Cutting by use of rotating axially moving tool – Tool of specific diverse material
Patent
1998-08-14
2000-10-17
Howell, Daniel W.
Cutting by use of rotating axially moving tool
Tool of specific diverse material
761086, 419 28, 428323, 428698, 408145, 408226, 408230, B23B 5102
Patent
active
061321486
DESCRIPTION:
BRIEF SUMMARY
The invention which is the subject of this application relates to the formation of a machining tool and the method and provision of blanks for the manufacture of same, said tools provided with a machining tip and/or machining faces formed at least partially by a suitable material containing abrasive polycrystalline diamond or cubic boron nitride referred to hereonin respectively as PCD and PCBN.
It is known that many attempts have been made to incorporate PCD or PCBN material onto the machining faces and edges of machining tools in an attempt to improve the performance and life of the machining tools. One method which is particularly well known is to attempt to fabricate the machining faces of the tools to include PCD or PCBN material by brazing multiple pieces of PCD or PCBN onto a body. Typically these pieces are brazed in positions to form machining faces and or cutting tips of machining tools and, if a sufficient depth of the material is to be obtained to render the machining tools economical, the material is required to be added to cover the tip and flutes of the tool. The common problem with known types of fabrication is that there is a risk that a gap, albeit narrow in size, exists between the body of the tool and the PCD or PCBN material. These gaps are susceptible during use of the tool as the cutting forces created during use tend to act to widen the gap and, in some instances, cause the PCD or PCBN material to be removed from the tool. Whether the gap is widened or the material wholly removed, the cutting effect of the tool is significantly reduced and the tolerances and quality of machining which are obtained are also reduced so that the tool is, in many instances, not usable and the advantages of the PCD or PCBN material in terms of hardness and long life are not realised.
A further problem is that the gap between the body and the PCD or PCBN pieces acts as a trap for foreign matter such as material from the articles which are machined, coolant and general debris. This acts to reduce the quality of machining and the life of the tool
A yet further problem is caused by the constraints of fabrication in terms of the complexity of fabrication which can be performed. For example, it is extremely difficult to fit PCD or PCBN pieces into position on the spiral flutes of machining tools and, in general, the difficulties cause the machining faces to be formed wholly of the PCD or PCBN material with reduced support provided for said pieces by the body due to the gaps created between the body and the pieces as discussed above.
While some of these problems have been overcome the tools produced have had limited success due to the performance and adaptability constraint problems.
It is also known that the chemical reaction between carbide material and PCD or PCBN material causes the same to be capable of fusing together as it is known that elements which are present in carbide leech into the PCD or PCBN material to effectively fuse the same together under the required conditions.
One known type of drill which includes reference to the direct application of PCD or PCBN material to carbide is disclosed in patent U.S. Pat. No. 4,713,286 wherein a single insert is provided for inclusion in a conical tip of a blank from which a drill can be manufactured for use in Printed Circuit Board machining and therefore drills of small diameter size of up to 3.2 mm diameter can be made at the present time. The method as disclosed in this patent is not regarded as suitable for the manufacture of larger diameter drills as is discussed in the U.S. Pat. No. 4,762,445 of the same proprietor which states that, for larger diameter drills, at least two, separate, veins of PCD or PCBN material are required in order to provide resistance to cracking of the single vein insert in larger diameter drills and this is an inherent problem of adding formed inserts into blanks by fabrication.
The aim of the present invention is to provide PCD or PCBN material as an integral part of a machining tool for any of a range of machining functions s
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Habit Diamond Limited
Howell Daniel W.
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