Cutting tool inserts and methods to manufacture
View Patent ↗A cutting insert includes a cutting insert body having a plurality of openings, a plurality of cutting tips, and a braze joint between each of the cutting tips and the cutting insert body. Each of the cutting tips may be disposed in a respective opening of the insert body. The cutting tips include an intermediate feature and a tip portion. The intermediate feature has a geometry that provides a mechanical bond when inserted into an opening of the cutting insert body.
1. A cutting insert comprising:
a cutting insert body having a plurality of openings;
a plurality of cutting tips, each of the plurality of cutting tips disposed in a respective opening, the cutting tips including an intermediate feature and a tip portion, the intermediate feature having a geometry that provides a mechanical bond when inserted into an opening of the cutting insert body, the intermediate feature formed of a different material than the tip portion, and the tip portion comprising a superabrasive material and having a cutting edge,
wherein said cutting tip is retained in the insert body primarily by mechanical forces derived from irreversible deformation of the mating geometrical features on insert body and/or cutting tip; and
a spot weld between each of the cutting tips and the cutting insert body.
2. The cutting insert of claim 1 , wherein the geometry comprises a generally trapezoidal anchor portion with its base substantially flat and spaced away from a cutting edge of the cutting tip.
3. The cutting insert of claim 1 , wherein the superabrasive material comprises cubic boron nitride or polycrystalline diamond.
4. The cutting insert of claim 3 , wherein the tip portion further comprises at least one of a metal, alloy, or mixture thereof or a carbide, boride or mixture thereof.
5. The cutting insert of claim 1 , wherein the tip portion comprises cubic boron nitride or polycrystalline diamond particles and a bonding matrix comprising a metal or alloy thereof.
6. The cutting insert of claim 1 , wherein each cutting tip comprises two cutting edges.
7. The cutting insert of claim 1 , wherein the geometry is in the form of a dovetail.
8. The cutting insert of claim 7 , wherein each cutting tip comprises a circle, oval, octagon, hexagon, or partial or complete ring shape.
9. The cutting insert of claim 1 , wherein the geometry of each cutting tip comprises a male feature that is shaped to fit within a female feature of the insert body.
10. The cutting insert of claim 9 , wherein the male feature comprises a flaring tenon, lip, rounded shape, circular pattern, or wedge.
11. The cutting insert of claim 1 , wherein the cutting insert body comprises a cemented carbide, steel, titanium, plastic, ceramic, metal or metal alloy.
12. The cutting insert of claim 1 , wherein the cutting insert is in the shape of a square, triangle, diamond, parallelogram, hexagon, octagon, pentagon, trigon, rectangle, trapezoid or round body.
13. The cutting insert of claim 1 , wherein each opening has a shape that is a mating geometric feature to the geometry of at least one of the cutting tips.
14. The cutting insert of claim 1 , wherein the cutting insert comprises a coating.
15. The cutting insert of claim 1 , wherein the cutting insert comprises a chip-breaking pattern.
16. The cutting insert of claim 1 , wherein the cutting insert comprises two cutting edges.
17. The cutting insert of claim 1 , wherein the cutting insert comprises four cutting edges.
18. The cutting insert of claim 1 , wherein the cutting tips are arranged symmetrically about the insert body.
19. The cutting insert of claim 1 , wherein the cutting insert is a turning insert.
20. The cutting insert of claim 1 , wherein the cutting insert is disposed on a drill.