Patent Publication Number: US-2013230360-A1

Title: Edge of a tool

Description:
FIELD OF THE INVENTION 
     Disclosed is an edge for a segment of a tool and/or an insert for a tool, adapted to the chip-removing-machining of materials. 
     BACKGROUND OF THE INVENTION 
     Generally, a segment, be it of a solid tool or of an insert designed to be permanently and/or removably connected (such as by a screw, a pin, a clamp, and/or brazed or welded) may comprise a rake face (over which chips removed from a workpiece flow) and a relief face whereby the workpiece and the working end move relatively to each other. The rake face and the relief face inter-sect to define an edge therebetween. The edge may be designed to machine, or remove chips, from the workpiece. Such chip removal necessitates penetrating a workpiece surface to shear-off material chips. To facilitate penetration, it is usually useful to elongate the cutting edge more than the span of the material to be removed. This may be achieved by meandering the cutting edge. 
     As an example, U.S. Pat. No. 7,101,122 shows therein (see  FIGS. 1 and 2  here, titled “prior art” and depicting original  FIGS. 1 and 5  in the above-cited document) discloses, inter alia, “ . . . The upper face  12  is further provided with a breaker inclined surface  12 D which inclines such that the distance from the bottom face  11  decreases as the distance from the plane surface  12 C increases (toward the pair of cutting edges  17 ) to connect the plane surface  12 C disposed around the through hole  19  to the inclined surfaces  12 A and  12 B and the undulating portions  16 .” . . . . 
     . . . “Here, the cutting edges  17 , which exhibit a wavy shape due to the concave portions  14  and the convex portions  15  of the undulating portions  16 , will be explained in detail. As shown in  FIG. 5 , when viewing the cutting edge  17  in the direction along which the concave portions  14  and the convex portions  15  extend, while viewing the side face  13 , that is, as viewed in an imaginary diagram in which the substantially arc-shaped cutting edge  17  is deformed as a plane, the cutting edge  17  exhibits a wavy shape in which curves, each having different radii of curvature, are smoothly connected one after another. 
     “Moreover, as shown in  FIG. 5 , among the concave portions  14  of the cutting edge  17 , the depth HB of the first shallow-concave portion  14 B, which is defined by a distance between apices  15 X of the convex portions  15  (the levels of the apices  15 X are arranged to be the same with respect to each other, and the apices  15 X are disposed in substantially the same plane as the plane portion  12 C) and the bottom  14 X of the concave portion  14  measured along the direction of thickness of the throwaway insert  10 , that is, along a direction perpendicular to the bottom face  11 , is set to be substantially equal to the depth HD of the second shallow-concave portion  14 D, and the depths HB and HD are preferably set in a range from 0.3 to 1.2 mm. In this embodiment, both the depth HB of the first shallow-concave portion  14 B and the depth HD of the second shallow-concave portion  14 D are set to be 0.8 mm. 
     “As is also shown in  FIG. 5 , among the concave portion  14  of the cutting edge  17 , the depth HC of the second deep-concave portion  14 C is set to be greater than the depth HA of the first deep-concave portion  14 A, and the depths HA and HC are preferably set in a range from 1.2 to 3.0 mm. In this embodiment, the depth HA of the first deep-concave portion  14 A is set to be 2.0 mm, and the depth HC of the second deep-concave portion  14 C is set to be 2.4 mm . . . .” 
     It would be desirable to have an improved edge that offers improved chip-removing machining performance. This may be attained with the subject matter in accordance with the claims. 
     SUMMARY OF THE INVENTION 
     In the following disclosure, aspects thereof are described and illustrated in conjunction with systems and methods which are meant to be exemplary and illustrative, not limiting in scope. 
     The present invention is broadly related to a cutting edge for a cutting segment intended to cut or remove chips from materials. The edge is formed at a meeting of a first surface and a second surface comprises at least one segment extending from a first peak to a second peak through a nadir disposed therebetween. The first peak has a first peak line passing therethrough, the second peak has a second peak line passing therethrough, and the nadir having a nadir line passing therethrough. The first peak line, the second peak line, and the nadir line are parallel to each other, and a first depth D 1  between the nadir line and the first peak line is greater than a second depth D 2  between the nadir line and the second peak line. 
     Possibly, the first surface may act as a rake face while the second face acts as a relief face. Alternatively, the first surface may act as a relief face while the second face acts as a rake face. 
     Possibly, the rake face undulates. However, alternatively, the relief face undulates. 
     Optionally, a plurality of adjacent segments may be formed, each edge of a respective segment may meander from the first peak to the second peak through the nadir. The first peaks may define a first peak line, the second peaks may define a second peak line, and the nadirs may define a nadir line, so that the first peak line is associated with a first peak plane extending parallel to a second peak plane associated with the second peak line and parallel to a nadir plane extending through the nadir line. 
     Moreover, the edge may be formed at a meeting of a first surface and a second surface which comprises at least one segment extending from a first peak to a second peak through a nadir interposed therebetween. The first peak may have a first peak normal passing therethrough, the second peak may have a second peak normal passing therethrough, and the nadir may have a nadir normal passing therethrough, so that the first peak normal, the second peak normal, and the nadir normal are parallel to each other and extend generally transversely to the edge. 
     Furthermore, a first breadth B 1  between the nadir normal and the first peak normal is smaller than a second breadth B 2  between the nadir normal and the second peak normal. 
     Possibly, the edge may comprise a plurality of adjacent segments, each segment meandering from the first peak to the second peak through the nadir. 
     Optionally, the plurality of segments may be arranged so that two adjacent first peaks merge. 
     Alternatively, the plurality of segments is arranged so that two adjacent second peaks merge. 
     Possibly, any two adjacent nadirs may be separated by two merging first peaks. 
     Alternatively, each two adjacent nadirs may be separated by two merging second peaks. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed descriptions. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Exemplary and/or illustrative embodiments of the present disclosure will be presented herein below in the following figures, by way of example only. The figures are not necessarily to scale, and some features may be exaggerated or minimized and/or roughly shown and/or omitted entirely, to show de-tails of particular components, intending that the present disclosure may become more fully understood from the detailed description and the accompanying schematic figures, wherein: 
         FIG. 1  shows  FIG. 1  of prior-art reference U.S. Pat. No. 7,101,122; 
         FIG. 2  shows corresponding  FIG. 5  of the above-referenced prior-art; 
         FIG. 3  is a schematic perspective view of a first exemplary embodiment of a cutting segment in accordance with the present invention; 
         FIG. 4  is a schematic detail view of the first cutting segment shown on  FIG. 3 ; 
         FIG. 5  is a schematic partial perspective detail view of a second exemplary embodiment of a cutting segment in accordance with the present invention; 
         FIG. 6  is a schematic partial perspective view of a generalized exemplary embodiment of a cutting tool carrying a schematic cutting segment in accordance with the present invention; 
         FIG. 7  is a schematic detail elevation view of a third exemplary embodiment of the generalized cutting segment shown on  FIG. 6 ; 
         FIG. 8  is a schematic detail elevation view of a fourth exemplary embodiment of the generalized cutting segment shown on  FIG. 6 ; 
         FIG. 9  is a perspective detail view of a fifth exemplary embodiment of a cutting segment in accordance with the present invention; and 
         FIG. 10  is a detail plan view of the fifth exemplary embodiment of the cutting segment shown on  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Attention is drawn to  FIG. 3 . An exemplary-only schematic illustration of a first embodiment of an insert  110  (also known in the art as a cutting plate and/or a cutting bit, among other variants) is shown. While in  FIG. 3  there appears an exemplary-only illustration of a generally square shaped insert  110 , many other shape variants, such as, but not limited to, rectangular, rhomb, parallelogram, any polyhedral shape and/or any generally rounded shapes, including, but not limited to, circular and/or generally circular shapes, to name a few, are known and used in the art. The first insert  110  may comprise at least one first segment  120 . The at least one first segment  120  comprises a first surface  122  and a second surface  124 . The first surface  122  and the second surface  124  meet at an edge  126 . Generally, when operative, the edge may be directed towards, and may bear against, a material of a work-piece from which chips are intended to be removed to machine the work-piece. As best appreciated from  FIG. 4 , the edge  126  meanders to comprise at least one first peak  130  and at least one second peak  132  with a nadir  134  disposed therebetween. The first and second peaks  130 , 132  are defined as local maxima, while the nadir  134  is defined as a local minimum of the edge  126  of the at least one first segment  120 . In the first embodiment discussed here, the first surface  122  of the at least one first segment  120  may act as a rake face, while the second surface  124  of the at least one first segment  120  may act as a relief face, as is known in the art. In the first embodiment, the relief face is undulated, causing the edge  126  to meander. 
     Attention continues with respect to  FIG. 4 . The edge  126  of the at least one first segment  120  extends from the first peak  130  dipping down to the nadir  134  and away therefrom to the second peak  132 . A nadir line L N  to the edge  126  passes through the nadir  134 . A first peak line L P1  and a second peak line L P2  to the edge  126  run parallel to the nadir line L N  through the first peak  130  and the second peak  132  respectively. In this particular embodiment of the cutting segment  120 , a first depth D 1  between the nadir line L N  and the first peak line L P1  is greater than a second depth D 2  between the nadir line L N  and the second peak line L P2 . A nadir normal N N  normal to the nadir  134  extends parallel to a first peak normal N P1  normal to the first peak  130  and to a second peak normal N P2  normal to the second peak  132 . A first breadth B 1  between the nadir normal N N  and the first peak normal N P1  is smaller than a second breadth B 2  between the nadir normal N N  and the second peak normal N P2 . When two or more second segments  120  exist adjacent to each other on a same or similar bearing, their respective nadirs  134  may rest at the distance D 1  from the adjacent first peak  130 . 
     Attention is now directed to  FIG. 5 . An exemplary-only schematic illustration of a second embodiment of an at least one segment  320  of a second cutting insert  310  (illustrated only partially) is shown. The at least one second segment  320  may have many features similar to those of the at least one first segment  120 . Similar features will be related to with similar numerals, increased by 200. The at least one second segment  320  comprises a first surface  322  and a second surface  324 . The first surface  322  and the second surface  324  meet at an edge  326 . The edge  326  meanders to comprise at least one first peak  330  and at least one second peak  332  with a nadir  334  interposed there-between. The first and second peaks  330 , 332  are defined as local maxima, while the nadir  334  is defined as a local minimum of the edge  326  of the at least one cutting segment  320  of the second cutting insert  310 . In the second embodiment discussed here, the first surface  322  of the at least one second segment  320  may act as a relief face, while the second surface  324  of the at least one second segment  320  may act as a rake face, as is known in the art. 
     The edge  326  of the at least one second segment  320  extends from the first peak  330  dipping down to the nadir  334  and away therefrom to the second peak  332 . A nadir line L N  to the edge  326  passes through the nadir  334 . A first peak line L P1  and a second peak line L P2  to the edge  326  run parallel to the nadir line L N  through the first peak  330  and the second peak  332  respectively. In this particular embodiment of the cutting segment  320 , a first depth D 1  between the nadir line L N  and the first peak line L P1  is greater than a second depth D 2  between the nadir line L N  and the second peak line L P2 . A nadir normal N N  normal to the nadir  334  extends parallel to a first peak normal N P1  normal to the first peak  330  and to a second peak normal N P2  normal to the second peak  332 . A first breadth B 1  between the nadir normal N N  and the first peak normal N P1  is smaller than a second breadth B 2  between the nadir normal N N  and the second peak normal N n . When two or more second segments  320  exist adjacent each other on a same or similar bearing, their respective nadirs  334  may rest at the distance D 1  from the adjacent first peak  330 . 
     When a curved edge exists (as is exemplarily illustrated on  FIG. 5 , but not limited to that particular embodiment) with a plurality of first peaks, a plurality of second peaks, and a plurality of nadirs, the plurality of first peaks may lie on the same first peak line, the plurality of second peaks may lie on the same second peak line, and the plurality of nadirs may lie on the same nadir line. The first peak line is associated with a first peak plane, the second peak line being associated with a second peak plane, and the nadir line is associated with a nadir plane, with the first peak plane, second peak plane, and the nadir plane being parallel to each other. In the first embodiment, the rake face is undulated, causing the edge  326  to meander. 
     Attention is now directed to  FIG. 6 , showing a schematic partial perspective view of a generalized exemplary embodiment of a tool  510  carrying at least one schematic generalized cutting segment in accordance with the present invention. The tool  510 , in this case a solid end mill and/or a drill and/or a combination thereof, has a generally longitudinally extending center core  512  and at least one lobe  514  extending generally radially away therefrom. 
     Drawing attention now additionally to  FIG. 7 , there is shown a third embodiment of an at least one segment  620  of the tool  510  (illustrated only partially). The at least one third segment  620  may have many features similar to those of the at least one first segment  120 . Similar features will be related to with similar numerals, increased by 500. The at least one third segment  620  comprises a first surface  622  and a second surface  624 . The first surface  622  and the second surface  624  meet at an edge  626 . The edge  626  meanders to comprise at least one first peak  630  and at least one second peak  632  with a nadir  634  interposed therebetween. The first and second peaks  630 ,  632  are defined as local maxima, while the nadir  634  is defined as a local minimum of the edge  626  of the at least one third segment  620  of the tool  510 . In the third embodiment discussed here, the first surface  622  of the at least one third segment  620  may act as a rake face, while the second surface  624  of the at least one third segment  620  may act as a relief face, as is known in the art. 
     The edge  626  of the at least one third segment  620  extends from the first peak  630  dipping down to the nadir  634  and away therefrom to the sec- and peak  632 . A nadir line L N  to the edge  626  passes through the nadir  634 . A first peak line L P1  and a second peak line L P2  to the edge  626  run parallel to the nadir line L N  through the first peak  630  and the second peak  632  respectively. In this particular embodiment of the at least one third segment  620 , a first depth D 1  between the nadir line L N  and the first peak line L P1  is greater than a second depth D 2  between the nadir line L N  and the second peak line L P2 . A nadir normal N N  normal to the nadir  634 , a first peak normal N P1  normal to the first peak  630 , and a second peak normal N P2  normal to the second peak  632  ex-tends parallel to each other and perpendicularly to the nadir line L N , first peak line L P1  and the second peak line L P2 . A first breadth B 1  between the nadir normal N N  and the first peak normal N P1  is smaller than a second breadth B 2  between the nadir normal N N  and the second peak normal N P2 . When two or more second segments  620  exist adjacent each other on a same or similar bearing, their respective nadirs  634  may rest at the distance D 1  from the adjacent first peak  630 . 
     Attention is now directed to  FIG. 6  and  FIG. 8 . A fourth embodiment of an at least one segment  720  of the tool  510  (illustrated only partially) is shown. The at least one fourth segment  720  may have many features similar to those of the at least one first segment  120 . Similar features will be related to with similar numerals, increased by 600. The at least one fourth segment  720  comprises a first surface  722  and a second surface  724 . The first surface  722  and the second surface  724  meet at an edge  726 . The edge  726  meanders to comprise at least one first peak  730  and at least one second peak  732  with a nadir  734  interposed therebetween. The first and second peaks  730 ,  732  are defined as local maxima, while the nadir  734  is defined as a local minimum of the edge  726  of the at least one fourth segment  720  of the tool  510 . In the fourth embodiment discussed here, the first surface  722  of the at least one fourth segment  720  may act as a rake face, while the second surface  724  of the at least one fourth segment  720  may act as a relief face, as is known in the art. 
     The edge  726  of the at least one fourth segment  720  extends from the first peak  730  dipping down to the nadir  734  and away therefrom to the second peak  732 . A nadir line L N  to the edge  726  passes through the nadir  734 . A first peak line L P1  and a second peak line L P2  to the edge  726  run parallel to the nadir line L N  through the first peak  730  and the second peak  732  respectively. In this particular embodiment of the at least one fourth segment  720 , a first depth D 1  between the nadir line L N  and the first peak line L P1  is greater than a second depth D 2  between the nadir line L N  and the second peak line L P2 . A nadir normal N N  normal to the nadir  734 , a first peak normal N P1  normal to the first peak  630 , and a second peak normal N P2  normal to the second peak  732  extends parallel to each other and perpendicularly to the nadir line L N , first peak line L P1  and the second peak line L P2 . A first breadth B 1  between the nadir normal N N  and the first peak normal N P1  is smaller than a second breadth B 2  between the nadir normal N N  and the second peak normal N P2 . When two or more fourth segments  720  exist adjacent each other on a same or similar bearing, their respective nadirs  734  may rest at the distance D 1  from the adjacent first peak  730 . 
     Directing attention now to  FIGS. 9 and 10 , there is disclosed a fifth exemplary-only embodiment of an at least one segment  820  of a tool and/or an insert  810  (illustrated only partially). The tool and/or insert  810  of this particular, illustrative-only embodiment has two adjoining segments  820  on a generally forward bearing and at least one sixth segment  920  on a generally transverse bearing. Different annotations are used for the forward segments  820  and for the transverse segments  920  in order to stress the fact that the forward and the transverse segments need not be identical. However, the forward fifth segment  820  and the transverse sixth segment  920  may have many features similar to those of the at least one first segment  120 . Similar features will be related to with similar numerals, increased by 700 for the fifth segment  820  and by 800 for the sixth segment  920 . For the most part, reference will be made to the fifth segment  820 . The at least one fifth segment  820  comprises a first surface  822  and a second surface  824 . The first surface  822  and the second surface  824  meet at an edge  826 . The edge  826  meanders to comprise at least one first peak  830  and at least one second peak  832  with a nadir  834  interposed there-between. The first and second peaks  830 ,  832  are defined as local maxima, while the nadir  834  is defined as a local minimum of the edge  826  of the at least one fifth segment  820  of the tool and/or insert  810 . In the fifth embodiment discussed here, the first surface  822  of the at least one fifth segment  820  may act as a rake face, while the second surface  824  of the at least one fifth segment  820  may act as a relief face, as is known in the art. 
     The edge  826  of the at least one fifth segment  820  extends from the first peak  830  dipping down to the nadir  834  and away therefrom to the second peak  832 . A nadir line L N  to the edge  826  passes through the nadir  834 . A first peak line L P1  and a second peak line L P2  to the edge  826  run parallel to the nadir line L N  through the first peak  830  and the second peak  832  respectively. In this particular embodiment of the at least one fifth segment  820 , a first depth D 1  between the nadir line L N  and the first peak line L P1  is greater than a second depth D 2  between the nadir line L N  and the second peak line L P2 . A nadir normal N N  normal to the nadir  834 , a first peak normal N P1  normal to the first peak  830 , and a second peak normal N P2  normal to the second peak  832  ex-tend parallel to each other and perpendicularly to the nadir line L N , first peak line L P1  and the second peak line L P2 . A first breadth B 1  between the nadir normal N N  and the first peak normal N P1  is smaller than a second breadth B 2  between the nadir normal N N  and the second peak normal N P2 . In this particular embodiment, and as may best be noticed on  FIG. 9 , where there are two fifth segments  820  disposed side-by-side on the forward bearing, their respective nadirs  834  may rest at the distance D 1  from the adjacent first peak  830 . 
     Similarly, the at least one sixth segment  920  comprises a first transverse surface  922  and a second transverse surface  924 . The first transverse surface  922  and the second transverse surface  924  meet at a transverse edge  926 . The transverse edge  926  meanders to comprise at least one first transverse peak  930  and at least one transverse second peak  932  with a transverse nadir  934  interposed therebetween. The transverse first and sec- and peaks  930 , 932  are defined as local maxima, while the transverse nadir  934  is defined as a local minimum of the transverse edge  926  of the at least one sixth segment  920  of the tool and/or insert  810 . A transverse nadir line L′ N  to the transverse edge  926  passes through the transverse nadir  934 . 
     All directional references (such as, but not limited to, upper, lower, upward, downward, right, left, rightward, leftward, top, bottom, above, below, vertical, horizontal, clockwise, and counter-clockwise, lineal, axial and/or radial, or any other directional and/or similar references) are only used for identification purposes to aid the reader&#39;s understanding of illustrative embodiments of the present disclosure, and may not create any limitations, particularly as to the position, orientation, or use unless specifically set forth in the claims. Similarly, joinder references (such as, but not limited to, attached, coupled, connect, accommodate and the like and their derivatives) are to be construed broadly and may include intermediate members between a connection of segments and relative movement between segments. As such, joinder references may not necessarily infer that two segments are directly connected and in fixed relation to each other. 
     In some instances, components are described with reference to “ends” having a particular characteristic and/or being connected with another part. However, those skilled in the art will recognize that the present disclosure is not limited to components which terminate immediately beyond their points of connection with other parts. Thus, the term “end” should be interpreted broadly, in a manner that includes areas adjacent, rearward, forward of, or otherwise near the terminus of a particular segment, link, component, part, member or the like. Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “fourth”, or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader&#39;s understanding of the various embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any embodiment, variation and/or modification relative to, or over, another embodiment, variation and/or modification. 
     In methodologies directly or indirectly set forth herein, various steps and operations are described in one possible order of operation, but those skilled in the art will recognize that steps and operations may be rearranged, replaced, or eliminated without necessarily departing from the spirit and scope of the present disclosure as set forth in the claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the present invention as defined in the appended claims. 
     While an exemplary embodiment has been described and shown in the accompanying drawings, it is to be understood that such an embodiment is merely illustrative of and not restrictive on the broad present disclosure, and that this disclosure may not be limited to the specific constructions and arrangements shown and described, since various other modifications and/or adaptations may occur to those of ordinary skill in the art. It is to be under-stood that individual features shown or described for the exemplary embodiment in the context of functional segments and such features may be replicated, or be omitted within the scope of the present invention and without departing from the spirit of the present disclosure as may be defined in the appended claims.