32. The method of claim 31, wherein the cutting insert body is formed from sintered carbide comprising WC and Co, the sintered carbide comprising 10-20 wt% Co.   The method according to claim 1, wherein the cutting insert body is defined by a polygon, an ellipse, or a circle.   The method of claim 1, wherein the cutting insert is defined by a polygonal shape.   The method of claim 1, wherein a shape complementary to the shape of the cutting tip received in the cavity is imparted to the cavity.   The method of claim 1, further comprising applying at least one coating to at least a portion of the cutting tip and / or the cutting insert body.   The method of claim 1, further comprising forming a chip breaker structure in the cutting insert body.   The method of claim 1, comprising forming the cutting insert body into a polygonal shape and providing no more than two cavities in the cutting insert body.   The method of claim 1, comprising forming the cutting insert body into a polygonal shape and providing no more than four cavities in the cutting insert body. A cutting insert,
A cutting insert body having a plurality of cavities formed therein;
A plurality of cutting tips, each of the plurality of cutting tips being disposed in a respective cavity, providing mechanical retention or locking when the cutting tip is inserted into the cavity of the cutting insert body. Having a shape, the shape including a substantially trapezoidal anchor portion, the base of the anchor portion being substantially flat and spaced from the cutting edge of the body, and the shape being each of the cutting tips and the cutting insert body A plurality of cutting tips further comprising a brazed joint between
A cutting insert comprising:   41. The cutting insert according to claim 40, wherein each of the cutting tips comprises at least partially a superhard material.   42. The cutting insert according to claim 41, wherein each of the cutting tips is manufactured entirely from a super-hard cutting material.   42. The cutting insert according to claim 41, wherein the ultra-hard material comprises cubic boron nitride or polycrystalline diamond.   44. The cutting insert according to claim 43, wherein the ultra-hard material further comprises at least one of nitride, carbonitride, metal oxide or boride selected from groups IVa-VIa of the periodic table. .   41. The superhard material comprises a composition having a first phase comprising cubic boron nitride or polycrystalline diamond particles and a second phase comprising a metal, metalloid, or alloy thereof. Cutting inserts.   41. The cutting tip of claim 40, wherein the cutting tip comprises a top surface and an opposite bottom surface, and the superhard material extends from the top surface to the bottom surface, thereby defining two cutting edges. Cutting insert.   41. A cutting insert according to claim 40, wherein the cutting tip is substantially dovetail and has a splice shape.   48. The cutting insert according to claim 47, wherein the cutting tip comprises a round forward nose and a pair of converging front faces that meet at the nose.   49. A cutting insert according to claim 48, wherein at least the rounded forward nose portion of the cutting tip comprises the ultra-hard material.   The ultra-hard material is provided with a leg length of at least 2 mm, the leg length being a first point on one of the converging front faces where the hard material is connected to the substrate material and before the converging. 50. A cutting insert according to claim 49, defined as a distance between a second point defined by an intersection between two imaginary lines drawn along each of the directions.   41. The cutting insert according to claim 40, wherein the leg length is at least 3 mm.   49. The cutting insert according to claim 48, wherein the cutting tip is provided with a reduced waist.   53. The cutting insert according to claim 52, wherein the waist portion comprises a first pair of inclined surfaces and a second pair of surfaces that meet at a reduced width portion.   52. The cutting insert according to claim 51, wherein the length of one surface of the second pair of surfaces is different from the other surface of the surfaces.   41. A cutting insert according to claim 40, wherein each base of the cutting tip has a length different from the length of the other base of the cutting tip.   41. The cutting insert according to claim 40, wherein the cutting insert body is formed from sintered carbide, cermet, or hard alloy.   57. The cutting insert according to claim 56, wherein the cutting insert body is formed from a sintered carbide comprising WC and Co, the sintered carbide comprising 10-20 wt% Co.   The cutting insert according to claim 40, wherein the cutting insert body has a polygonal shape, an oval shape, or a circular shape.   59. The cutting insert according to claim 58, wherein the cutting insert body has a polygonal shape.   41. The cutting insert according to claim 40, wherein the cavity has a shape that is complementary to the shape of the cutting tip.   41. The cutting insert according to claim 40, wherein at least one of the cutting tip and the cutting insert body has a coating disposed on at least a portion of the at least one.   41. The cutting insert according to claim 40, wherein the cutting insert body comprises a chip breaker structure.   41. A cutting insert according to claim 40, wherein the cutting insert comprises no more than two cutting tips.   41. The cutting insert according to claim 40, wherein the cutting insert comprises 4 or fewer cutting tips.   41. A cutting insert according to claim 40, wherein the cutting tips are symmetrically arranged around a bisector through a corner of the insert.   41. The cutting insert according to claim 40, wherein the cutting tip is disposed asymmetrically around a bisector through a corner of the insert.   41. The cutting insert according to claim 40, wherein the cutting insert is a turning insert.   41. The cutting insert according to claim 40, wherein the cutting insert is applied to a drill.   69. The cutting insert according to claim 68, wherein the cutting insert is disposed substantially parallel to a central axis of the drill.   69. The cutting insert according to claim 68, wherein the cutting insert is disposed substantially perpendicular to a center axis of the drill.

Images