FIELD OF THE INVENTION

The present invention relates to a rotary cutting tool and an indexable cutting insert which in a top view of its top surface is generally square-shaped. The tool and insert are for use in metal cutting processes in general, and for milling operations with high feed rates in particular.

BACKGROUND OF THE INVENTION

Within the field of cutting tools used in milling operations with high feed rates, there are many examples of generally square-shaped single-sided indexable cutting inserts having four primary or major cutting edges, in a top view of their top surface.

US 6,945,740 in its Figs. 4 to 8, discloses a single-sided indexable cutting insert having a generally square shape in a top view. The insert includes first and second pairs of mutually parallel primary (major) cutting edges, four corners, and four secondary (wiper) edges. Each wiper edge is situated between a major cutting edge and a respective corner. The wiper edges are shorter than the major cutting edges and are inclined relative thereto, wherein an imaginary extension line of the wiper edge forms a first acute angle with the respective major cutting edge as the insert is viewed in a direction perpendicular to the top surface. The cutting seats are arranged to orient the inserts wherein an axially forwardmost wiper edge of each insert lies in a plane oriented perpendicular to the axis, and wherein a radially outermost wiper edge of each insert is oriented parallel to the axis.

US 7,220,083 in its Figs. 4A to 4C, discloses a single-sided indexable cutting insert having a generally square shape in a top view. The insert has four identical convex cutting edges connected by nose corners. Each of the four convex cutting edges includes a curved primary (major) cutting edge portion with a large curvature radius, and two straight secondary (minor) cutting edge portions. The curved major cutting edge portions are said to provide the cutting insert with favorable cutting edge strength. A conical clearance surface extends downward from each major cutting edge portion, and a planar clearance surface extends downward from each minor cutting edge portion. A plurality of cutting insert are arranged in pockets of a cutting body such that a minor cutting edge portion of each insert is perpendicular to the cutting axis to guarantee good surface finish on the machined surface.

US 4,681,488 in its Figs. 2 to 4, discloses a single-sided indexable cutting insert having a generally square shape in a top view. In this insert, each of the corner cutting edges comprises a plurality of straight cutting edge segments.

US 5,807,031 in its Figs. 16 and 24, discloses a double-sided indexable cutting insert having a generally square shape in a top view. The insert has straight primary cutting edges, both ends of which form angles with adjacent straight cutting edge segments belonging to secondary and/or corner cutting edges.

US 2012/0070242 A 1 in its Fig. 25, discloses a single-sided indexable cutting insert having a generally square shape in a top view. The insert has straight primary cutting edges which form an angle with adjacent straight secondary cutting edge segments.

US 6,957,935 in its Figs. 2 to 4, discloses a single-sided indexable cutting insert having a generally square shape in a top view. The insert has curved primary cutting edges connecting with adjacent straight secondary cutting edges, each secondary cutting edge basically functioning as a wiper in square shoulder milling operations to improve surface finish of a workpiece.

US 2014/0341660A1 in its Fig. 7, discloses a double-sided indexable cutting insert having a generally square shape in a top view. The insert has straight primary cutting edges which form an angle of less than 180° with adjacent straight secondary cutting edges ("wiper edges"), the wiper edges basically functioning to improve surface finish of a workpiece in square shoulder milling operations.

It is an object of the present invention to provide an economically efficient indexable cutting insert suitable for use in milling operations with high feed rates.

It is also an object of the present invention to provide a robust cutting insert with prolonged service life.

It is further an object of the present invention to provide an improved rotary cutting tool in which the indexable cutting insert is removably secured in a cutting body with a high level of stability.

SUMMARY OF THE INVENTION In accordance with the present invention, there is provided an indexable cutting insert comprising:

opposing upper and lower surfaces with a peripheral surface and an insert axis extending therebetween,

the peripheral surface intersecting the upper surface to form a continuous upper peripheral edge, and including four insert side surfaces alternating with four corner surfaces, each insert side surface intersecting the upper surface to form a side cutting edge, and each corner surface intersecting the upper surface to form a curved corner cutting edge,

wherein each side cutting edge includes a primary cutting edge adjoining one of the corner cutting edges at a first endpoint and a secondary cutting edge adjoining another one of the corner cutting edges at a second endpoint, and

wherein in a top view of the cutting insert along the insert axis:

the upper surface is square-shaped with each of the four primary cutting edges being straight, and the four primary cutting edges defining four sides of an imaginary first square,

each primary cutting edge is tangential to its adjoining corner cutting edge, and

each secondary cutting edge is continuously curved and entirely located in a corresponding one of four imaginary quadrants defined by two mutually perpendicular imaginary lines bisecting the imaginary first square's four sides.

Also in accordance with the present invention, there is provided a rotary cutting tool rotatable about a tool axis defining a forward-rearward direction, and comprising a cutting body having at least one insert receiving pocket, and at least one cutting insert of the sort described above removably secured in the insert receiving pocket.

The continuously curved secondary cutting edges of the cutting insert in the present invention are configured to increase the strength of the side cutting edges, and provide a robust cutting insert with prolonged service life, suitable for use in milling operations with high feed rates.

BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding, the invention will now be described, by way of example only, with reference to the accompanying drawings in which chain-dash lines represent cut-off boundaries for partial views of a member and in which:

Fig. 1 is a perspective view of a cutting insert in accordance with some embodiments of the present invention;

Fig. 2 is a side view of the cutting insert shown in Fig. 1 ;

Fig. 3a is a top view of the cutting insert shown in Fig. 1 ;

Fig. 3b is a detailed top view of the cutting insert shown in Fig. 1 ;

Fig. 4 is a cross-sectional view of the cutting insert shown in Fig. 2, taken along the line IV-

IV;

Fig. 5 is a partial cross-sectional view of the cutting insert shown in Fig. 3a, taken along the line V-V;

Fig. 6a is a top view of a cutting insert in accordance with a first further embodiment of the present invention;

Fig. 6b is a partial cross-sectional view of the cutting insert shown in Fig. 6a, taken along the line VIb-VIb;

Fig. 6c is a partial cross-sectional view of the cutting insert shown in Fig. 6a, taken along the line Vic- Vic;

Fig. 7a is a top view of a cutting insert in accordance with a second further embodiment of the present invention;

Fig. 7b is a partial cross-sectional view of the cutting insert shown in Fig. 7a, taken along the line Vllb-VIIb;

Fig. 7c is a partial cross-sectional view of the cutting insert shown in Fig. 7a, taken along the line VIIc-VIIc;

Fig. 8 is a perspective view of the cutting tool in accordance with some embodiments of the present invention;

Fig. 9 is a detailed side view of the cutting tool shown in Fig. 8; and

Fig. 10 is a detailed exploded perspective view of the cutting tool shown in Fig. 8.

DETAILED DESCRIPTION OF THE INVENTION As shown in Figs. 1 to 5, a first aspect of the present invention relates to an indexable cutting insert 20 having opposing upper and lower surfaces 22, 24 with a peripheral surface 26 and an insert axis Al extending therebetween.

In some embodiments of the present invention the cutting insert 20 may be indexable about the insert axis Al.

Also in some embodiments of the present invention, the cutting insert 20 may preferably be manufactured by form pressing and sintering a cemented carbide, such as tungsten carbide, and may be coated or uncoated.

Further in some embodiments of the present invention, the insert's entire peripheral surface 26 may be devoid of ground surface portions of the sort resulting from grinding operations. As known to those skilled in the art, such ground surfaces are characterized by low surface roughness Ra values (e.g., Ra of 0.3 μπι or less) not achievable by pressing and sintering.

It should be appreciated that peripheral grinding of a cutting insert is typically performed individually and can be time-consuming, and thus forgoing this manufacturing step can be economically beneficial.

As shown in Fig. 2, the lower surface 24 may be planar and perpendicular to the insert axis

Al.

In other embodiments of the present invention, the lower surface 24 may include a plurality of coplanar lower sub-surfaces (not shown).

As shown in Figs. 1 and 2, the peripheral surface 26 intersects the upper surface 22 to form a continuous upper peripheral edge 28, and includes four insert side surfaces 30 circumferentially alternating with four insert corner surfaces 32.

In some embodiments of the present invention, the entire upper peripheral edge 28 may be contained in a first plane PI.

As shown in Fig. 2, the first plane PI may be perpendicular to the insert axis Al.

In some embodiments of the present invention, the upper surface 22 may include a continuous land surface 34 intersecting the upper peripheral edge 28.

Also in some embodiments of the present invention, the upper surface 22 may include a planar central region 36 entirely located between the first plane PI and the lower surface 24.

Further in some embodiments of the present invention, the upper surface 22 may include a continuous rake surface 38 extending between the land surface 34 and the central region 36. As shown in Figs. 1 and 2, each insert side surface 30 intersects the upper surface 22 to form a side cutting edge 40, and each insert corner surface 32 intersects the upper surface 22 to form a curved corner cutting edge 42.

In some embodiments of the present invention, the lower surface 24 may devoid of cutting edges, and the cutting insert 20 may be described a 'single-sided'. In other embodiments (not shown), the insert may have cutting edges on both the upper and lower surfaces 22, 24, and thus be described as 'double-sided'.

Also in some embodiments of the present invention, a through bore 44 coaxial with the insert axis Al may intersect the upper and lower surfaces 22, 24.

Further in some embodiments of the present invention, the cutting insert 20 may exhibit four-fold rotational symmetry about the insert axis Al.

As shown in Figs. 3a and 3b, each side cutting edge 40 includes a primary cutting edge 46 adjoining one of the corner cutting edges 42 at a first endpoint Nl and a secondary cutting edge 48 adjoining another one of the corner cutting edges 42 at a second endpoint N2.

According to the present invention, in a top view of the cutting insert 20 along the insert axis Al, as shown in Fig. 3a:

each of the four primary cutting edges 46 is straight, and the four primary cutting edges 46 define four sides of an imaginary first square SI,

each primary cutting edge 46 is tangential to its adjoining corner cutting edge 42, and each secondary cutting edge 48 is continuously curved and entirely located in a corresponding one of four imaginary quadrants Ql, Q2, Q3, Q4 defined by two mutually perpendicular imaginary lines bisecting the imaginary first square's four sides.

It should be appreciated that in the top view of the cutting insert 20, each curved corner cutting edge 42 extends from an adjoining straight primary cutting edge 46 belonging to a first side cutting edge 40, to an adjoining continuously curved secondary cutting edge 48 belonging to a circumferentially adjacent second side cutting edge 40.

It should also be appreciated that in the present context, a "continuously curved" cutting edge is one that is devoid of discontinuities, such as those formed from linear segments which are angled with respect to one another.

In some embodiments of the present invention, the imaginary first square SI may have its center point contained in the insert axis Al. It should be appreciated that each secondary cutting edge 48 being continuously curved, increases the strength of the side cutting edges 40, thus providing a robust cutting insert 20 with prolonged service life, suitable for use in milling operations with high feed rates.

In the top view of the cutting insert 20, as shown in Fig. 3a, each primary cutting edge 46 may extend across two of the four imaginary quadrants Ql, Q2, Q3, Q4.

In some embodiments of the present invention, each primary cutting edge 46 may be straight, i.e. linear, in both the top view of the cutting insert 20 and also in a side view.

As seen in Fig. 2, in a side view of a given insert side surface 30, at least a portion of the primary cutting edge 46 associated with a circumferentially adjacent first insert side surface 30 is visible, and at least a portion of the secondary cutting edge 48 associated with a circumferentially adjacent second insert side surface 30 is visible, the first and second insert side surfaces 30 being opposite one another.

In the top view of the cutting insert 20, as shown in Fig. 3 a, no portion of the upper peripheral edge 28 may extend outside the imaginary first square SI.

In some embodiments of the present invention, as shown in Fig. 3 a, no portion of the cutting insert 20 may extend outside the imaginary first square SI.

As shown in Figs. 3a and 3b, each corner cutting edge 42 may be continuously curved and have a constant first radius of curvature Rl, and each continuously curved secondary cutting edge 48 may have a constant second radius of curvature R2.

In some embodiments of the present invention, the second radius of curvature R2 may be greater than the first radius of curvature Rl.

Also in some embodiments of the present invention, the second radius of curvature R2 may be at least three times greater, and at most ten times greater, than the first radius of curvature Rl, i.e. 3*R1 < R2 < 10*R1.

In the top view of the cutting insert 20, as shown in Fig. 3 a, each continuously curved corner cutting edge 42 may have a first radial center point CI, and the four first radial center points CI may define four corners of an imaginary second square S2.

In some embodiments of the present invention, the imaginary second square S2 may have its center point contained in the insert axis Al. As shown in Fig. 3a, by means of two pairs of mutually perpendicular imaginary lines intersecting the imaginary first and second square's four corners, the imaginary first square SI may be rotationally offset from the imaginary second square S2 by a first offset angle Θ1.

In some embodiments of the present invention, the first offset angle Θ1 may be less than 5 degrees, i.e. Θ1 < 5°.

In the top view of the cutting insert 20, as shown in Fig. 3b, a first imaginary straight line LI containing one of the second endpoints N2 may be tangential to both its associated secondary cutting edge 48 and also to the adjoining corner cutting edge 42.

It should be appreciated that the tangentiality of the first imaginary straight line LI with respect to its associated secondary cutting edge 48 and the adjoining corner cutting edge 42 ensures a smooth transition therebetween, thus providing a robust cutting insert 20 with prolonged service life, suitable for use in milling operations with high feed rates.

As shown in Fig. 3b, the first imaginary straight line LI may form an acute primary cutting angle al with the primary cutting edge 46 contained in the same side cutting edge 40 as its associated secondary cutting edge 48.

In some embodiments of the present invention, the primary cutting angle al may be at least 5 degrees and at most 15 degrees, i.e. 5° < al < 15°.

In the top view of the cutting insert 20, as shown in Figs. 3a and 3b, each primary cutting edge 46 may tangentially adjoin the secondary cutting edge 48 contained in the same side cutting edge 40 at a transition point Ντ.

As shown in Fig. 3a, each primary cutting edge 46 may have a primary cutting length LP and each side of the imaginary first square SI may have a first side length Lsl.

In some embodiments of the present invention, the primary cutting length LP may be greater than half the first side length Lsl.

As shown in Figs. 1 and 2, each insert side surface 30 may include an insert side relief surface 50 intersecting the upper surface 22, and an insert side abutment surface 52 between the insert side relief surface 50 and the lower surface 24.

In some embodiments of the present invention, each insert side relief surface 50 may include a primary relief surface 54 adjacent its associated primary cutting edge 46, and a secondary relief surface 56 adjacent its associated secondary cutting edge 48. Also in some embodiments of the present invention, each primary relief surface 54 may be planar, and each secondary relief surface 56 may be convex.

Further in some embodiments of the present invention, each insert side abutment surface 52 may be planar.

As shown in Fig. 4, in a cross-section taken in a second plane P2 perpendicular to the insert axis Al and intersecting the four insert side abutment surfaces 52, the four insert side abutment surfaces 52 may define four sides of an imaginary third square S3.

In some embodiments of the present invention, the imaginary third square S3 may have its center point contained in the insert axis Al.

In the cross-section taken in the second plane P2, as shown in Fig. 4, each insert side abutment surface 52 may intersect two circumferentially adjacent insert corner surfaces 32.

In some embodiments of the present invention, the second plane P2 may be located closer to the first plane PI than to the lower surface 24.

As shown in Fig. 4, by means of two pairs of mutually perpendicular imaginary lines intersecting the imaginary first and third square's four corners, the imaginary first square SI may be rotationally offset from the imaginary third square S3 by a second offset angle Θ2.

In some embodiments of the present invention, the second offset angle Θ2 may be less than 5 degrees, i.e. Θ2 < 5°.

It should be appreciated that for embodiments of the present invention in which the imaginary first square SI is rotationally offset from the imaginary third square S3, a greater flexibility of design is provided for the cutting insert 20, allowing same size cutting inserts 20 to have different second offset angles Θ2.

As shown in Fig. 4, the imaginary third square S3 may be entirely located inside the imaginary first square SI.

In some embodiments of the present invention, the second offset angle Θ2 may be equal to the first offset angle Θ1.

Also in some embodiments of the present invention, the imaginary second and third squares S2, S3 may be rotationally coincident, and the imaginary second square S2 may be entirely located inside the imaginary third square S3. As shown in Fig. 5, each primary relief surface 54 may be inclined at a positive acute first clearance angle 61, and each insert side abutment surface 52 may be inclined at a positive acute second clearance angle 52.

It should be appreciated that the first and second clearance angles 51, 52 are measured relative to an imaginary line parallel to the insert axis Al at a cross-section taken in a third plane P3 containing the insert axis Al and intersecting one of the four insert side surfaces 30, and the term "positive" signifies inclination of the primary relief surface 54 and the insert side abutment surface 52 towards the insert axis Al as they extend away from the upper surface 22.

In some embodiments of the present invention, the first clearance angle 51 may be greater than the second clearance angle 52.

Attention is now drawn to Figs. 6a to 6c and Figs. 7a to 7c, showing cutting inserts 120, 220 in accordance with first and second further embodiments of the present invention, respectively, where the same reference numerals have been used for features that are common to those of the aforementioned cutting insert 20.

As shown in Figs. 6b and 6c, the land surface 34 may have a first land width Wl at each first endpoint Nl, and a second land width W2 at each second endpoint N2.

As shown in Figs. 7b and 7c, the land surface 34 may have a zero or negative acute first land angle βΐ at each first endpoint Nl, and a zero or negative acute second land angle β2 at each second endpoint N2.

It should be appreciated that the first and second land angles βΐ, β2 are measured relative to an imaginary line perpendicular to the insert axis Al at cross-sections taken along the upper peripheral edge 28 at the first and second endpoints Nl, N2, respectively, and the term "negative" signifies inclination of the land surface 34 away from the lower surface 24 as it extends away from the upper peripheral edge 28.

In further embodiments of the present invention, either the second land width W2 may be greater than the first land width Wl, or the second land angle β2 may be greater than the first land angle βΐ, or both.

Also in further embodiments of the present invention, the second land angle β2 may be at least 15 degrees greater than the first land angle βΐ, i.e. β2 > βΐ + 15°.

For further embodiments of the present invention in which the second land angle W2 is greater than the first land angle Wl, as shown in Figs. 6b and 6c, each side cutting edge 40 is strengthened in the region of its second endpoint N2, thus providing a robust cutting insert 20 with prolonged service life, suitable for use in milling operations with high feed rates.

For further embodiments of the present invention in which the second land width β2 is greater than the first land width βΐ, as shown in Figs. 7b and 7c, each side cutting edge 40 is strengthened in the region of its second endpoint N2, thus providing a robust cutting insert 20 with prolonged service life, suitable for use in milling operations with high feed rates.

As shown in Figs. 8 to 10, a second aspect of the present invention relates to a rotary cutting tool 58 comprising a cutting body 60 and at least one of the aforementioned indexable cutting inserts 20. Each cutting insert 20 is removably secured in an insert receiving pocket 62 of the cutting body 60.

Although the cutting insert 20 in accordance with some embodiments of the present invention is included in Figs. 8 to 10 and referred to below, it should be appreciated that the cutting inserts 120, 220 in accordance with the first and second further embodiments of the present invention are interchangeable therewith.

In some embodiments of the present invention, as shown in Figs. 8 to 10, the cutting tool 58 may be rotatable about a tool axis AT defining a forward-rearward direction Dr, DR, and each insert receiving pocket 62 may open out at a forward end surface 64 of the cutting body 60.

As shown in Fig. 9, an operative first of each insert's four secondary cutting edges 48' may contain an axially forwardmost point NA of its associated upper peripheral edge 28.

It should be appreciated that during some cutting operations, the axially forwardmost point NA of each insert's upper peripheral edge 28 may be subjected to significant axial cutting forces, and thus it is advantageous for the four secondary cutting edges 48 to be continuously curved and inherently strong.

Configuring the secondary cutting edges 48 to be continuously curved, also ensures that the axially forwardmost point NA of each upper peripheral edge 28 is reliably contained in its associated first secondary cutting edge 48' for embodiments of the present invention having wider manufacturing tolerances, for example, when each insert's peripheral surface 26 is devoid of ground surface portions.

Also, as shown in Fig. 9, an operative second of each insert's four secondary cutting edges 48" may contain a radially outermost point NR of its associated upper peripheral edge 28. It should be appreciated that during some cutting operations, the radially outermost point NR of each insert's upper peripheral edge 28 may be subjected to significant radial cutting forces, and thus it is advantageous for the four secondary cutting edges 48 to be inherently strong.

Further as shown in Fig. 9, an operative first of each insert's four primary cutting edges 46', contained in the same side cutting edge 40 as the first operative secondary cutting edge 48', may be inclined at a lead angle γΐ to a radial plane PR perpendicular to the tool axis AT.

In some embodiments of the present invention, the lead angle γΐ may be at least 5 degrees and at most 15 degrees, 5° < γΐ < 15°.

As shown in Fig. 9, the axial distance between the first endpoint Nl of each insert's first operative primary cutting edge 46' and the axially forwardmost point NA of its associated upper peripheral edge 28 defines the insert cutting depth AP.

It should be appreciated that for embodiments of the present invention in which the primary cutting length LP is greater than half the first side length Lsl, the lead angle γΐ is effective for most of the insert cutting depth AP, thus advantageously producing cutting chips of uniform width.

In some embodiments of the present invention, the lead angle γΐ may be less than or equal to the primary cutting angle al.

It should be appreciated that a maximum insert cutting depth AP is provided when the lead angle γΐ is equal to the primary cutting angle al, and the second endpoint N2 of the first operative secondary cutting edge 48' is coincident with the axially forwardmost point NA of the upper peripheral edge 28.

As shown in Fig. 10, each insert receiving pocket 60 may have a base surface 66 and first and second pocket walls 68, 70 transverse to the base surface 66.

In some embodiments of the present invention, as shown in Figs. 9 and 10, each first pocket wall 68 may face axially forwardly and include an axial support surface 72a, 72b, and each second pocket wall 70 may face radially outwardly and include a radial support surface 74.

Also in some embodiments of the present invention, each first pocket wall 68 may include two spaced apart axial support surfaces 72a, 72b.

As shown in Fig. 10, each cutting insert 20 may be removably secured in its insert receiving pocket 62 by means of a clamping screw 76 extending through its through bore 44 and threadingly engaging a screw bore 78 in the base surface 66. In some embodiments of the present invention, a first insert side abutment surface 52 may abut against the first pocket wall's axial support surface 72a, 72b and a circumferentially adjacent second insert side abutment surface 52 may abut against the second pocket wall's radial support surface 74.

It should be appreciated that for embodiments of the present invention in which each first pocket wall 68 has two spaced apart axial support surfaces 72a,72b and each second pocket wall 70 has a single radial support surface 74, abutting contact can be advantageously achieved at three contact zones along each insert's peripheral surface 26, resulting in stable mounting of each cutting insert 20 in its insert receiving pocket 62.

Also in some embodiments of the present invention, the second plane P2 may intersect the axial and radial support surfaces 72a, 72b; 74, as shown in Fig. 10 by means of three coplanar dashed lines extending along the axial and radial support surfaces 72a, 72b; 74.

It should be appreciated that for embodiments of the present invention in which the second plane P2 intersects the axial and radial support surfaces 72a, 72b; 74, and the imaginary first square SI is rotationally offset from the imaginary third square S3, a greater flexibility of design is provided to stably mount same size cutting inserts 20 having different primary cutting angles al in the same insert receiving pocket 62.

It should also be appreciated that for embodiments of the present invention in which the second plane P2 is located closer to the first plane PI than to the lower surface 24, and in the cross-section taken in the second plane P2 each insert side abutment surface 52 intersects two circumferentially adjacent insert corner surfaces 32, abutting contact can advantageously be achieved in the upper half of each insert's peripheral surface 26 at three contact zones located adjacent three of the four insert corner surfaces 32, resulting in stable mounting of each cutting insert 20 in its insert receiving pocket 62.

Although the present invention has been described to a certain degree of particularity, it should be understood that various alterations and modifications could be made without departing from the spirit or scope of the invention as hereinafter claimed.