WO2007075140A1

WO2007075140A1 - A ceramic cutting insert with a concave unground intermediate surface as well as a method for the manufacture of such cutting inserts .

Info

Publication number: WO2007075140A1
Application number: PCT/SE2006/050565
Authority: WO
Inventors: Per Blomstedt
Original assignee: Sandvik Intellectual Property Ab
Priority date: 2005-12-27
Filing date: 2006-12-11
Publication date: 2007-07-05
Also published as: US7837417B2; KR20080087800A; SE529421C2; CN101351288B; SE0502929L; US20070183858A1; JP5260309B2; EP1968762A4; KR101315598B1; JP2009521336A; EP1968762A1; CN101351288A

Abstract

The invention relates to a ceramic cutting insert of the type that comprises a face ground top surface (1) and at least one peripheral clearance surface (2) adjacent to an edge (3), from which a reinforcing, sloping chamfer surface (4a) extends inward, which forms an acute angle ( ) with a reference plane (P) parallel to the top surface (1). Between the top surface (1) and the chamfer surface (4a), an unground intermediate surface (7) is formed, which is narrower than the chamfer surface, and which in the transition thereof to the top surface forms a second angle (ß) with the same that is greater than the first- mentioned angle ( ). In a second aspect, the invention also relates to a method for the manufacture of such ceramic cutting inserts.

Description

A ceramic cutting insert with a concave unground intermediate surface as well as a method for the manufacture of such cutting inserts .

Technical Field of the Invention

In a first aspect, this invention relates to a ceramic cutting insert of the type that comprises a face ground, upper surface, and at least one 0 peripheral clearance surface adjacent to an edge from which a reinforcing chamfer surface extends inward, which forms an acute angle with a reference plane parallel to the top surface.

In a second aspect, the invention also relates to a method for the manufacture of such ceramic cutting inserts. 5

Prior Art

Within the modern technique of chip removing machining, tools having replaceable wear parts in the form of cutting inserts are mostly used, which are mounted in form-fitted seatings or insert seats in the different basic 0 bodies that are suitable for, e.g., milling, drilling and turning, respectively. Generally, the cutting inserts are manufactured from a material that is considerably harder and more wear-resistant than the material of the basic bodies, such as steel, aluminium and the like. For the applications and machining methods that through the years have been developed to efficiently 5 machine myriads of details of most varying materials, in particular metallic materials, there have been provided cutting inserts of a range of different materials that have their individual advantages and disadvantages for the various applications. A dominant material of the cutting inserts is cemented carbide, which is an overall denomination of such powder metallurgical products 0 that are built up from a number of hard carbides (wolfram carbide, titanium carbide, tantalum carbide, niobium carbide) in a binder metal (usually cobalt). Cutting inserts of cemented carbide have generally good properties in respect of hardness in combination with a certain toughness (imparted by the binder metal), which among other things means that the cutting inserts may fairly freely be constructed in a most varying geometrical shape.

However, for certain applications, cemented-carbide inserts are unsuitable, for instance, as a consequence of the limited hot hardness of the cemented carbide, i.e., the capability of the material to retain its hardness at high temperatures. During machining of certain types of metals, and under certain outer conditions, extreme quantities of heat are generated upon the chip removal, which tend to make cemented-carbide inserts less suitable for their purpose. However, in such cases, ceramic cutting inserts can often be used in a successful way. The ceramic material and the cemented carbide have, per se, certain common properties, but also differ from each other in several important respects. Thus, compared with cemented-carbide inserts, the ceramic cutting inserts have a considerably greater hardness and better hot hardness. Therefore, the ceramic cutting inserts usually have a long service life and can operate at extraordinary high temperatures, as well as with a very high cutting capacity. However, the ceramic cutting inserts are fairly brittle so far that the compression strength is considerably greater than the tensile strength. Furthermore, the ceramic cutting inserts are difficult to grind, in particular surfaces having irregular or complex shape. This limits the tool designer's latitude to decide the geometry of the cutting inserts. Therefore, ceramic cutting inserts have, without exception, a fairly simple basic shape, which mostly has planar and/or rotationally symmetrical surfaces.

As to the geometry of the chip-removing edge of ceramic cutting inserts, two main categories can be distinguished, VJz₁ chamfer-reinforced edges and rounded, so-called ER-edges (ER = Edge Radius), each one of which has its advantages and disadvantages. Rounded edges of the ER-type are found on cutting inserts, the edge of which is formed simply by the transition between a ground top surface and a ground clearance surface at an angle to the same, the edge being given the rounded shape thereof by a simple finishing, such as brushing. Such cutting inserts have, on one hand, the advantage of being comparatively easy-cutting, i.e., exposed only to moderate cutting forces, but on the other hand the disadvantage of being mechanically weak and thereby inclined to become damaged or break (and therefore have an unpredictable service life). The edge of chamfer-reinforced cutting inserts is provided by grinding a slender chamfer surface in the transition between the top surface and the clearance surface, which chamfer surface forms an angle with the top surface as well as the clearance surface. For reasons of grinding technique, this angle (which is defined as the angle between the chamfer surface and an imaginary plane in the extension of the top surface) is traditionally in the range of 15-30°. Most commonly, the angle amounts to 20°. In such a way, a mechanically comparatively strong edge is provided, the resultant of the cutting forces that act against the chamfer surface being directed inward/downward in the cutting insert. Generally, the edge becomes more easy-cutting the smaller the above-mentioned angles are. However, a disadvantage of chamfer-reinforced cutting inserts is that the cutting forces become great, i.e., the cutting insert becomes blunt-cutting.

The fact that the two edge types have so very different properties in the mentioned respects causes problems for the users, so far that it is difficult to predetermine which type of cutting inserts that should be chosen in order to give optimal results for a given machining operation. Therefore, there is a need for ceramic cutting inserts, the strength and robustness of which is better than of the ER-inserts, and the cutting performance of which simultaneously is better than of the chamfer-reinforced cutting inserts.

Objects and Features of the Invention

The present invention aims at providing for the above-mentioned needs and at providing a ceramic cutting insert that is more universally useful than previously known ceramic cutting inserts. Therefore, a primary object of the invention is to provide a ceramic cutting insert that combines the advantages of the ER-inserts and of the chamfer-reinforced cutting inserts, without, for that reason, having the disadvantages thereof to too high an extent. In other words, the edges of the cutting inserts should be both fairly strong and fairly easy-cutting. An additional object is to provide a ceramic cutting insert that can be made with more complex geometries than previously known ceramic cutting inserts. Another object is to provide a ceramic cutting insert that has a repeatable exterior even if it is made with geometrically irregular surfaces, so far that the border lines between the different surfaces of the cutting inserts always should become similar and situated at the same locations, irrespective of variations in the manufacture, in order to give a confident impression on the operator.

According to the invention, at least the primary object is attained by the features defined in the characterizing clause of claim 1. Preferred embodiments of the ceramic cutting insert according to the invention are furthermore defined in the dependent claims 2-6.

The invention relates furthermore to a method for the manufacture of ceramic cutting inserts. This method is defined in claims 7 and 8.

Further Elucidation of the Prior Art

US 4963061 discloses a ceramic cutting insert which is formed with a chamfer surface in the adjacency of a clearance surface as well as a subsiding chip-breaking surface, which extends the chamfer surface and a flat upper side of the cutting insert. In this case, however, the chamfer surface has a width which amounts to merely a fraction of the width of the chip-breaking surface, the chamfer surface serving solely as a narrow edge strengthening in the vicinity of a conventional chip breaker.

What is more, US 4963061 does not deal with the technical problem of providing distinct borderlines between a chamfer surface and an upper surface in connection with the grinding of the cutting insert and thereby providing a repeateble shape of the individual cutting inserts.

Brief Description of the Appended Drawings

In the drawings: Fig. 1 is a schematic illustration of an ER-edge of a ceramic cutting insert

(Prior Art) on an extremely enlarged scale, Fig. 2 is an analogous illustration of a chamfer-reinforced edge of a ceramic cutting insert (Prior Art),

Fig. 3 is a perspective view of a ceramic cutting insert according to the present invention,

Fig. 4 is a side view of the same ceramic cutting insert, Fig. 5 is a plan view from above of the ceramic cutting insert, Fig. 6 is an enlarged detailed section A-A in Fig. 5, and Fig. 7 is an enlarged detailed section B-B in Fig. 5. Before the invention is described more in detail, reference is made to Figs. 1 and 2, which schematically illustrate the design of known ceramic cutting inserts having ER-edges and chamfer-reinforced ceramic cutting inserts, respectively.

Thus, in Fig. 1 an ER-edge is illustrated, which is shown in section, as well as adjacent to a corner of a ceramic cutting insert. The cutting insert has a planar, ground top surface 1 , and a likewise ground clearance surface 2, which in this case is planar and oriented at an angle of 90° to the top surface. Between the surfaces 1 and 2, an edge 3 is provided in the form of a rounded surface of radius r. In practice, the radius r may be in the range of 40-60 Qn, the surface in question being provided e.g., by brushing the cutting insert after the grinding of the surfaces 1 , 2.

In Fig. 2, a chamfer-reinforced cutting insert is illustrated. Also in this case, the top surface 1 and the clearance surface 2 are face ground and generally oriented at an angle of 90° to each other. Adjacent to the edge line 3, a chamfer surface 4 is formed, by grinding, which transforms into the top surface 1 via a border line 5. An imaginary plane in the extension of the top surface 1 is designated P. As previously pointed out, the angle D between the chamfer surface 4 and the plane P usually amounts to 15-30°. In the example, the angle is D = 20°. The width W of the chamfer surface usually amounts to 0,25 mm. The forming of the chamfer surface 4 is carried out by a grinding operation, which is effected after the surfaces 1 , 2 having been ground.

Already here it should be pointed out that ceramic cutting inserts of the kind in question are manufactured by pressing and hardening a powdered, ceramic compound, which forms a blank the actual dimension of which is somewhat greater than the desired nominal dimension of the cutting insert. In other words, the blank is formed having a certain grinding allowance from all sides (in practice, approx. 0,1 mm).

Detailed Description of a Preferred Embodiment of the Invention

In Figs. 3-7, a ceramic cutting insert made in accordance with the invention is shown, which includes ground surfaces 1 , 2. In order to distinguish the surface 1 from the other surfaces of the cutting insert in terms of the level, the same is henceforth denominated "the top surface". In the example shown, the cutting insert is meant to be turnable or double-sided, and therefore not only the topside but also the underside of the cutting insert is formed in the form of ground surfaces, which alternately can serve as a support surface for the cutting insert. The surfaces 2 are peripheral and form clearance surfaces adjacent to chip-removing edges 3. In this case, the cutting insert includes four cutting edges 3 and consequently four clearance surfaces 2. Between the last- mentioned ones, there are also a number of facet surfaces and transition surfaces, which lack importance to the invention, and have therefore not been given any reference designations. Like the clearance surfaces 2, all other, peripheral surfaces of the cutting insert may be ground. The ceramic cutting insert in question may - but need not - be formed with a central hole 6 for a tightening screw.

In the example, the cutting insert has a negative basic geometry so far that the angle between the top surface and the individual clearance surface amounts to 90°. However, the cutting insert may also have a positive geometry, the angle in question being acute.

Now the attention is directed to Figs. 5-7, which in enlargement show the unique shape of the cutting insert adjacent to the individual cutting edge 3. From the edge 3, a reinforcing chamfer surface 4a extends inward toward the centre of the cutting insert, which chamfer surface inwardly is delimited by a border line 5a. In the example, this chamfer surface is planar, such as is shown in Figs. 6 and 7. However, in contrast to the conventional chamfer surface 4 shown in Fig. 2, the chamfer surface 4a and a reference plane P parallel to the top surface 1 form an angle D of only 3°. In other words, the chamfer surface 4a slopes in a considerably flatter or smaller angle than the traditional chamfer surface 4 according to Fig. 2.

Characteristic of the invention is furthermore that between the top surface 1 and the border line 5a of the chamfer surface 4a, an intermediate surface in its entirety designated 7 is formed, which transforms into the top surface 1 via a second, inner border line 8 that is situated on a higher level than the first-mentioned border line 5a. In the shown, preferred embodiment, the intermediate surface 7 includes two part surfaces, viz. a planar part surface 9, as well as a concavely arched part surface 10 in the form of a so-called radius transition, which is separated from the planar part surface 9 by a third border line 1 1. The last-mentioned part surface 9 forms an acute angle D with the reference plane P1 that extends in the extension of the top surface 1. The intermediate surface, which in its entirety is designated 7 and includes the part surfaces 9, 10, is generally concave, so far that the surface is in its entirety located inside/underneath any imaginary, straight line that extends between the border lines 5a and 8. Here, it should be pointed out that the intermediate surface 7 may be given varying shapes provided that the same is concave. For instance, the surface could be provided in the form of a single, concavely arched surface, i.e., without any planar part surface. The vital thing is that the surface in question, like the shown, planar part surface 9, forms an angle D that is considerably greater than the angle Q In the example, the angle β amounts to 40°, i.e., a relatively steep angle. In practice, the angle β should be at least five times as large as the angle D, and amount to at least 15° and at most 85°. Advantageously, the angle β may amount to at least 25° and at most 65°.

The angle D may as well deviate from the exemplified value of 3°. However, the angle D should, on one hand, not be below 2°, and on the other hand not exceed 5°. In this way, the desire of an improved strength of the edge portion, as well as the desire that the edge portion should be easy-cutting, are provided for (the strength increases with increasing D, while the cutting forces decrease with decreasing D).

While the top surface 1 and suitably also the clearance surface 2 are ground in accordance with standard manufacturing methods, at least the intermediate surface 7, and preferably also the chamfer surface 4a, are unground. In other words, the surfaces 4a, 7 in all essentials retain the original shape thereof, even if they are after-treated by brushing with the purpose of giving a shiny surface structure, as well as providing an edge rounding of the ER-type along the edge line 3. Thus, by the brushing, possible chips are removed that may remain after the grinding of the clearance surface 2, the used brush being sufficiently strong so as to provide a certain radius along the edge line. This radius may be as moderate as 20 μm and should not exceed 40 μm. However, in contrast to the grinding, the brushing does not effect any material- removal in the surface layer of the cutting insert other than in the vicinity of the edge line. In Figs. 6 and 7, WF designates the width of the chamfer surface 4a, while WM designates the width of the intermediate surface 7 (in projection). The width WM of the intermediate surface is smaller than the width WF of the chamfer surface 4a. For a 15 mm cutting insert (IC = 15 mm), the width WF of the chamfer surface may amount to 1 ,5 mm, while the width WM of the intermediate surface amounts to 0,8 mm. In doing so, the depth T (such as this is defined as the vertical distance between the edge 3 and the reference plane P1 ) may amount to approx. 0,7 mm. It should be noted that the width of the surfaces 4a, 7 successively decreases from the section A-A to the section B-B, without, for that reason, the relation between the width dimensions WF and WM radically being altered. On the other hand, the width of the part surface 9 in relation to the width of the part surface 10 is decreased, i.e. the width WF of the chamfer surface is greater than the width WM of the intermediate surface in arbitrary sections (A-A and B-B respectively) along the length extension of the surfaces.

The Manufacture of the Cutting Insert

The manufacture of the ceramic cutting insert according to the invention is carried out in the following way: In a first step, a powdered, ceramic compound is compression-moulded and hardened (sintered) into a blank. The pressing is carried out in a mould that generates two generally planar and parallel major faces, which later will form the surfaces 1 of the cutting insert. Furthermore, a peripheral clearance surface and a reinforcing chamfer surface adjacent to each cutting edge should be formed in the blank. Furthermore, an intermediate surface 7 of the type described above should be formed. When the blank has got the desired hardness, not only the side surfaces, but also each major face are ground while forming a completed, planar surface 1. Upon grinding, the grinding disc will break through the surface 9 while forming the border line 8. Because the surface 9 has a comparatively steep angle of inclination D, said border line 8 will become distinct (as viewed in the projection from above) and be located in a predetermined position, even if the surface 9 would include minor irregularities, e.g., streaks of long narrow depressions that extend up to the border line 8. In such a way, the intermediate surface 7 as well as the reinforcing chamfer surface 4a may be left unground, without the exterior of the cutting insert being impaired in an aesthetical respect.

In this connection, the attention is directed to the conceived alternative that the grinding would be made in direct connection to the flatly sloping chamfer surface 4a, which in the example has an angle of inclination D of only 3°. In case the grinding disc would be allowed to break through directly in such a chamfer surface, the position of the border line in relation to the edge line 3 should vary between different cutting inserts because of thickness variations between different production outcomes. When the surfaces 1 , 2 have been ground, suitably the cutting insert is completed by brushing said chamfer and intermediate surfaces 4a, 7 while forming an ER-rounded edge line 3.

Advantages of the Invention One of the advantages of the ceramic cutting insert according to the invention is that the cutting insert becomes more universally useful for various applications. Instead of continually needing to change between ER-ground cutting inserts and chamfer-reinforced cutting inserts, respectively, in many applications the user can use his/her tools equipped with one and the same type of cutting inserts. Another advantage is that the requisite chamfer surfaces adjacent to the cutting edges may be realized by direct pressing, i.e., without grinding. This entails a greater latitude for the tool designer to form surfaces having a complex shape adjacent to the cutting edges. An additional advantage is that the cutting insert can be produced in an aesthetically attractive and reassuring manner, in spite of the surfaces between the face ground top surface and the individual, ground clearance surface being made without being ground. Thus, due to the steep inclination of the intermediate surface, one and the same width of the surface that extends from the edge to the top surface is obtained with reliable repeatability, even if the surface would have irregularities. In conclusion, it should be emphasized that the intermediate surface formed in accordance with the invention is not intended to serve as a chip breaker. Hence, in the applications for which the ceramic cutting insert is suitable, the chip will primarily be broken already against the chamfer surface positioned closest to the edge line. Feasible Modifications of the Invention

The invention is not limited only to the embodiment described above and shown in the drawings. Thus, it is feasible to make the chamfer surface positioned closest to the edge and the intermediate surface positioned closest to the top surface in the form of parts of a single, continuous, concavely arched surface without any marked turning or border line between the part surfaces. For instance, such a surface could cross-section-wise be defined by an arched line, the radius of curvature of which is comparatively great closest to the edge and then successively decreasing toward the top surface. In general, it may be said that the shape of the unground surface between the edge line and the border line to the top surface is incidental provided that the surface is generally concave, i.e., located under an imaginary plane between the edge line and said border line, at the same time as the part surface (the intermediate surface) positioned closest to the top surface slopes at a considerably greater angle than the part surface (the chamfer surface) positioned closest to the edge line.

Claims

1. Ceramic cutting insert, comprising a face ground top surface (1), and at least one peripheral clearance surface (2) adjacent to an edge (3), from which a reinforcing chamfer surface (4a) extends inward, which forms an acute angle (D) with a reference plane (P) parallel to the top surface (1), characterized in that a generally concave unground intermediate surface (7) is formed between the top surface (1) and the chamfer surface (4a), which intermediate surface in the transition thereof to the top surface forms a second angle (D) with the same that is greater than the first-mentioned angle (D), and that the width (WF) of the chamfer surface (4a) is greater than the width (WM) of the intermediate surface (7) .

2. Ceramic cutting insert according to claim 1, characterized in that the intermediate surface includes two part surfaces (9, 10) at least one (9) of which is planar and the other one (10) concave.

3. Ceramic cutting insert according to claim 1 or 2, characterized in that the second angle (D) is at least five times as large as the first angle (D).

4. Ceramic cutting insert according to any one of the preceding claims, characterized /nthat the first angle (D) amounts to at least 2° and at most 5°.

5. Ceramic cutting insert according to any one of the preceding claims, characterized in that the edge (3) is rounded into a radius of at most 40 μm.

6. Ceramic cutting insert according to any one of the preceding claims, characterized in that the same is turnable by comprising two opposite, face ground surfaces (1), which are parallel and individually transforms into at least one unground intermediate surface (7) as well as a connecting chamfer surface (4a).

7. Method for the manufacture of a ceramic cutting insert according to any one of claims 1-6, c h a r a c t e r i z e d b y the steps of: a) compression-moulding and hardening a powdered, ceramic compound into a blank, which includes at least one generally planar major face, a peripheral clearance surface, a reinforcing chamfer surface adjacent to a chip-removing edge, and an intermediate surface positioned between the chamfer surface and the major face, which intermediate surface is steeper inclined and narrower than the chamfer surface, b) grinding said major face while forming a completed top surface (1 ), which breaks through the intermediate surface (7) where the same has a steep angle of inclination (β), and c) leaving at least the intermediate surface (7) unground.

8. Method according to claim 7, c h a ra c t e r i z e d i n that the chamfer surface (4a) as well as the intermediate surface (7) are finished by brushing in order to improve the surface smoothness as well as to impart the edge a rounded shape.