Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
  • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
  • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
  • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
  • B23P15/32—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools twist-drills
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
  • C04B35/528—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes

Definitions

• the invention which is the subject of this application relates to the formation of machining tools and the method making machining tool blanks for the manufacture of same, the tools provided with a machining tip and/or machining faces formed at least partially by a suitable material containing abrasive polycrystalline diamond or cubic boron nitride referred to respectively as PCD and PCBN.
• [4]FTG. 1 is a side plan view of an embodiment of a machining tool blank.
• [5]FTG. 2 is a side view of an embodiment of a machining tool blank.
• [6]FTG. 3 is a side plan view of an embodiment of a drill bit.
• [7]FTG. 4 is a perspective view of an embodiment of a machining tool blank.
• [8]FTG. 5 is a side review of an embodiment of a machining tool blank.
• [9]FTG. 6 is a top view of the machining tool blank.
• [10]FTGS. 7a-7d show embodiments of geometries of recesses of the machining tool blank.
• [11]FTGS. 8a-8e show embodiments of geometries of radii of the machining tool blank.
• [12]FTG. 9a is a side view of a profile of an embodiment of a machining tool blank.
• [13]FTG. 9b is a side view of a profile of an embodiment of a machining tool blank.
• [14]FTG. 10 is a perspective view of the as-sintered machining tool blank.
• FIG. 1 depicts a side plan view of machining tool blank.
• the machining tool blank may be made of any suitable material such as tungsten carbide.
• the machining tool blank 2 has a body 4 including at least one end face 5. At least two recesses 6, 10, and/or 12, 14 are formed in end face 5.
• first recess 6 extends from the at least one end face 5 at an angle C of about 33°. Angle C may range from about 15° to about 60°.
• a second recess 10 continues from said first recess 6 and extends from the end face 5 at an angle B of about 77°. Angle B may range from about 40° to about 90°.
• the first recess 6 and the second recess 10 converge at first radius 3.
• first recess 6 and second recess 10 form a first side recess 11.
• first side recess 11 extends along at least one side of said blank from axial center point 8 of the blank at an angle A of about 30°. Angle A may range from about 0° to about 50°.
• the blank 2 may further include a third recess 12 extending from end face 5 at an angle D of about 33°. Angle D may range from about 15° to about 60°. A fourth recess 14 continues from third recess 12 and extends from the end face 5 at an angle E of about 77°. Angle E may range from about 40° to about 80°. Third recess 12 and fourth recess 14 converge at second radius 7. As shown in FIG. 1, third recess 12 and fourth recess 14 form a second side recess 15. As further shown in FIG. 2, second side recess 15 extends along at least one side of said blank from axial center point 8 of the blank at an angle F of about 30°. Angle F may range from about 0° to about 50°.
• the aforementioned side recesses may be any shape and may be curved or flare at the bottom of the recess. End portion 39 of side recess may be any shape.
• FIGS. 7a-7c Examples of geometries of end portions are shown in FIGS. 7a-7c.
• FIGS. 8a-8e [21]Also shown in FIGS. 8a-8e,. the geometries of radius 3 and radius 7 are shown.
• geometries include sickle-shaped, flat, curved, triangular, square, rectangular, zig-zag, etc. and combinations thereof.
• FIG. 5 shows blank 30 having at least one recess 34. Additionally, recess 36 may be present. The recesses 34, 36 may form one continuous recess or may be two separate recesses that do not connect (not shown). Optionally, a cavity (not shown) may be present, to join to separate recesses. In an embodiment, as shown in FIG. 6 a cavity 13 may be made in the blank 2. The cavity may be any shape and serves to join recesses 6 and 12. [22]Although cylindrical blanks have been described and shown, it is possible that the machining tool blanks have other shapes such as rectangular, triangular, hexagonal, octagonal, etc.
• FIG. 4 illustrates the perspective view of blank 2 of Figs. 1 and 2.
• machining tool blank 2 has body 4 including at least one end face 5.
• first recess 6, second recess 10 radius 3 and third recess 12 are shown.
• Cavity 13 joins recesses 6 and 12.
• the blank 2 is first machined to remove the material from which the blank is made into the required form including the formation of the recess portion(s).
• the recesses are provided in a location such that the PCD or PCBN material subsequently formed therein will be located to form at least part of the subsequently formed machining end face(s) of the tool in order to obtain the benefit of the PCD or PCBN material used.
• the machining tool blank 2 may be formed from carbide such as tungsten carbide or other materials of similar hardness.
• a mass of abrasive particles e.g., polycrystalline diamond (PCD) or polycrystalline cubic boron nitride PCBN, of a mean size of about 0.1 micron to about 200 microns may be used to fill the recess(es).
• binder materials such as alcohols, or any other binder material that may be used in the art may be added to the abrasive particles to form a slurry.
• the abrasive particles/slurry is packed into the recess(es) so as to at least partially fill the recess(es) of the blank.
• the recess(es) may be completely filled or even overfilled with abrasive particles/slurry.
• the blank containing PCD or PCBN powder or slurry may be subjected to pressures of about 45 Kbar to about 75 Kbar and temperatures of about 1200°C to about 1600° C for approximately about 1 to about 50 minutes. Apparatus and techniques for such sintering are disclosed in U.S. Pat. Nos. 2,941, 248; 3,141,746; 3,745,623; and 3,743,489 which are herein incorporated herein by reference.
• the abrasive mass is fully sintered, with the particles bonded directly to each other and to the carbide by the sintering process, the blank is removed from the press.
• the resultant composite sintered abrasive blank is made up of a cemented carbide cylinder 40 with a at least one vein of fully sintered abrasive particles 41 imbedded in and extending across one end of the blank thereof.
• FIG. 3 depicts a machining tool 24 made from the machining tool blank as described herein.
• Blank 2 is bonded to shank 43 may any means including, but not limited to brazing or bonding.
• blank 2 is bonded to shank 43 at bond line 40. The tool is then machined to form the final tool 24.
• the end face may be machined to contain a chamfer, FIG. 9a, or a plurality of chamfers, see FIG. 9b.
• the blank may be machined either before or after filling the recess(es) with PCD or PCBN and sintering to create the alternative profiles.
• machining tool blanks having multiple recesses fabricated from the design depicted in FIG. 9a exhibit 60% less stress (leading to defects) compared to blanks containing a single recess.
• the end face of the blank in which the recess is provided can be of any required form depending on the subsequent tool to be formed.
• the end face may have a conical shape and typically the angle of the bottom surface of the recess and the slope of the bottom face of the element will match that of the top face.
• the top face of the element which is formed may match the angle of the conical tip of the blank due to the pressing action of the forming apparatus which can be a conventional mould press for this purpose.
• the angle of the conical tip is dependent upon the specific purpose for the tool but one common angle is 118 degrees. If the tool to be formed is a recess drill or end mill as opposed to a twist drill no conical tip will be formed.
• the blank may be provided with an integral shank.
• the blank as described above may be connected to a shank portion which may be formed of another material such as a suitable cemented carbide, a ceramic, an elemental metal or alloy depending upon the specific requirements for the tool.
• a suitable cemented carbide such as a ceramic, an elemental metal or alloy depending upon the specific requirements for the tool.
• the shank portion may be formed of another material such as a suitable cemented carbide, a ceramic, an elemental metal or alloy depending upon the specific requirements for the tool.
• the shank can be made of any suitable material such as carbide, steel or steel alloy.
• the blank once formed, may be joined to the shank to form the machining tool by brazing and can be machined prior to attachment to the body shank portion such that the flutes and machining faces are formed therein.
• the blank then may be attached to the shank and the remaining required flutes then formed in the shank.
• the blank is first joined to the shank and the machining faces then formed in blank and the shank as it is easier from a manufacturing standpoint to align the machining faces and flutes formed.
• an end mill may have an angle C of between about 0° to about 60°
• a brad mill may have an angle C of any negative angle measurement to 0°
• a dental bur may have an angle C of from about 60° to about 90°.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Organic Chemistry (AREA)
• Ceramic Engineering (AREA)
• Composite Materials (AREA)
• Metallurgy (AREA)
• Structural Engineering (AREA)
• Drilling Tools (AREA)
• Forging (AREA)
• Milling Processes (AREA)

Priority Applications (13)

Applications Claiming Priority (2)

Publications (2)

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Family Applications (1)

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Cited By (2)

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Citations (4)

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• 2010
  • 2010-12-30 MX MX2012007641A patent/MX2012007641A/es active IP Right Grant
  • 2010-12-30 CA CA2782802A patent/CA2782802A1/en not_active Abandoned
  • 2010-12-30 ES ES10818115.7T patent/ES2440775T3/es active Active
  • 2010-12-30 AU AU2010339640A patent/AU2010339640B2/en not_active Ceased
  • 2010-12-30 JP JP2012547293A patent/JP5856074B2/ja active Active
  • 2010-12-30 CN CN201080059602.4A patent/CN102695581B/zh active Active
  • 2010-12-30 US US12/981,694 patent/US8667866B2/en active Active
  • 2010-12-30 PT PT108181157T patent/PT2519378E/pt unknown
  • 2010-12-30 DK DK10818115.7T patent/DK2519378T3/da active
  • 2010-12-30 SI SI201030475T patent/SI2519378T1/sl unknown
  • 2010-12-30 PL PL10818115T patent/PL2519378T3/pl unknown
  • 2010-12-30 WO PCT/US2010/062475 patent/WO2011084864A2/en not_active Ceased
  • 2010-12-30 BR BR112012016192A patent/BR112012016192A2/pt not_active IP Right Cessation
  • 2010-12-30 EP EP10818115.7A patent/EP2519378B1/en active Active
  • 2010-12-30 KR KR1020127016624A patent/KR101882025B1/ko active Active
• 2012
  • 2012-06-26 ZA ZA2012/04769A patent/ZA201204769B/en unknown

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