A metal cutting tool

Abstract: A metal cutting tool having a metal cutting tip (3) with at least one cutting edge (4) defined between a rake face and a relief flank (6) and at least one recess formed in said relief flank (6) and constituting a coolant channel (8) and extending towards said cutting edge and being spaced therefrom by a spacing s which is of the order of the prescribed permissible width of flank wear VB max .

Description: This invention relates to a metal cutting tool of the kind having a metal cutting tip which either forms an integral part of the tool or is formed on a metal cutting insert releasably retained in an insert holder of the tool. The invention also relates to metal cutting inserts for use with such metal cutting tools. With such metal cutting tools, the cutting edge of the tip is defined between a rake surface thereof and a relief flank or clearance face and, in use, the cutting edge and the portion of the relief flank adjacent thereto, become rapidly worn and, where the tip is formed on a replaceable insert, the latter must therefore be frequently replaced or rotated so as to index a fresh cutting edge in position. Similarly, where the tip forms an integral part of the cutting tool, the tip must be frequently reset or the entire tool must be replaced. With such cutting tips there is generally specified (by the manufacturers) a maximum degree of wear of the relief flank after which replacement, resetting or indexing must be effected. This maximum degree of wear is usually specified in terms of the maximum width VB max of wear of the relief flank when measured from the cutting edge. Thus, when the flank wear reaches the specified maximum VB max , the tip should be reset or replaced. It is well-known that one of the factors determining flank wear is the hardness of the insert material. Thus, the harder the material the less will be the rate of wear and the longer the insert can be used before wear has reached VB max requiring replacement. However, this hardness is directly related to the working temperature and with rise of working temperature there is an associated reduction in hardness, with a consequent increase in the rate of wear. It is for this reason that, in the use of such cutting tools, means have been provided for the fluid cooling of the cutting insert in the region of the cutting edge thereof. In one known method of fluid cooling, the upper surface of the cutting tip or insert is sprayed with a coolant fluid but it is found that the continued movement of the chip over the rake surface of the cutting insert disturbs the effective cooling of the insert by the coolant. In another known method of cooling, a coolant is passed through the cutting tip from the base thereof to the upper rake surface. It is found in practice, however, that the pressure of the chip on the upper rake surface prevents the coolant from effectively reaching the region of the cutting edge, and here again the efficiency of cooling is limited. A further method which has been employed has been to direct a coolant through a duct formed in the cutting insert or cutting tip, which duct emerges from an aperture in the relief flank of the cutting insert. It is found, however, that in order to ensure effective distribution of the coolant liquid around the relief flank and in the vicinity of the cutting edge, a number of such coolant ducts must be provided and this, in turn, leads to a significant weakening of the insert. Furthermore, the penetration of the coolant is hindered by the narrow gap between the relief flank and the workpiece. It has also been proposed to direct a jet of a coolant liquid into the space between the relief flank and the workpiece, but this method is of very limited value, particularly when the tool involved is a grooving or parting tool, seeing that the region between the relief flank and the workpiece is of extremely limited accessibility as compared with a turning tool. FR-A-1 115 922 discloses a metal cutting tool with an elongated internal coolant channel merging with a short slanted section which extends towards the relief flank and terminals in an opening located in the relief flank. It is therefore an object of the present invention to provide a metal cutting tool having a metal cutting tip, and which is provided with fluid coolant means wherein the above-referred-to disadvantages are substantially reduced or overcome. It is equally an object of the present invention to provide a metal cutting insert for use in a metal cutting tool, provided with fluid coolant means wherein these disadvantages are substantially reduced or overcome. These objects are solved with the features of the claims. With such a cutting tool, whether having an integrally formed cutting tip or a replaceable cutting insert, coolant is directed into the coolant channel formed in the relief flank of the tip and is thus guided to and concentrated in the region of expected flank wear. Thus, cooling takes place in the region of the cutting insert where it is most required and, in this way, the rate of flank wear is significantly reduced. This, in turn, reduces the frequency with which cutting inserts have to be replaced when the wear thereof has reached the maximum permissible level. Various embodiments of metal cutting inserts in accordance with the present invention will now be described by way of example and with reference to the accompanying drawings, in which Fig. 1 is a schematic perspective view of a part of a grooving or parting tool in accordance with the invention and fitted with a replaceable insert; Fig. 2 is a side elevation (partially sectioned) of the tool shown in Fig. 1; Fig. 3 is a schematic front elevation of a relief flank of a replaceable insert in accordance with the invention. Fig. 4 is an enlarged view of detail A of the tool shown in Fig. 2; Figs. 5 and 6 are schematic views of differing forms of inserts in accordance with the invention; Fig. 7 is a schematic perspective view of a portion of a milling or turning tool fitted with a replaceable insert in accordance with the invention; and Figs. 8 and 9 are views of differing forms of turning or milling inserts in accordance with the invention. Referring to Fig. 1, there is here shown schematically a grooving or parting tool 1 having a tool holder 2 in which is wedge clamped a replaceable cutting insert 3 having a cutting edge 4 defined between an upper rake surface 5 and a front relief flank 6. Formed in the relief flank 6 and extending from a base 7 of the insert 3 is an elongated recess 8 constituting a coolant channel, the recess being bounded on either side by unrecessed portions 6a and 6b of the relief flank 6. A coolant duct 9 is formed in the insert holder 2 and has an outlet aperture 10 which communicates with the open, lower end of the recess 8. As can be seen in Figs. 2, 3 and 4 of the drawings, the recess 8 tapers in depth from the broadest depth in the region of the base towards the direction of the cutting edge. The upper extremity of the recess is spaced from the cutting edge by a spacing s . Fig. 4 shows the prescribed maximum permissible extent of flank wear VB max . As can be seen, s is slightly greater than VB max , the invention requiring that s is of the order of VB max . Preferably, s lies substantially within the range of VB max and 4VB max with a preferred value of s being substantially equal to 1.5VB max . On the other hand, the depth d of the recess 8 in the region closest to the cutting edge should be greater than or equal to the spacing s , the preferred value being that the depth d is substantially equal to 2VB max . In the embodiment shown in Figs. 1, 2, and 4, the relief flank 6 is provided with a single, centrally-disposed recess 8, the relief flank 6 being bounded on either side thereof by unrecessed portions 6a and 6b thereof. Depending on the size of the cutting inserts, the relief flank 6 can be provided with a plurality of such coolant recesses 8 (as, for example, shown in Fig. 3 of the drawings) and whilst the general considerations outlined above in connection with the spacing of these coolant recesses from the cutting edge apply to the situation where a plurality of such recesses are provided, the actual locations of the terminal positions of the recesses adjacent the cutting edge may differ slightly one from the other. Both for the case where the relief flank is provided with a single coolant recess and for the case where the relief flank is provided with a plurality of such coolant recesses, the overall transverse extent W of the recesses, i.e. the sum total of the transverse dimensions thereof, should lie within the range of 0.2 L to 0.7 L , where L (as seen in Fig. 3) is the transverse extent of the cutting edge as a whole. Where the insert is designed for use in turning (as, for example, in tools known by the trademark CUT-GRIP ), the tool, as shown in Fig. 5, is provided with side cutting edges 11 and with coolant recesses 12 formed in side relief flanks 13. In the embodiment shown in Fig. 6 of the drawings, coolant recesses 14 are formed at the corners defined by side and front relief flanks and extend towards the corners of the cutting edge. Such an arrangement is believed to be advantageous, seeing that in practice it is found that the magnitude of VB max at the corners is greater than in the central positions, and cooling which is concentrated at the corners is believed to be particularly effective in reducing the rate of flank wear. Reference will now be made to Figs. 7, 8 and 9 of the drawings, where there are illustrated the application of the invention to a turning tool. As seen in Fig. 7, a turning tool 21 comprises a holder 22 formed with a pocket 23 in which is fitted a turning insert 24. In the case of this turning insert, clearance faces of the insert 24 are provided with a succession of coolant recesses 25. In Figs. 8 and 9 are shown various alternative locations for the coolant recesses in the insert of the tool. Thus, in Fig. 8 the recesses 26 are adjacent the insert corners whilst in Fig. 9 the recesses 27 are located at the insert corners. The recesses 25, 26 and 27 extend as before to a region of the insert adjacent the cutting edges and spaced therefrom by a spacing of the order of the maximum permissible depth of flank wear. The recesses extend into the base of the insert and communicate there with outlet apertures of coolant ducts formed in the holder 22. Whilst in all the embodiments described above the coolant channels communicate with the outlets of coolant ducts formed in the holders and coolant fluid emerging from these outlets pass through the coolant channels and are guided thereby into the region adjacent the cutting edges, in other embodiments (not illustrated) coolant fluid may be directed into the coolant channels from externally disposed coolant ducts or nozzles. Furthermore, whilst in all the embodiments described above the coolant channels extend into and through the base of the inserts, the invention is equally applicable to the situation where the coolant channel extends from the region of the base but not necessarily through the base. In such embodiments, the coolant fluid is directed into the coolant channels from externally located ducts or nozzles. Whilst in all the embodiments described above the invention has been applied to replaceable cutting inserts, it will be understood that the invention is equally applicable in the case of cutting tools having integrally formed cutting tips.

Claims: A metal cutting tool having a metal cutting tip with at least one cutting edge defined between a rake face and a relief flank (6), characterised in that said relief flank (6) has a prescribed permissible extent of flank wear of the cutting edge during use as measured in a direction from said cutting edge and along said relief flank, at least one elongated recess (8) is formed in said relief flank (6) and constituting a coolant channel and extending towards said cutting edge (4) and the upper extremity of said recess is spaced therefrom by a spacing s which is of the order of said prescribed permissible extent of flank wear VB max . A metal cutting tool according to Claim 1, characterised in that said cutting tip is constituted by a replaceable cutting insert (3) and furthermore comprises an insert holder (2) for releasably retaining such insert (3). A metal cutting tool according to Claim 2, characterised in that said insert holder (2) is formed with a fluid coolant duct (9) through which coolant fluid can be directed into said coolant channel. A metal cutting insert for use in a metal cutting tool according to Claim 2 or 3, and comprising at least one cutting edge defined between a rake face and a relief flank, and characterised in that said relief flank (6) has a prescribed permissible extent of flank wear of the cutting edge during use as measured in a direction from said cutting edge and along said relief flank, at least one elongated recess (8) is formed in said relief flank (6) and constituting a coolant channel and extending from the region of a base (7) of the insert (3) towards said cutting edge (4) and the upper extremity of said recess is spaced therefrom by a spacing s which is of the order of said prescribed maximum permissible extent of flank wear VB max . An insert according to Claim 4, characterised in that said recess (8) extends from and through said base (7). An insert according to Claim 4 or 5, characterised in that said relief flank (6) is bounded on either side thereof by unrecessed portions (6a and 6b) thereof. An insert according to any one of the preceding claims, characterised in that s lies substantially within the range VB max to 4VB max . An insert according to Claim 7, characterised in that s is substantially equal to 1.5VB max . An insert according to any one of the preceding claims, characterised in that said recess (8) has a depth d in the region thereof closest to the cutting edge (4) wherein d is substantially equal to 2VB max . An insert according to any one of the preceding claims, characterised in that the total transverse extent W of the recesses (8) lies substantially within the range 0.2 L to 0.7 L , where L is the transverse extent of the cutting edge (4). An insert according to any one of the preceding claims, characterised in that recesses (14) are formed in corners thereof respectively defined by said relief flank (6) and a pair of adjacent side relief flanks (13). An insert according to any one of the preceding claims, characterised in that said relief flank (6) is a front relief flank. An insert according to any one of the preceding claims and having a plurality of cutting edges respectively defined between a rake face and a like plurality of relief flanks, characterised in that in each of said relief flanks (6, 13) is formed at least one of said recesses (8, 14). The insert according to claim 4 or any of claims 6 to 13 as dependent on claim 4, wherein said recess (8) extends from the region of said base (7) and does not pass therethrough.

Inventors: WERTHEIM RAPHAEL, WERTHEIM, RAPHAEL
Applicants: ISCAR LTD, ISCAR LTD.
Application year: 1992
Main classification: B23B27
IPC codes: B23Q1, B23B27