Abstract:
A cutting insert having an upper and a lower base face; side walls adjoining the faces; at least one cutting edge formed at an intersection of the upper face and a side wall; and at least one cutting corner formed at an intersection of an adjacent pair of side walls. A chip control structure is formed in the upper face extending along the cutting edge from the cutting corner for at least an effective cutting length of the cutting edge. A land surface spaces the chip control structure from the cutting edge. The chip control structure includes multiple radially spaced grooves, wherein the grooves of the chip control structure have a depth generally decreasing from the land toward the center of the insert.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a cutting insert including multiple grooves for chip control. More particularly, the present invention is directed to a cutting insert including multiple grooves for chip control which is effective over a broad range of operational conditions namely, a wide range of materials cutting depths and feed rates.  
           [0003]    2. Description of the Related Art  
           [0004]    Cutting inserts are well known and a large percentage of them are of the throw away design. Such inserts are detachably clamped on a toolholder and then are discarded when they become dull or chipped. Throw away inserts are usually indexable and/or invertable so that an insert can be provided with at least two cutting edges for selective presentation to the cutting position. An indexable and/or invertable insert having multiple cutting edges is more economical because when one edge has been used, the insert may simply be indexed or inverted to the next usable edge. Such a feature is especially important when considering the high cost of materials from which inserts are produced.  
           [0005]    In general, inserts must be securely and accurately held in place within a toolholder during the cutting operation. This is especially true when the inserts are deployed with numerically controlled machines which depend for accuracy upon an accurately located and firmly supported insert. When the inserts are large enough, it is possible to secure the insert both accurately and firmly within the pocket of a toolholder by providing the insert with a central hole and the toolholder with a pin-type clamping device. In other cases, such inserts may be held in place by a top clamp of a design well known in the art.  
           [0006]    The main object of metal machining is the shaping of a new work surface. Much attention is paid to the formation of the chip during the machining process, even though the chip is a waste product, because the consumption of energy occurs mainly in the formation and movement of the chip. Thus an essential feature of any metalcutting operation is effective chip control. A principal class of chips is the discontinuous chip which has the practical advantage of being easily cleared from the cutting area. While some metals and alloys generate discontinuous chips during cutting operations, many do not. It is therefore very desirable to produce discontinuous chips during a cutting operation, regardless of the workpiece material and the machining conditions.  
           [0007]    Because chip control is an important consideration in metal cutting operations, it has been a long standing objective in the art of metal cutting to develop improved chip control surfaces for use with cutting inserts. The present invention is directed to a cutting insert which is effective over a broad range of operational conditions namely a wide range of materials cutting depths and feed rates.  
         SUMMARY OF THE INVENTION  
         [0008]    Briefly, according to the present invention there is provided a cutting insert having an upper and a lower base face; side walls adjoining the faces; at least one cutting edge formed at an intersection of the upper face and a side wall; and at least one cutting corner formed at an intersection of an adjacent pair of side walls. A chip control structure is formed in the upper face extending along the cutting edge from the cutting corner for at least an effective cutting length of the cutting edge. A land surface spaces the chip control structure from the cutting edge. The chip control structure includes multiple radially spaced grooves, wherein the grooves of the chip control structure have a depth generally decreasing from the land toward the center of the insert. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    Further features of this invention as well as the advantages derived therefrom will become clear from the following detailed description made with reference to the drawings in which:  
         [0010]    [0010]FIG. 1 is a perspective view of a cutting insert in accordance with the present invention;  
         [0011]    [0011]FIG. 2 is a top view of the insert of FIG. 1;  
         [0012]    [0012]FIG. 3 is a cross sectional view of the insert of FIG. 2 taken along line  3 - 3 ; and  
         [0013]    [0013]FIG. 4 is an enlarged partial cross sectional view of the insert of FIG. 2 taken along line  4 - 4 . 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0014]    In the following description, like reference characters designate like or corresponding parts. Also in the following description, it is to be understood that such terms as “downwardly”, “upwardly”, “inwardly”, and the like, are words of convenience and are not to be construed as limiting terms apart from the invention as claimed.  
         [0015]    Referring to the drawings there is a shown a cutting insert  10  in accordance with the present invention. The cutting insert  10  is of a regular rhombic shape and is formed of a hard material of a type well know in the art, such as a cemented tungsten carbide material or cermet. It will be appreciated that although the insert  10  is shown as a diamond shape, the cutting insert may be of most any desired shape including square shape and triangular shape but having chip control structures  12  essentially similar to those described more fully below.  
         [0016]    The insert  10  has an upper face  14  and a substantially planar base face  16  with side walls  18  perpendicular to and joining the faces  14  and  16 . For the specific embodiment shown in the figures, a central pin receiving hole  12  is provided through the insert  10  for retention of the insert within a tool holder (not shown). Curved cutting corners  20  are respectively at the intersections of the side walls  18  whilst cutting edges  22  are respectively formed at the intersections of each side wall  18  and upper face  14 .  
         [0017]    In a preferred embodiment, it should be noted that the cutting insert  10  shown throughout the figures is an indexable insert and therefore the detailed features described in conjunction with one cutting edge region of the insert are present within at least an effective cutting length of the cutting edge of the other cutting edge regions. Therefore, only the cutting edge region  24  shown in FIG. 4 and those insert portions directly related to this cutting edge region will hereafter be discussed in detail.  
         [0018]    As shown in FIGS. 1 and 2, the chip control structure  12  in accordance with the present invention is formed in the upper face  14  and extends continuously along the cutting edges  22  and is spaced from the cutting edges by a land surface  26 . The chip control structure  12  is formed of multiple radially spaced grooves  36   a,    36   b,    36   c  defined by floor regions  28   a,    28   b  and  28   c  and deflector surfaces  30   a,    30   b  and  30   c,  respectively.  
         [0019]    Referring to FIGS. 3 and 4, the contour of the chip control structure  12  is more fully shown. The chip control structure  12  extends from the inner edge of the land surface  26  to a first descending surface  32 . The first descending surface  32  extends downwardly towards the base face  16  and inwardly toward the center of the insert to a first floor region  28   a.  The descending surface  32  slopes downwardly from its associated land surface  26  towards the base face  16  at an angle of approximately 18 degrees. In one example, the angle of slope varies from about 10 degree to about 20 degree.  
         [0020]    From the first floor region  28   a  the chip control structure  12  ascends upwardly toward the upper face  14  and inwardly toward the center of the insert  10  along a first chip deflector surface  30   a  to a first island  34 . The first chip deflector surface  30   a  slopes upwardly towards the upper face  14  at an angle of approximately 40 degrees. In one example, the angle of slope varies from about 35 degree to about 45 degree. The first island  34  is a generally horizontal surface and is at a depth lower than the depth of the land surface  26 . The first floor region  28   a  and the first chip deflector  30   a  cooperatively define a first groove  36   a  of the chip control structure  12 .  
         [0021]    As used herein, the depth is determined with reference to an imaginary plane formed by the peripheral edge of the land surface  26  and the center island  38  of the cutting insert  10 .  
         [0022]    The chip control structure  12  extends from the first island  34  downwardly toward the base face  16  and inwardly toward the center of the insert along a second descending surface  40  to a second floor region  28   b.  The descending surface  40  slopes downwardly towards the base face  16  at an angle of approximately 18 degrees. In one example, the angle of slope varies from about 10 degree to about 20 degree. The second floor region  28   b  is a generally horizontally extending surface. The depth of the first floor region  28   a  is greater than the depth of the second floor region  28   b.    
         [0023]    The chip control structure  12  extends from the second floor region  28   b  upwardly toward the upper face  14  and inwardly toward the center of the insert along a second chip deflector surface  30   b  to a third floor region  28   c.  The second chip deflector surface  30   b  slopes upwardly towards the upper face  14  at an angle of approximately 35 degrees. In one example, the angle of slope varies from about 30 degree to about 40 degree. The second chip deflector surface  30   b  and the second floor region  28   b  cooperatively define a second groove  36   b  of the chip control structure  12 . The third floor region  28   c  is a generally horizontally extending surface and is generally of the same depth as the first island  34 .  
         [0024]    From the third floor region  28   c,  the chip control structure  12  extends along a third chip deflector surface  30   c  upwardly toward the upper face  14  and inwardly toward the center of the insert. The third chip deflector  30   c  surface slopes upwardly towards the upper face  14  at an angle of approximately 30 degrees. In one example, the angle of slope varies from about 25 degree to about 35 degree. The third chip deflector surface  30   c  and the third floor region  28   c  form a third groove  36   c  of the chip control structure  12 .  
         [0025]    It will be appreciated that, although only three grooves  36   a,    36   b  and  36   c  are shown in the present invention, most any number of grooves may be formed in the upper face  14  of the insert  10  as long as the depth of the grooves of the chip control structure  12  generally decreases from the land  26  to the center of the insert. As shown in FIG. 4, it will be appreciated that the depths of the three groove embodiment of the invention, namely  36   a,    36   b  and  36   c,  have been specifically selected to control chip formation over three ranges of materials cutting depths and feed rates. More particularly, groove  36   a  is of a depth suited for low depth of cut and feed rates, groove  36   b  is of a depth suited for medium depth of cut and feed rates and groove  36   c  is of a depth suited for heavy depths of cut and higher feed rates. Groove  36   a  is the deepest to provide sufficient control of the formation of the chip at low depth of cut and feed rates, groove  36   b  is less deep to prevent cratering of the insert at medium depths of cuts and feed rates and groove  36   c  is the shallowest at heavy depth of cut and feed rates in view of the fact that the chip is typically large enough such that a shallow groove is sufficient for chip formation. Typically, by way of example, low feed rates range between about 0.002-0.006 IPR (inches per revolution) and depth of cut between about 0.005-0.025 in., medium feed rates range between about 0.006-0.012 IPR (inches per revolution) and depth of cut between about 0.025-0.075 in., and high feed rates range between about 0.012-0.020 IPR (inches per revolution) and depth of cut between about 0.075-0.250 in.  
         [0026]    The distance from the cutting edge  22  to groove  36   a  may vary as a function of the insert IC size. The IC size is defined as the diameter of the largest inscribed circle that may fit within the perimeter of the insert. The larger the IC size, the greater distance that groove  36   a  may be from the cutting edge  22 . Similarly, the distance of groove  36   b  from groove  36   a  is selected as a function of the distance of groove  36   a  from the cutting edge  22 . In a preferred embodiment, the distance from the groove  36   a  to groove  36   b  may vary between 45-55 percent more than the distance from the cutting edge  22  to groove  36   a.  Correspondingly, the distance of groove  36   c  from groove  36   a  may vary between 95-105 percent more than the distance from the cutting edge  22  to groove  36   a.    
         [0027]    While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.