FIELD OF THE DISCLOSURE

[0001] In general, the invention relates to cutting tools, and more particularly, to a lightweight rotary cutting tool, such as a rotating boring tool, and the like, comprising a support structure having a plurality of support members with a geometric arrangement and physical dimensions that are determined using a topology optimization technique and is manufactured using additive manufacturing.

BACKGROUND OF THE DISCLOSURE

[0002] In certain machining applications, the weight of the cutting tool can become a significant constraint. Heavy tools are problematic for operators who must handle the tools. In addition, the time to accelerate and decelerate the tool to its desired speed decreases with reduced tool weight and moment of inertia. Further, large heavy tools become difficult or impractical to move by hand, thereby requiring the use of automatic tool changers. Even further, heavy cutting tools can cause issues with tool change efficiency or even result in poor machining quality if the tilting moment of the tool is too high for the machine connection. Thus, there is a need to minimize the weight of heavy conventional cutting tools, while retaining adequate stiffness, to allow for easier handling and reduced operating costs.

SUMMARY OF THE DISCLOSURE

[0003] The problem of reducing the weight of a rotary cutting tool, such as a reamer, and the like, is solved by using a topology optimization technique combined with additive manufacturing (i.e., 3D printing) to produce a support structure that drastically reduces the overall weight of the rotary cutting tool, while maintaining the strength, stiffness, and functionality of the rotary cutting tool.

[0004] Topology optimization uses a finite element analysis (FEA) or a finite element method (FEM) to optimize the distribution of material in a structure for a given volume based on the applied loads and constraints. The current proliferation of 3D printer technology has allowed designers and engineers to use topology optimization techniques when designing new products. Topology optimization combined with 3D printing can result in lightweight, improved structural performance and shortened design-to- manufacturing cycle.

[0005] The geometric arrangement and physical dimensions of each support member of the support structure of the rotary cutting tool is determined using a topology optimization technique to provide a support structure having the highest possible stiffness to weight ratio for the given material, volume, and loads/constraints. The support structure of the invention has a complex geometry that can be combined with 3D printing, thereby resulting in a lightweight structure with improved structural performance.

[0006] In one aspect, a rotary cutting tool comprises a support structure comprising a central hub located at an axially rearward end of the rotary cutting tool and a plurality of support members extending in different axial and radial directions in three-dimensional space with respect to a central, rotational axis of the rotary cutting tool. A pocket region is supported by one of the plurality of support members. The rotary cutting tool further comprises and an adapter connected to the central hub for connecting the support structure to a rear machine connection member, wherein the central hub extends in a plane that is substantially perpendicular to the central, rotational axis of the rotary cutting tool.

[0007] In another aspect, a support structure for a rotary cutting tool comprises a central hub located at an axially rearward end of the rotary cutting tool. A plurality of support members extend in different axial and radial directions in three-dimensional space with respect to a central, rotational axis of the rotary cutting tool. A pocket region is supported by one of the plurality of support members, wherein each of the plurality of support members have a different physical dimension.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] While various embodiments of the invention are illustrated, the particular embodiments shown should not be construed to limit the claims. It is anticipated that various changes and modifications may be made without departing from the scope of this invention.

[0009] FIG. 1 is a front perspective view of a rotary cutting tool, such as a rotating boring tool, according to an embodiment of the disclosure;

[00010] FIG. 2 is a rear perspective view of the rotary cutting tool of FIG. i;

[00011] FIG. 3 is a side view of a support structure of the rotary cutting tool of FIG. 1 ;

[00012] FIG. 4 is another side view of a support structure of the rotary cutting tool of FIG. 1;

[00013] FIG. 5 is a rear view of the support structure of the rotary cutting tool of FIG. 1 ;

[00014] FIG. 6 is a cross-sectional view of the support structure taken along line 6-6 of FIG. 5; and

[00015] FIG. 7 is a cross-sectional view of the support structure taken along line 7-7 of FIG. 5.

DETAILED DESCRIPTION OF THE DISCLOSURE

[00016] Referring now to FIGS. 1-5, a rotary cutting tool 10 is shown according to an embodiment of the invention. In the illustrated embodiment, the rotary cutting tool 10 comprises a rotating boring tool that rotates in the direction, R, about a central, rotational axis, RA, during operation. Although the rotary cutting tool 10 comprises a rotating boring tool in the illustrated embodiment, it should be appreciated that the principles of the invention can be applied to any cutting tool for metal cutting operations, such as a milling cutter, reamer, and the like. In addition, the description herein of specific applications should not be a limitation on the scope and extent of the use of the rotary cutting tool.

[00017] Directional phrases used herein, such as, for example, left, right, front, back, top, bottom and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein. Identical parts are provided with the same reference number in all drawings.

[00018] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[00019] Throughout the text and the claims, use of the word "about" in relation to a range of values (e.g., "about 22 to 35 wt %") is intended to modify both the high and low values recited, and reflects the penumbra of variation associated with measurement, significant figures, and interchangeability, all as understood by a person having ordinary skill in the art to which this invention pertains.

[00020] For purposes of this specification (other than in the operating examples), unless otherwise indicated, all numbers expressing quantities and ranges of ingredients, process conditions, etc., are to be understood as modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in this specification and attached claims are approximations that can vary depending upon the desired results sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Further, as used in this specification and the appended claims, the singular forms "a", "an" and "the" are intended to include plural referents, unless expressly and unequivocally limited to one referent.

[00021] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements including that found in the measuring instrument. Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10, i.e., a range having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.

[00022] In the following specification and the claims, a number of terms are referenced that have the following meanings. [00023] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[00024] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[00025] As used herein, the term “3D printing” or “additive manufacturing” is the construction of a three-dimensional object from a CAD model or a digital 3D model. The term “3D printing” can refer to a variety of processes in which material is deposited, joined or solidified under computer control to create a three- dimensional object, with material being added together, such as liquid molecules or powder grains being fused together, typically layer by layer.

[00026] As used herein, the term “topology” is defined as the way in which constituent parts are interrelated or arranged.

[00027] As used herein, the phrase “topology optimization” is defined as a mathematical method that optimizes material layout within a given design space, for a given set of loads, boundary conditions and constraints with the goal of maximizing the performance of the system. Topology optimization is different from shape optimization and sizing optimization in the sense that the design can attain any shape within the design space, instead of dealing with predefined configurations. The conventional topology optimization technique uses a finite element analysis (FEA) or a finite element method (FEM) to evaluate the design performance. The design is optimized using either gradient-based mathematical programming techniques, such as the optimality criteria algorithm and the method of moving asymptotes or non-gradient-based algorithms, such as genetic algorithms. There are a variety of commercially available software programs for topology optimization including, but not limited to, Ansys Mechanical, Altair Inspire, Siemens NX, and Solidworks. [00028] As used herein, the phrase “physical dimension” of a support member is defined as length and cross-sectional area of the support member.

[00029] As used herein, the term “cantilever” is defined as a rigid structural element that extends horizontally and is supported at only one end.

[00030] As used herein, the term “void” is defined as a completely empty space.

[00031] In general, the rotary cutting tool 10 comprises an axially forward end 12 and an axially rearward end 14. A support structure, shown generally at 16, comprises a central hub 18 located proximate an adapter 20 for attaching the support structure 16 to a rear machine connection member 22 at the axially rearward end 14 of the rotary cutting tool 10.

[00032] As shown in FIG. 4, the central hub 18 extends in a plane, P, that is substantially perpendicular to the central, rotational axis, RA, of the rotary cutting tool 10. In addition, the central hub 18 has an asymmetric, non-circular cross-sectional shape, as indicated by the dashed lines in FIGS. 2 and 5. In the illustrated embodiment, for example, the central hub 18 is substantially star shaped.

[00033] In the illustrated embodiment, the support structure 16 comprises three different types of support members:

1) a primary support member 24;

2) a secondary support member 26; and

3) a tertiary support member 28.

The number and size of the tertiary support members 28 depend on the centrifugal and cutting forces exerted on the support structure 16 during use and can be provided to prevent deflection of the support structure 16 during a cutting operation. It should be noted that the secondary support members 26 and/or the tertiary support members 28 may not be needed and can be omitted from the support structure 16, depending on the centrifugal and cutting forces exerted on the support structure 16. [00034] In general, the primary support member 24 extends from the central hub 18 to either a secondary support member 26 or to a pocket region 30. In the illustrated embodiment, the support structure 16 has a plurality of primary support members 24 extending axially and radially outward from the central hub 18 in different directions in three-dimensional space. Generally, the primary support member 24 has a larger cross-sectional area (i.e. , thickness) than either the secondary support member 26 or the tertiary support member 28. However, some tertiary support members 28 can have a larger cross-sectional area than the primary support member 24 and/or the secondary support member 26. In addition, the cross-sectional area of each of the primary support members 24 varies along its length. Further, each of the primary support members 24 have different physical dimensions, such as length, thickness, and the like.

[00035] In general, the secondary support member 26 extends from either a primary support member 24 to the pocket region 30 or from another secondary support member 26 to the pocket region 30. In the illustrated embodiment, the support structure 16 has a plurality of secondary support members 26 extending in different directions in three-dimensional space. Typically, the secondary support member 26 has a smaller cross-sectional area (i.e., thickness) than the primary support member 24, but may not necessarily have a larger cross-sectional area than the tertiary support member 28. In addition, the cross-sectional area of each of the secondary support members 26 varies along its length. Further, each of the secondary support members 26 have different physical dimensions, such as length, thickness, and the like.

[00036] As mentioned above, the cross-sectional area of each of the plurality of primary support members 24 is generally greater than a cross-sectional area of each of the plurality of secondary support members 26. It is noted that the size of the primary support members 24 depend on the forces exerted on the pocket region 30 during a cutting operation. Specifically, the higher the forces exerted on the pocket region 30, the larger the cross-sectional area of the corresponding support member 24, 26. Thus, it is possible that one or more of the secondary support members 26 can have a greater cross-sectional area than one or more of the primary support members 24.

[00037] In general, the tertiary support member 28 extends from a primary support member 24 to another primary support member 24, a primary support member 24 to a secondary support member 26, a secondary support member 26 to another secondary support member 26, or from a pocket region 30 to another pocket region 30. In addition, the tertiary support member 28 can extend from a primary support member 24 to the central hub 18, another tertiary support member 28 to the pocket region 30, and one tertiary support member 28 to another tertiary support member 28. In the illustrated embodiment, the support structure 16 has a plurality of tertiary support members 28 extending in different directions in three-dimensional space. In general, the cross-sectional area (i.e. , thickness) of the tertiary support member 28 depends on the amount of support necessary for that particular region of the support structure 16. The larger the forces exerted on the support structure 16, the larger the cross-sectional area of the tertiary support member 28, and vice versa. In addition, the cross- sectional area of each of the tertiary support members 28 varies along its length. Further, each of the tertiary support members 28 have different physical dimensions, such as length, thickness, and the like.

[00038] It will be appreciated that the invention is not limited to the support structure 16 having all three different types of support members 24, 26, 28, and that the invention can be practiced with a support structure 16 having any number of different types of support members 24, 26, 28. For example, the support structure 16 may comprise only a plurality of primary support members 24, depending on the design requirements of the support structure 16. In another example, the support structure 16 may comprise only of a plurality of primary support members 24 and one or more secondary support members 24, depending on the design requirements of the support structure 16. However, in every embodiment, the support structure 16 will include at least one primary support member 24 extending from the central hub 18.

[00039] As mentioned above, each of the primary, secondary and tertiary support members 24, 26, 28 generally have different physical dimensions and extend in different directions in three-dimensional space. As a result, the support structure 16 is asymmetric with respect to the central, rotational axis, RA, of the rotary cutting tool 10. The support structure 16 may include one or more balancing masses 38 to rotationally balance the support structure 16 about the central, rotational axis, RA, if necessary. However, it should be appreciated that the support structure 16 can be substantially symmetric about the central, rotational axis, RA, of the rotary cutting tool 10, depending on the above-mentioned design requirements. If so, the balancing masses 38 are not necessary and can be omitted. It is also possible that an asymmetric support structure 16 can be rotationally balanced, in which case, the balancing masses 38 can be omitted.

[00040] As mentioned above, the support structure 16 includes a plurality of pocket regions 30 that are supported by the support structure 16. It should be understood that each pocket region 30 can support a cutting member, such as an insert-receiving cartridge with a cutting insert mounted therein, a cutting insert mounted in an insert-receiving pocket, and the like. In the illustrated embodiment, for example, each pocket region 30 receives an insert-receiving cartridge 31 with a cutting insert 32 mounted therein, as shown in FIG. 1. Alternatively, the cutting inserts 32 can be mounted directly to an insert-receiving pocket of a type known in the art. Because the primary and secondary support members 24, 26 extend radially outward at different axial locations in three-dimensional space, the pocket regions 30 are cantilevered from the central hub 18 at different axial and radial locations in three-dimensional space with respect to the central, rotational axis, RA. In the illustrated embodiment, the pocket region 30 may include an optional boss 40 to provide sufficient material for securing the cutting member to the pocket region 30, as shown in FIGS. 1, 3 and 4. Because each of the primary and second support arms 24, 26 extend differently in three-dimensional space (i.e., in the x-, y- and z-directions), each of the pocket regions 30 are located in three-dimensional space at a different location with respect to the central hub 18 of the rotary cutting tool 10.

[00041] As shown in FIGS. 3-5, the central hub 18 has an outer surface 18a facing the rear of the rotary cutting tool 10 that is substantially non-planar. In order to adequately couple the support structure 16 to the adapter 20, the support structure 16 also includes a coupling interface 34 with a substantially planar outer surface 34a. In the illustrated embodiment, the coupling interface 34 can be integrally formed with the support structure 16 using additive manufacturing (i.e., 3D printing).

[00042] The support structure 16 also includes one or more voids 36 between each of the primary support members 24, secondary support members 26 and tertiary support members 28. Some voids 36 extend completely through the central hub 18. The voids 36 reduce the overall weight of the rotary cutting tool 10, while the support members 24, 26, 28 maintain the stiffness of the rotary cutting tool 10, thereby significantly increasing the stiffhess-to- weight ratio of the rotary cutting tool 10.

[00043] As shown in FIGS. 6 and 7, one or more primary support members 24, one or more secondary support members 26 and one or more tertiary support members 28 may have an internal cavity 44, 46, 48, respectively, that may extend the entire length of the support member 24, 26, 28 to help further reduce the weight of the rotary cutting tool 10 and assist in rotationally balancing the rotary cutting tool 10. In addition, the central hub 18 may also include an internal cavity 50 to further reduce the weight and assist in rotationally balancing the rotary cutting tool 10.

[00044] The internal cavities 44, 46, 48 of the support members 24, 26, 28 may define fluid channels that enable fluid to be transported from a fluid entry 52 of the rear machine connection member 22 to the pocket region 30. It should be understood that each pocket region 30 is capable of delivering the fluid to cutting insert/workpiece interface, if desired. However, it should be understood that some internal cavities 44, 46, 48 of the support members 24, 26, 28 are not used to transport fluid, but instead are used to reduce the overall weight of the support structure 16.

[00045] As seen in FIGS. 6 and 7, each of the internal cavities 44, 46, 48 that transport fluid may vary in cross-sectional area, depending on the fluid flow necessary to provide a sufficient amount of fluid to the pocket region 30. As a general rule of thumb, a support member 24, 26, 28 with a relatively larger cross-sectional area (i.e., thickness) will have a relatively larger internal cavity portion for reducing the overall weight of the support structure 16. In addition, it will be appreciated that the invention is not limited by the number, size and/or shape of the internal cavities 44, 46, 48, and that the invention can be practiced with one or more internal cavities 44, 46, 48 having any desirable size and shape to reduce the weight of the support structure 16, so long as sufficient fluid flow is provided to the insert/workpiece interface of the cutting insert 32, if desired.

[00046] As mentioned above, the geometric arrangement and physical dimensions of the support structure 16 is determined using a topology optimization technique and manufactured using additive manufacturing (i.e., 3D printing). The geometric arrangement and physical dimensions of the support structure 16 depends on the design requirements, such as volume, tilting moment, forces, loads, total mass, and the like, of the rotary cutting tool 10. As a result, each of the plurality of primary support members 24, each of the plurality of secondary support members 26 and each of the plurality of tertiary support members 28 in the illustrated embodiment have different physical dimensions. In addition, the physical dimensions of each primary support member 24, each secondary support member 26 and each tertiary support member 28 varies along its length.

[00047] As described above, the rotary cutting tool 10 comprises a support structure 16 having a geometric arrangement and physical dimensions that are determined using a topology optimization technique and manufactured using additive manufacturing (i.e., 3D printing).

[00048] The patents and publications referred to herein are hereby incorporated by reference.

[00049] Having described presently preferred embodiments the invention may be otherwise embodied within the scope of the appended claims.

PARTS LIST

10 cutting tool (boring bar)

12 axially forward end

14 axially rearward end

16 support structure

18 central hub

18a outer surface

20 adapter

22 rear machine connection member

24 primary support member

26 secondary support member

28 tertiary support member

30 pocket region

31 insert-receiving cartridge

32 cutting insert

34 coupling interface

34a outer surface

36 void

38 balancing mass

40 boss

44 interior cavity (primary member)

46 interior cavity (secondary member)

48 interior cavity (tertiary member)

50 interior cavity (central hub)

52 fluid entry

RA central, rotational axis

R direction of rotation