Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C5/00—Milling-cutters
  • B23C5/16—Milling-cutters characterised by physical features other than shape
  • B23C5/20—Milling-cutters characterised by physical features other than shape with removable cutter bits or teeth or cutting inserts
  • B23C5/202—Plate-like cutting inserts with special form
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C5/00—Milling-cutters
  • B23C5/16—Milling-cutters characterised by physical features other than shape
  • B23C5/20—Milling-cutters characterised by physical features other than shape with removable cutter bits or teeth or cutting inserts
  • B23C5/202—Plate-like cutting inserts with special form
  • B23C5/205—Plate-like cutting inserts with special form characterised by chip-breakers of special form
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C5/00—Milling-cutters
  • B23C5/02—Milling-cutters characterised by the shape of the cutter
  • B23C5/06—Face-milling cutters, i.e. having only or primarily a substantially flat cutting surface
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/04—Overall shape
  • B23C2200/0433—Parallelogram
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/08—Rake or top surfaces
  • B23C2200/085—Rake or top surfaces discontinuous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/12—Side or flank surfaces
  • B23C2200/125—Side or flank surfaces discontinuous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/12—Side or flank surfaces
  • B23C2200/125—Side or flank surfaces discontinuous
  • B23C2200/126—Side or flank surfaces discontinuous stepped
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/20—Top or side views of the cutting edge
  • B23C2200/208—Wiper, i.e. an auxiliary cutting edge to improve surface finish
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/28—Angles
  • B23C2200/281—Negative rake angles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/28—Angles
  • B23C2200/287—Positive rake angles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C2200/00—Details of milling cutting inserts
  • B23C2200/36—Other features of the milling insert not covered by B23C2200/04 - B23C2200/32
  • B23C2200/365—Lands, i.e. the outer peripheral section of rake faces
  • B23C2200/366—Variable
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T407/00—Cutters, for shaping
  • Y10T407/19—Rotary cutting tool
  • Y10T407/1906—Rotary cutting tool including holder [i.e., head] having seat for inserted tool
  • Y10T407/1908—Face or end mill
  • Y10T407/1924—Specified tool shape
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T407/00—Cutters, for shaping
  • Y10T407/23—Cutters, for shaping including tool having plural alternatively usable cutting edges
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T407/00—Cutters, for shaping
  • Y10T407/24—Cutters, for shaping with chip breaker, guide or deflector
  • Y10T407/245—Cutters, for shaping with chip breaker, guide or deflector comprising concave surface in cutting face of tool

Definitions

• the present disclosure is directed to cutting inserts and tool holders for replaceable and indexable cutting inserts.
• cutting inserts according to the present disclosure are particularly useful in peripheral rotary milling applications for machining difficult-to-machine materials.
• Cutting inserts suffer from a limited service life in peripheral rotary milling applications, especially when machining difficult-to-machine materials. Difficult- to-machine materials include, for example, specialty metals such as titanium and titanium alloys, nickel and nickel alloys, superalloys, and certain exotic metals. Cutting inserts comprising a positive rake face geometry on both the axial cutting face and the radial cutting face are commonly employed in milling operations involving the use of a peripheral rotary tool holder with an indexable capability. The positive cutting geometry of the inserts reduces the cutting forces and consequently reduces power consumption, resulting in a more efficient milling operation.
• the cutting inserts typically used in peripheral rotary milling are generally parallelogram-shaped (Ae., each has a generally parallelogram-shaped profile when viewed from a point above the insert's top surface), with two long sides forming two main cutting edges and two short sides forming two minor cutting edges.
• These types of cutting inserts provide more efficient machining by providing the capability of a larger depth of cut, though such inserts are not as strong as square-shaped cutting inserts.
• European Patent No. 0 239 045 provides a parallelogram-shaped cutting insert having a constant positive radial rake angle and a constant radial clearance angle along the major cutting edges.
• United States Patent No. 5,071,292 describes a parallelogram-shaped cutting insert having a continuous curved radial cutting face and radial clearance face wherein both the radial rake angle and the radial clearance angle remain substantially the same along the main cutting edge with respect to the associated cutter or tool holder.
• United States Patent No. 5,052,863 provides a method for securely locating a parallelogram-shaped cutting insert having a relatively large positive radial clearance angle along the main cutting edge in a tool holder.
• the method involves adapting a tool holder designed to accommodate an insert having a lower radial clearance angle, to overcome the strength problems associated with greater unsupported overhang when using the parallelogram-shaped cutting inserts having larger radial clearance angle.
• United States Patent No. 5,388,932 describes an angled chamfer at the elevated corner nose area of a parallelogram-shaped cutting insert, wherein the angled chamfer increases the cutting edge strength at the main corner nose while maintaining a positive radial rake angle along the main cutting edge.
• United States Patent No. 6,142,716 also describes an angled chamfer with a positive radial rake angle, but further comprises a recess at the major cutting sides enabling more rigid localization of the cutting insert in the tool holder and use of less material in manufacturing the cutting insert.
• Efforts in the industry to develop new or improved parallelogram- shaped cutting inserts have been directed toward achieving reduced cutting forces, reduced power consumption, increased cutting edge strength, and increased tool life. From the point view of geometrical design, maintaining a positive or a positive plus constant radial rake angle along the main cutting edge has been a fundamental goal of these efforts.
• the position of the cutting insert in the associated tool holder may also contribute to achieving the goals of reducing cutting forces and increasing cutting edge strength.
• Known patent publications and published literature regarding parallelogram- shaped cutting inserts including those described above do not recognize a quantitative relationship between the cutting insert geometry and the position of the cutting insert in the associated tool holder.
• a generally parallelogram-shaped cutting insert comprising: a top face; first and second main radial clearance faces, each intersecting the top face; first and second minor axial clearance faces each intersecting the top face and connecting the first and second main radial clearance faces; and a main cutting edge at the intersection of the top face and the first main radial clearance face.
• the main cutting edge comprises a variable radial rake angle including a portion having a positive radial rake angle and a portion having a negative radial rake angle.
• a peripheral cutting tool comprising a tool holder including at least one insert pocket.
• a cutting insert may be located in the at least one insert pocket of the tool holder such that a midpoint of the main cutting edge of the cutting insert is located in a radial plane comprising the axis of rotation of the tool holder, and wherein a support plane including a bottom surface of the insert pocket is perpendicular to a secondary radial plane.
• the secondary radial plane comprises the axis of rotation of the tool holder and is perpendicular to the primary radial plane.
• a method for positioning a cutting insert comprising a main cutting edge in an insert pocket of a tool holder of peripheral cutting tool.
• the method comprises positioning the cutting insert in the insert pocket so that a midpoint of the main cutting edge is located in a primary radial plane comprising the axis of rotation of the tool holder, and wherein a support plane including a bottom surface of the insert pocket is perpendicular to a secondary radial plane that comprises the axis of rotation of the tool holder and is perpendicular to the primary radial plane.
• Figure 1 is a simplified drawing of a top view of a parallelogram-shaped cutting insert showing certain basic elements of the cutting insert
• Figure 2 includes simplified drawings of various views of a parallelogram-shaped cutting insert showing certain basic elements
• Figures 3a, 3b, 3c, and 3d are views illustrating features of one non- limiting embodiment of a parallelogram-shaped cutting insert according to the present disclosure
• Figures 4a, 4b, 4c, 4d, 4e, and 4f are various views illustrating the pattern of radial rake angles along the main cutting edge and axial rake angles along the minor cutting edge for one non-limiting embodiment of a parallelogram-shaped cutting insert according to the present disclosure
• Figure 5 shows an additional non-limiting embodiment of a parallelogram-shaped cutting insert according to the present disclosure wherein the curve of the main corner nose tangent to the facet edge differs from that of the parallelogram-shaped cutting insert shown in Figure 3, wherein the main corner nose is truncated by the facet edge;
• Figure 6 provides views of one non-limiting embodiment of a milling cutting tool system according to the present disclosure including seven identical parallelogram-shaped cutting inserts and an associated tool holder;
• Figure 7a is a side view and Figure 7b is a front-end view of a non- limiting embodiment of a milling cutting tool system according to the present disclosure including seven identical parallelogram-shaped cutting inserts and an associated tool holder;
• Figure 8 provides a front-end view along with a magnified view of one cutting insert of a non-limiting embodiment of a milling cutting tool system according to the present disclosure including seven identical parallelogram-shaped cutting inserts and an associated tool holder for a milling cutting tool system of this invention with seven identical parallelogram-shaped cutting inserts and an associated tool holder; and
• Figure 9 is a front-end view and a magnified view of a non-limiting embodiment of a milling cutting tool system according to the present disclosure including seven identical parallelogram-shaped cutting inserts and an associated tool holder.
• Parallelogram-shaped cutting inserts are typically used in peripheral rotary milling due to their relatively large depth of cut obtained by the relatively longer main cutting edge as compared to square cutting inserts. The longer main cutting edge, however, increases the load on the cutting insert.
• Certain non-limiting embodiments according to the present disclosure include a generally parallelogram-shaped cutting insert comprising: a top face; first and second main radial clearance faces, each intersecting the top face; first and second minor axial clearance faces, each intersecting the top face and connecting the first and second main radial clearance faces; and a main cutting edge at the intersection of the top face and the first main radial clearance face.
• Certain non-limiting embodiments may further comprise a variable radial rake angle along the length of the main cutting edge comprising a portion having a positive radial rake angle and a portion having a negative radial rake angle.
• variable radial rake angle of the cutting insert changes, preferably gradually, from a positive radial rake angle to a negative radial rake angle.
• the radial rake angle near the main cutting corner is positive, and the radial rake angle near the minor cutting corner is negative.
• Such a design provides a stronger cutting edge with a longer service life than a parallelogram-shaped cutting insert having a positive radial rake angle across the entire cutting edge.
• Certain non-limiting embodiments of a parallelogram-shaped cutting insert according to the present disclosure comprise a main corner nose.
• the main corner nose provides a significant portion of the active cutting action by the cutting insert.
• the portion of the main cutting edge comprising the positive radial rake angle is longer than the portion of the main cutting edge comprising the negative radial rake angle.
• the portion of the main cutting edge comprising a positive radial rake angle is at least three times longer than the portion of the main cutting edge comprising a negative radial rake angle.
• the portion of the main cutting edge comprising a positive radial rake angle is at least seven times longer than the portion of the main cutting edge comprising a negative radial rake angle.
• Non- limiting cutting insert embodiments according to the present disclosure comprise at least one point wherein the radial rake angle is zero, and one of the points having a zero rake angle is between the portion of the main cutting edge comprising the positive radial rake angle and the portion of the main cutting edge comprising the negative radial rake angle.
• Parallelogram-shaped cutting inserts are typically indexable and often comprise a first main cutting edge at the intersection of the top face and the first main radial clearance face and a second cutting edge at the intersection of the top face and the second main radial clearance face.
• each cutting edge comprises a variable radial rake angle along the length of the cutting edge, comprising a portion having a positive radial rake angle and a portion having a negative radial rake angle.
• Figures 1 and 2 are simplified drawings of parallelogram-shaped cutting inserts showing some basic elements.
• Figure 1 is a top view of parallelogram-shaped cutting insert 1 that includes a center hole 2 for securing the cutting insert 1 to a tool holder; a top face 3 (the top face of a parallelogram-shaped cutting insert may comprise a flat face, an angled flat face, or a curved surface); two main cutting edges 4a and 4b; two minor cutting edges 5a and 5b; two main corner noses 6a and 6b; and two minor corner noses 7a and 7b.
• Figure 2 is a set of drawings of different simplified views of an embodiment of another parallelogram-shaped cutting insert 8 comprising: a top face 9 having rake cutting face 10 (functioning as a chip breaker to promote chip flow/chip breaking during machining); a bottom face 11 ; two main corner noses 12a and 12b; two main radial cutting edges 13a and 13b; two minor corner noses 14a and 14b; two minor cutting edges 15a and 15b; two radial clearance faces 16a and 16b below the two main cutting edges 13a and 13b; two axial clearance faces 17a and 17b below the two minor cutting edges 15a and 15b; two conical clearance faces 18a and 18b below the main corner noses 12a and 12b; and two conical clearance faces 19a and 19b below the minor corner noses 14a and 14b.
• the radial clearance angle 0RC is formed between the cutting insert center axis 20 and the radial clearance face 16a (or 16b).
• the radial rake angle 0RR is formed between the top flat plane (a plane that is parallel to the bottom surface and intersects the cutting edge) and the rake cutting face 10.
• the axial clearance angle 0AC is formed between the cutting insert center axis 20 and the axial clearance face 17a (or 17b), and the axial rake angle 0AR is formed between the top flat plane and the rake cutting face 10.
• FIG. 1 is a set of views illustrating some more detailed features of a non-limiting embodiment of a parallelogram-shaped cutting insert 27 according to the present disclosure, having a top face 28 with a chip breaker 29, a bottom surface 30, and a center hole 31.
• the cutting insert 27 includes: two main radial cutting edges 32a and 32b (which in this embodiment are curved cutting edges with a relatively large radius); two main corner noses 33a and 33b; two minor corner noses 34a and 34b; and two minor cutting edges, each of which includes two portions, i.e., a first portion 35a (or 35b) connecting to the main corner nose 33a (or 33b) and a second portion 36a (or 36b) connecting to the minor corner nose 34a (or 34b).
• the first portion of the minor radial cutting edge 35a (or 35b), a facet edge may be a line parallel to the bottom face 30.
• the second portion of the minor cutting edge 36a (or 36b) is at an angle to the facet edge 35a (or 35b) and would not usually participate in cutting the material.
• the main corner noses 33a and 33b are at the highest points of the embodiment of cutting insert 27, while the minor corner noses 34a and 34b are at the lowest points, when viewed from the side as shown in Figure 3b.
• the main cutting edges 32a, 32b and the second portion of the minor cutting edges 36a, 36b are not parallel to the bottom surface 30 of the cutting insert 27.
• the effective cutting length of the cutting insert 27 is defined as the length (LE) as shown in Figure 3b, which is measured parallel to the main cutting edge 32a (or 32b) from the first portion of the minor cutting edge or the facet edge 35a (or 35b) to the intersection point between the main cutting edge 32a (or 32b) and the minor corner noses 34a (or 34b).
• L E determines the maximal depth of cut of a parallelogram- shaped cutting insert when seated in a tool holder.
• Cutting insert 27 has multiple ⁇ i.e., at least two) clearance faces below each of the cutting edges at the top face 28.
• first axial clearance face 41 or the facet face, below the first portion of the minor cutting edge (35a or 35b) functions as a wiper contact face to improve the surface finish of the work materials in peripheral rotary milling operations (see Figure 3c).
• the upper second axial clearance face 42 (see below) is formed right below the second portion of the minor cutting edge (36a or 36b).
• one non-limiting embodiment of a parallelogram-shaped cutting insert comprises a notch 43 that extends across the entire second axial clearance face and separates it into an upper second axial clearance face 42 and a lower second axial clearance face 45.
• the notch 43 may form an angle A with respect to the bottom face 30. Angle A is 0 degrees in the embodiment shown in Figure 3c (i.e., notch 43 is parallel to bottom face 30), but in certain embodiments may be up to 20 degrees.
• the notch is also grooved into the second axial clearance face at an angle B (see the cross-sectional view in Figure 3d) ranging from, for example, 90 to 105 degrees with respect to the bottom face 30.
• a function of the notch 43 is to prevent the cutting insert 27 from slipping inside the pocket on a tool holder.
• the axial clearance faces 46 and 47 provide additional clearance for the cutting insert 27 in a tool holder.
• Cutting insert 27 also includes a notch 55 across the entire main side of the cutting insert, functioning as a separation between the upper radial clearance face 51 and lower radial clearance face 52. Similar to notch 43, notch 55 may have an angular shape, for example, a triangular or dovetail shape, or may have curved walls and be shaped as a semicircular groove.
• FIG. 4b-f Another feature of the embodiment shown as cutting insert 27 is illustrated in the various cross-sectional views of Figures 4b-f, wherein the radial rake angle (0RR) along the main cutting edge 61a (or 61b) changes from positive near the main corner nose 62a (or 62b) to negative near the minor corner nose 63a (or 63b).
• Two concave surfaces 64a and 64b are formed near the minor corner noses 63a and 63b, respectively.
• the concave surface 64a (or 64b) is formed on the top face 28 with chip breaker 29 of cutting insert 27 and intersects with the main cutting edge 61 a (or 61b), which in this embodiment is a curved cutting edge with a relatively large radius.
• the rake angle At a point along each main cutting edge, typically in the concave section 64a or 64b, the rake angle will be zero.
• Certain non-limiting embodiments of the cutting insert of the present invention comprising a variable radial rake angle along the length of the cutting edge will not comprise a point where the rake angle is zero.
• the distance measured in cutting insert's top view plane from the minor corner nose to the point at which the rake angle is zero is defined as.
• the distance L N for one embodiment is shown in Figure 4a.
• the length of effective cutting edge L E in Figure 3b
• the length of effective cutting edge (L E in Figure 3b) may be projected onto the plane of the top view of Figure 4a and defined as L TO p.
• the radial rake angle (0RR) at different points along the main cutting edge 61a can be defined by the following equations:
• Figure 5 shows another non-limiting embodiment of a parallelogram- shaped cutting insert 71 according to the present disclosure.
• the cutting insert 71 shown in Figure 5 is different from the cutting insert 27 shown in Figures 3 and 4 at least in that the first portion of the minor cutting edge, or the facet edge, 72a (or 72b) is tangent to the main corner nose 73a (73b).
• Cutting insert 27 ( Figure 3) comprises a first portion of the minor cutting edge, or the facet edge, 35a (or 35b) that is not tangent to the main corner nose 33a (or 33b).
• the cutting insert shown in Figure 5 has full main corner noses 73a and 73b, while the cutting insert shown in Figure 3 has truncated main corner noses 33a and 33b.
• a milling cutting tool system for machining difficult-to-machine materials may also be improved by modifying the associated tool holder to optimize how a parallelogram-shaped cutting insert is positioned in the insert pocket.
• a tool holder is provided that maintains a certain quantitative relationship between the geometry of a parallelogram-shaped cutting insert and its position in the associated tool holder to thereby provide balanced and optimized cutting performance for the cutting inserts and the tool holder.
• a non-limiting embodiment of a milling cutting tool system 80 including multiple parallelogram-shaped cutting inserts 81 a, 81b, 81c, 81 d, 81 e, 81f, 81 g seated in a tool holder 82 is shown in Figures 6a and 6b.
• the tool holder 82 has multiple insert pockets 83 to secure each cutting insert with a fastener, such as screw 84.
• the tool holder 82 may optionally comprise cooling hole 85 and relief surface 86 for each pocket.
• the tool holder 82 together with all cutting inserts rotates about its axial centerline 87.
• Figures 6a and 6b further show radial centerlines 88 and 89 of tool holder 82.
• Certain non-limiting embodiments of a peripheral cutting tool comprise a tool holder comprising at least one insert pocket.
• the tool holder may have more than one insert pocket and typically comprises from 2- 25 insert pockets.
• a cutting insert must be attached in each pocket.
• the cutting insert comprises a main cutting edge. The inventors have found that the cutting operation may be performed more efficiently if the cutting insert is positioned in the insert pocket of the tool holder such that a midpoint of the main cutting edge is located in a radial plane comprising the axis of rotation of the tool holder.
• tool holder 91 has seven parallelogram-shaped cutting inserts, 92a, 92b, 92c, 92d, 92e, 92f and 92g.
• the axis of rotation 93 of the tool holder 91 shown in the side view of Figure 7a, will appear on end as point P in the front view of Figure 7b.
• the midpoint of the main cutting edge 101 is located in the primary radial plane 102 comprising the axis of rotation 93 (i.e. through the point P in Figure 7b) of the tool holder 91.
• Secondary radial plane 104 is perpendicular to primary radial plane 102 and includes the axis of rotation 93.
• a support plane including the bottom surface 103 of the cutting insert 92a (or including the bottom surface of the insert pocket of toolholder 91) is also perpendicular to the secondary radial plane 104.
• cutting insert 92d comprises midpoint 111 of the main cutting edge.
• Midpoint 111 is located in the primary radial plane 112 comprising the axis of rotation 93 (i.e., through the point P in Figure 7b) of the tool holder 91 and, at the same time, a plane including the bottom surface 113 of the cutting insert 92d is perpendicular to the secondary radial plane 114, which also comprises the axis of rotation 93 of the tool holder 91 and is perpendicular to the primary radial plane 112.
• the projected side view shown in Figure 8 is obtained by rotating the tool holder 121 around the axis of rotation 122, which is collinear with the X axis of the Cartesian coordinate system as illustrated, until the bottom surface 123 of the cutting insert 124 (as an example) is perpendicular to the X-Y plane (equivalent to the secondary radial plane 104 as shown in Figure 7b) of the Cartesian coordinate system.
• the first equation for positioning the middle point D (as shown in the Magnified View of Figure 8) of the main cutting edge 125 so as to intersect the axis of rotation 122 of the tool holder 121 in the X-Z plane of Figure 8, or in other words, positioning the middle point D in the X-Z plane which is equivalent to the primary radial plane 102 as shown in Figure 7b, can be mathematically expressed as:
• the second equation is to set an equalized radial cutting angle to position each parallelogram-shaped cutting insert, for instance cutting insert 131, in the associated tool holder 132, as shown in the front-end and magnified insert views of Figure 9, which can be mathematically described as: where 0RC-DI is the radial cutting angle formed between the cutting edge start point D-i in the radial plane with the center at P and the radial center line 133, and 0R C -D2 is the radial cutting angle formed between the cutting edge end point D 2 in the radial plane with the center at P and the radial center line 133.
• 0RC-DI is the radial cutting angle formed between the cutting edge start point D-i in the radial plane with the center at P and the radial center line 133
• 0R C -D2 is the radial cutting angle formed between the cutting edge end point D 2 in the radial plane with the center at P and the radial center line 133.
• certain non-limiting embodiments according to the present disclosure relate to multiple parallelogram-shaped cutting inserts and an associated tool holder. It will be understood, however, that inserts and tool holders within the scope of the present disclosure may be embodied in forms and applied to end uses that are not specifically and expressly described herein. For example, one skilled in the art will appreciate that embodiments within the scope of the present disclosure and the following claims may be manufactured as cutting inserts and/or tool holders adapted for other methods of removing metal from all types of work materials.
• Certain non-limiting embodiments according to the present disclosure are directed to parallelogram-shaped cutting inserts providing a combination of advantages exhibited by varying the radial rake angle along the main cutting edge to achieve balanced and optimal performance between efficient cutting action and an enhanced cutting edge.
• the parallelogram-shaped cutting inserts described herein may be of conventional size and adapted for conventional use in a variety of machining applications.
• Certain other embodiments according to the present disclosure are directed to a tool holder and a unique and quantitative method to determine how to position parallelogram-shaped cutting inserts in the tool holder to achieve optimized performance for the cutting inserts and the tool holder as an entity.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Milling Processes (AREA)
• Turning (AREA)
• Sampling And Sample Adjustment (AREA)
• Cutting Tools, Boring Holders, And Turrets (AREA)

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• 2007
  • 2007-05-03 US US11/743,803 patent/US7905687B2/en not_active Expired - Fee Related
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