TOOL FOR ROTARY CHIP REMOVAL, A TOOL TIP AND A METHOD FOR MANUFACTURING A TOOL TIP

Abstract: The present invention relates to a tool and a tool tip for chip removal, wherein the tool in operative position preferably rotates around its longitudinal centre axis. The invention also relates to a method for manufacturing a tool tip. The tool tip (10") contains two hard metal grades, a tough less wear resistant grade in the inner portion (40") and a more brittle more wear resistant grade in the external portion (41"). The tool tip is made by injection moulding and the two grades have the same shrinkage. The inner portion (40") is entirely surrounded by the external portion (41") except for in the feed direction and the retraction direction. The tool tip has a thread (25) formed in the tougher hard metal such to endure high tensions.

Description: TOOL FOR ROTARY CHIP REMOVAL, A TOOL TIP AND A METHOD FOR MANUFACTURING A TOOL TIP Background of the invention The present invention relates to a tool for rotary chip removal, comprising a tool body, a tool tip and means for fastening. The invention also relates to a tool tip per se, and to a method for manufacturing a tool tip. Prior art It is previously known to use interchangeable cutting edges at different types of tools for chip removal. However this technique has its practical limitation due to strength reasons when it comes to milling and drilling tools rotating about their longitudinal axes, since the cutting edges then are submitted to variable cutting speed. Through U.S. patent No. 5,947,660 is previously known a drill with an injection moulded releasable tool tip anchored in a tool body by means of a pull rod. A drawback with the known drill as for most drills is that it's not optimised for variable cutting speed. In addition, the thread in the known drill tends to crack at high tension. It is known through for example WO 98/28455 to press a core and a surrounding tube of material powder in two steps. The material powder consists of wolframkarbid (WC) together with cobalt (Co), which is compressed between a stamp and a die and is subsequently sintered such that the binder metal melts and ties the carbides such to shape tool material for chip removing machining. The object of the known technique is to obtain two different properties depending on radial position in a solid body. Drawbacks with this technique are problems with cracks in the radially external portion or porosities in the radially inner portion. Objects of the invention The present invention has as one object to provide an embodiment of milling or drilling tools with interchangeable cutting edges, whereby said embodiment eliminates the problems of prior art tools. Another object of the present invention is to provide a rigid tool, preferably for drilling or milling, where the radially external parts of the cutting edges, which are subjected to relatively high cutting speed, have better wear resistance than the radially inner parts of the cutting edges. Another object of the present invention is to provide a tool, preferably for drilling or milling, where the radially inner parts of the cutting edges, which are subjected to relatively low cutting speed, have higher toughness than the radially external parts of the cutting edges. Another object of the present invention is to provide a tool, preferably for drilling or milling, where the risk for tool tip breakage is reduced. Still another object of the present invention is to provide a tool tip with a thread that endures high tension. Still another object of the present invention is to provide a method for manufacturing a tool tip from injection moulded hard metal whereby the degree of freedom for geometrical appearance is substantially unlimited and whereby grinding work is reduced. Still another object of the present invention is to provide a method for manufacturing a tool tip from injection moulded hard metal whereby cracks and porosities are avoided. These and other objects have been achieved by a tool, a tool tip and a method as defined in the appended claims with reference to the drawings. Description of the drawings Fig. 1 shows a drilling tool according to the present invention, partly in section. Fig. 2 shows a tool tip according to the present invention in a side view. Fig. 3 shows the tool tip in another side view. Fig. 4 shows the tool tip in a bottom view. Fig. 5 shows a cross-section according to the line V-V in Fig. 3. Fig. 6 shows a cross-section like in Fig. 5 of an alternative embodiment of a tool tip according to the present invention. Fig. 7 shows a cross-section like in Fig. 5 of still an alternative embodiment of a tool tip according to the present invention. Fig. 8 shows a drill body according to the present invention in a side view. Fig. 9 shows the drill body in a top view. Fig. 10 shows an end of the drill body in an enlarged side view. Fig. 11 shows a device in a bottom view for manufacturing of a tool tip according to the present invention. Fig. 12 shows a cross-section according to the line XII-XII in Fig. 11. Fig. 13 shows the device in a second manufacturing step in a cross-section corresponding to Fig. 11. Fig. 14 shows the device at the second step in a cross-section according to the line XIV-XIV in Fig. 13. Fig. 15 shows still an alternative embodiment of a tool end according to the present invention in an exploded view. Detailed description of the invention The embodiment in Fig. 1 of a tool according to the invention is a so called helix drill, which in this case includes a tool tip 10, a pull rod 11 , a tool body 12, a locking screw 50, a spring 51 and a stop screw 52. With this tool it is possible to untighten and change the tool tip although the tool body is fixed in a machine. The drilling tool has also been described in U.S. patent No. 5,947,660 and EP patent application No. 96913765.2, which are hereby incorporated into the present description. The tool tip 10 is provided with at least one cutting edge 19 at the end facing away from the drill body 12, which edge is given a design depending on the area of application. Thus the cutting edge is or the cutting edges are substantially straight and parallel to the longitudinal centre axis of the cutting portion when it is an end mill, while the cutting edges are circular when it is a ball nose end mill. The forward end of the cutting portion 10 in the figures shows an edge 19 for drilling including a chisel edge 24. The tool tip 10 and the tool body 12 includes support surfaces 22 and front surfaces 14 in accordance with WO 9900208 A1 , which is hereby incorporated into the present description. The tool tip 10 is made of injection moulded hard metal. Such as is apparent from Figs. 2-4 the tool tip comprises two upper clearance surfaces 15, a support surface 22 and these connecting first 17 and second 18 curved surfaces. All these surfaces and connected edges are made in injection moulded hard metal. Lines of intersection between the second curved surfaces or the chip flutes 18 and the clearance surfaces 15 shape main cutting edges 19, preferably via reinforcing chamfers, not shown. Lines of intersection between the first curved the surfaces 17 and the chip flutes 18 form secondary cutting edges 20. The chip flute may alternatively be adapted for a tool body with straight chip flutes. The biggest diameter of the tool tip is the diametrical distance between radial extreme points of the minor cutting edges 20. The height of the tool tip is substantially equal to the diameter. The biggest diameter of the support surface 22 is preferably smaller than the biggest diameter of the tool tip, so that clearance can be obtained at machining. A flushing hole 23 can run substantially parallel with the central axis CL through the tool tip from the support surface 22 and terminate in the respective upper clearance surface 15. The flushing holes intersect a normal to the central axis CL at each side of the central axis. The support surface 22 has a circular basic shape and includes two groove parts 22A, 22B. Each groove part covers substantially the entire support surface 22 and comprises a number of from each other separate, identical flutes or grooves. The grooves in the groove parts have two main directions, which are perpendicular to each other. Substantially each groove in both groove parts 22A, 22B intersects the jacket surface of the holder at two places. Each groove is elongated and substantially v-shaped in cross-section. Each groove has two flanks which, via sharp or rounded transitions, connect to a bottom. The flanks form an acute angle with each other. The angle lies in the interval of 40° to 80°, preferably 55° to 60°. Each flank is preferably planar and connects to the associated flank via an obtuse inner, soft or sharp, transition. The number of grooves in each groove part depends of how the front surface of the holder is formed and the number is chosen in the interval of 5 to 20 grooves. The design of the groove parts 22A, 22B gives a considerably larger specific surface than if this would be planar. The groove parts 22A, 22B cover at least 80%, preferably 90-100%, of the accessible area on the support surface 22. The tool tip has a blind hole with an integral thread 25 that co-operates with a threaded free end of the pull rod 11. Thereby is obtained the possibility to provide cutting edges towards the rotational axis for drilling. In the in Fig. 4 shown embodiment the groove parts 22A, 22B have been made through direct pressing and sintering or through grinding. The tool body is provided with chip flutes 18a, which follow the protruding lands of the drill along a helical path at a distance from the central axis CL. The chip flutes may extend along the entire body or along a part thereof. The chip flutes may alternatively be straight. The tool body 12 is equipped with a front surface 14 at the end facing towards the tool tip 10, which surface is provided to abut against the support surface 22 of the tool tip 10. The biggest diameter of the front surface is smaller than the biggest diameter of the tool tip but preferably equal to the smallest diameter of the tool tip. The tool body has flush channels 23A. The tool body 12 may be made of steel, hard metal or high speed steel. One free end or shank portion of the tool body 12 is intended to be secured in a rotatable spindle (not shown) in a drill while the opposed other free end surface includes a front surface 14 and a hole 15A. The free end of the pull rod is provided to project through the hole 15A. The front surface 14 has a circular basic shape and includes two groove parts 16A, 16B. Each groove part covers substantially half of the front surface 14 and includes number of from each other separate, identical flutes or grooves. The grooves in the groove parts have two main directions S1 , S2, which are perpendicular to each other. A second groove part 16A is bordered by a first groove part 16B. Substantially each groove in that first the groove part 16B intersects the jacket surface of the holder in two places, while substantially each groove in the second groove part 16A intersects the jacket surface of the holder in one place. Each groove is elongated as well as substantially v-shaped in cross-section. Each groove has two flanks which, via sharp or rounded transitions, connect to a bottom, and a width W. The flanks form an acute angle with each other. The angle lies in the interval 40° to 80°, preferably 55° to 60°. Each surface is preferably planarly formed and connects to the associated flank via an obtuse inner, soft or sharp, transition. The number of grooves in each groove part depends of how the support surface of the tool tip is formed and the number is chosen in the interval 5 to 20 grooves. The bottom can alternatively be described with a radius of about 0,2 to 0,4 mm. The design of the groove parts 16A, 16B gives a considerably bigger specific surface than if these should be planar. The groove parts 16A, 16B cover at least 80%, preferably 90- 100%, of the accessible area of the front surface 14. In the embodiment shown in Fig. 9 the first groove part 16b has been made, by hobbing or grinding, with feed direction parallel with the direction S2. Subsequently the second groove part 16A has been machined with the same tool in direction parallel with the direction S1. To obtain full depth in each groove in the second groove part 16A it is appropriate that the tool is fed somewhat into the first groove part 16B. Then said tool will also machine material of the first groove part 16B, which appears from for example Fig. 9, wherein completely or partly pyramid-shaped projections are formed at the termination of the second groove part 16A in the first groove part 16B. In the shown embodiment the area of the second groove part 16A is somewhat bigger than the area of the first groove part 16B. At mounting the grooves in the groove parts in the tool body and the tool tip are adapted such that the flush channels and the chip flutes are aligned with each other in the respective part. Mounting of the tool tip 10 on the tool body 12 is done as follows. The pull rod is brought into a boring in the shank portion and through the tool body 12 until the forward portion of the pull rod projects centrally from the front surface 14. Then the spring 51 is inserted and the stop screw 52 is threaded inwardly. Said mounting is kind of a one-time action since the user normally only needs to change the tool tip. Subsequently the threaded end surface is brought into the recess 25 whereafter the tool tip is rotated and is threaded onto the pull rod. Then the support surface 22 of the tool tip is brought by hand into contact with the front surface 14 such that the grooves in the groove parts in the tool body 12 and the tool tip 10 and flush channels and the chip flutes become aligned with each other. The tool tip 10 will be drawn firmly against the front surface by rotating the locking screw 50, i.e. the position according to Fig. 1 has been achieved. The tool tip 10 is now anchored to the tool body 12 in a satisfactorily manner. The pull rod in this position is substantially intended to retain the tool tip at retraction of the tool from the machined hole while the ridges and the grooves receive the forces and the torque which is created at chip removal. The force from the pull rod however, is large enough to avoid play at the joint between the tool tip and the body at retraction. In this connection shall be pointed out that the threaded connection between the tool tip and the pull rod has two purposes, namely to place the tool tip 10 in a fixed position on the tool body at mounting, and at use of the cutting the tool to always ensure that the tool tip 10 is held in its fixed position. When the tool tip 10 shall be exchanged the mounting is reversed, whereby the tool tip 10 can be removed from the tool body 12 and be exchanged. Invention is applicable also for milling cutters. Layers of for example AI 2 O 3 , TiN and/or TiCN preferably coat the tool tip. In certain cases it can be well founded to braze super hard material such as CBN or PCD on the cutting edges. Likewise it is possible to use other clamping means than a central pull rod; for example it is possible to retain the tool tip by means of a bayonet coupling such as is indicated in U.S. patent No. 5,988,953 or as shown in Fig. 15. In addition shall be pointed out that the above described embodiments relates to tools which rotate relative to their longitudinal axis or the centre axis of the workpiece and that the means for retention rotates with the tool. The embodiments can be used also as stationary but then in combination with a rotary work piece. So far the present description has described prior art substantially as it is described in WO 9900208 A1. A new feature of the tool and the tool tip according to the present invention is to provide a rigid tool preferably for drilling or milling where each of the radially external portions 41-41'" of the tool tip, which is subjected to relatively high cutting speed, has a better wear resistance than each of the radially inner portions 40-40'" of the tool tip simultaneous as the blind hole 25 is made in a relatively tough hard metal, which endures high tensions, see Figs. 5 - 7. This is attained by filling a first mould 60 for injection moulding via the inlet 62 with a first mixture under high pressure and certain temperature, about 180 °C. The mould comprises a first cylindrical or elliptical cavity or recess for the case that the tool tip has an appearance according to Fig. 5 and Fig. 6, respectively, and a centrally placed, externally threaded core 65. The method is explained more closely with reference to Figs. 11-13 wherein an additional alternative embodiment of a tool tip 41", Fig. 7, according to the present invention is shown. In this embodiment the contour of the cavity has the appearance of a peanut or hour-glass, in a bottom view according to Fig. 11 , such to form a core 61 which surrounds the flushing holes 23 and the blind hole 25. The mould 60 includes an externally threaded spigot 65 that forms the threaded blind hole 25. The flushing holes and the blind hole are formed when the spigot and somewhat conical core pins 66 are surrounded by the liquid mixture during the first phase of the injection moulding process. The mixture consists of hard metal powder with relatively high cobalt content and a binder, for example plastics, which is mixed and is shaped to pellets or granulates. Thereby a core 61 including flushing holes 23 and an internal thread 25 is created. The core 61 is then after cooling surrounded by a second mould 63 for injection moulding, Figs. 13 and 14, preferably by replacing the two first jaws used at the first injection with new jaws. The second mould 63 includes portions for forming chip flutes and the other parts of the tool tip. The conical core pins 66 are used for fixing the insert during the second injection. Consequently the core 61 is fixed centrally in the second mould whereafter a second mixture 67 is injected via the inlet 64 into the second mould. The second mixture 67 differs from the first mixture foremost in the amount of cobalt being smaller in the second mixture. The difference in metallic binder lies within the interval of 1-10 weight percent units. With the term "cobalt" shall here be understood a metallic binder which alternatively can be exchanged for or include other metals, for example nickel, Ni. Furthermore, the existing machine can be used by changing only the form- giving jaws from the first injection. This is a good manufacturing solution since the core pins can accompany the core 61 and position the core during its subsequent treatment. In the position according to Fig. 14 the threaded spigot 65 is not needed. A blank for a tool tip has been obtained after the second step of the injection moulding, after cooling, which after sintering forms a tool tip of at least two hard metal grades after grinding of cutting edges 19 and a chisel edge 24. The core 61 defines after sintering the inner portion 40" while the second mixture 67 constitutes the external portion 41". The plastic binder is first removed from the shaped part, and the resulting compact is then sintered. The lower side of the tool tip is machined and obtains the above-described waffle pattern 22. Furthermore, with the assistance of this method the tool tip geometry can be chosen independent of the limitations of the conventional form pressing method. Chip breakers, for example, can be formed on surfaces that until now only have been possible to ground. Fig. 15 shows still an alternative embodiment of a drill according to the present invention. The drill has a drill body 12' and a drill tip 10'". The body and the tip are connected to each other via a known bayonet coupling. The inner portion 40'" of the tool tip 10'" is made from the tougher cemented carbide material since that portion comprises a projection 25' defining relative sharp concave corner portions. The tougher material is marked grey in Fig. 15. A more wear resistant cemented carbide material 41"' is positioned radially outside the tougher cemented carbide material as discussed above. The tool tip 10'" can be provided with flush channels. It is understood that although the cross-section of the drill in Fig. 15 mostly resemble the cross-section of Fig. 6 it could very well be made as in Figs. 5 or 7. Consequently the tool tip contains at least two hard metal grades, a tough, less wear resistant grade in the inner portion 40-40'" and a more brittle, more wear resistant grade in the external portion 41-41'". The tool tip is manufactured by injection moulding and the at least two grades have the same shrinkage, and therefor problems with cracks in the external portion or porosity in the inner portion, which may arise by conventional pressing, is eliminated. The tool tip has been shown in four alternative embodiments, two (Figs. 5 and 7) with an internal core, entirely surrounded by the external portion except for in the feed direction and the retraction direction, and two (Figs. 6 and 15) with a through-going central portion, not entirely surrounded by the external portion. The difference in cobalt content between the inner portion and the external portion lies in the range of 1 - 10 % by weight. The inner portion is made of a material with 6 - 20 % by weight cobalt while the material in the external portion contains 5 - 15 % by weight cobalt. In two of the embodiments the inner portion 40, 40' does not reach the flush channels 23. The fourth embodiment (Fig. 15) does not disclose flush channels at all. The central portion of the tool tip is formed in a tougher hard metal such that its thread 25/protrusion 25' will endure high tensions and such that its cutting forward end 21 such as the chisel edge 24 will endure low cutting speed. The invention is in no way limited to the above described embodiments but can be varied freely within the scope of the appended claims.

Claims: Claims 1. Tool for relative to a work piece, rotary chip removal, including a tool body (12), a tool tip (10-10'") and means for fastening, said tool body having a front surface (14) and the said tool tip having a support surface (22) provided to releaseably abut against each other, said body having a shank portion, said tool tip consisting of injection moulded hard metal and includes at least one cutting edge (19) and a hole (25) or protrusion (25') to cooperate with the means for fastening, said hole/protrusion and the cutting edge being integral with the tool tip (10-10'"), c h a r a c t e r i z e d i n that the hole (25) or the protrusion (25') at least partially is formed in an integral inner portion (40-40'") of the tool tip in a material which is tougher than the material of which the remainder (41-41'") of the tool tip is made. 2. The tool according to claim 1 , wherein the hole (25) is a central blind hole and comprises an internal thread or wherein the protrusion (25') form part of a bayonet coupling, and wherein a central portion of the cutting edge (19) is made of the tougher material. 3. The tool according to claim 2, wherein the tougher material surrounds the blind hole (25) and extends from a forward end (21) of the tool tip to the support surface (22) essentially parallel with the centre axis (CL) of the tool tip. 4. The tool according to claim 1, wherein the tool tip (10; 10") has an internal integral core (40;40"), entirely surrounded by the external portion (41 ;41") except for in the feed direction and the retraction direction. 5. The tool according to claim 1, wherein the tool tip (10') has a through-going ellipse shaped central portion (40'), partly surrounded by the external portion (41') or wherein the tool tip (10") has a through-going central portion (40") which surrounds the flushing hole (23) and the central hole (25). 6. Tool tip for rotary chip removal, wherein the tool tip (10-10'") has a circular basic shape and has at least one cutting edge (19), which is integral with the tool tip (10-10'"), which is provided with a support surface (22) at the end facing away from the cutting edge, said tool tip consisting of injection moulded hard metal and including a hole (25) or protrusion (25') to cooperate with a means for fastening, said hole/protrusion and the cutting edge being integral with the tool tip, c h a r a c t e r i z e d i n that the hole (25) or the protrusion (25') at least partially is formed in an integral inner portion (40-40'") of the tool tip in a material which is tougher than the material of which the remainder (41-41'") of the tool tip is made. 7. The tool according to claim 6, wherein the hole (25) is a central blind hole and comprises an internal thread or wherein the protrusion (25') form part of a bayonet coupling, and wherein a central portion of the cutting edge (19) is made of the tougher material. 8. The tool according to claim 7, wherein the tougher material surrounds the blind hole (25) and extends from a forward end (21) of the tool tip to the support surface (22) essentially parallel with the centre axis (CL) of the tool tip. 9. The tool according to claim 6, wherein the tool tip (10-10"') has an internal integral core (40-40'"), entirely or partly surrounded by the external portion (41- 41'") or wherein the tool tip (10") has a through-going central portion (40") which surrounds the flushing hole (23) and the central hole (25). 10. Method for manufacturing a tool tip (10-10'") provided with an edge, for rotary chip removal, said tool tip (10-10'") having a circular basic shape and having at least one cutting edge (19,24), which is integral with the tool tip (10-10'"), which is provided with a support surface (22) at the end facing away from the cutting edge, and a hole (25) or a protrusion (25') to cooperate with a means for fastening, said hole/protrusion and the cutting edge being integral with the tool tip (10-10'"), c h a r a c t e r i z e d i n that hard metal powder having a first content of metallic binder, and a plastic binder is mixed whereafter the mixture is inserted into a moulding machine and heated to a suitable temperature for the mixture, whereafter the mixture under high pressure and certain temperature is injected into a first mould (60) including a first recess and a spigot (65) with the intention to shape a core (61) with at least one hole (23,25) whereafter the mixture solidifies in the first mould, whereafter the core (61) is surrounded by and is positioned with the assistance of said hole (23,25) in a second mould (63) in a moulding machine, wherein a second mixture including hard metal powder having a lower second content of metallic binder and a plastic binder is inserted and is heated to a suitable temperature for the mixture, said second mould (63) including portions forming directly or indirectly at least one cutting edge, at least one clearance surface, a support surface and one or more cores, with the intention to bring the design to the tool tip, whereafter the mixture solidifies in the mould, whereafter the tool tip is plucked from the mould and is sintered and possible finish machining such as grinding is made.

Inventors: BRUHN JOHNNY, GROENKVIST MIKAEL, PUIDE MATTIAS, BRUHN, JOHNNY, GROENKVIST, MIKAEL, PUIDE, MATTIAS
Applicants: SECO TOOLS AB PUBL, SECO TOOLS AB (PUBL)
Application year: 2000
Main classification: B23B51
IPC codes: B23B31, B23B51