Cutting insert with internal coolant passages and method of making same

Abstract

A cutting insert ( 100,100′ ) includes a body ( 102 ) having a top face ( 104 ), a bottom face ( 106 ) opposite the top face ( 104 ), and at least one flank face ( 108, 110, 112, 114 ). A coolant inlet aperture ( 126 ), a coolant outlet aperture ( 132, 134 ), and an internal coolant passage ( 128, 130 ) in fluid communication with the coolant inlet aperture ( 126 ) and the coolant outlet aperture ( 132, 134 ) are formed using electro-magnetic radiation. The coolant inlet aperture ( 126 ) can be formed in the top face ( 104 ), the bottom face ( 106 ) and/or the flank face ( 108, 110, 112, 114 ), and the coolant outlet aperture ( 132, 134 ) can be formed in any different face ( 104, 106, 108, 110, 112, 114 ). A method of forming the internal coolant passages ( 128, 130 ) is described.

1 . A toolholder assembly comprising:
 a body portion and a cutting end portion extending from the body portion, the cutting end portion including a pocket having a bottom support surface and at least one side support surface;   a cutting insert mounted in the pocket, the cutting insert having a top face, a bottom face opposite the top face, at least one flank face, a coolant inlet aperture formed in one of the top face, the bottom face, and the at least one flank face, a coolant outlet aperture formed in a different one of the top face, the bottom face and the at least one of the flank face, and an internal coolant passage in fluid communication with the coolant inlet aperture and the coolant outlet aperture,   wherein the coolant inlet aperture, the at least one internal coolant passage and the coolant outlet aperture are formed by using electro-magnetic radiation; and   wherein the cutting insert has a cutting edge, and the coolant outlet aperture is formed proximate the cutting edge and is directed towards the cutting edge.   
     
     
         2 . The toolholder assembly of  claim 1 , wherein one of the coolant inlet aperture, the at least one internal coolant passage, and the coolant outlet aperture are circular in cross-sectional shape. 
     
     
         3 . The toolholder assembly of  claim 1 , wherein one of the coolant inlet aperture, the at least one internal coolant passage, and the coolant outlet aperture are non-circular in cross-sectional shape. 
     
     
         4 . The toolholder assembly of  claim 1 , wherein the coolant inlet aperture is formed in the top face and the coolant outlet aperture is formed in one of the bottom face and the at least one flank face of the cutting insert. 
     
     
         5 . The toolholder assembly of  claim 1 , wherein the coolant inlet aperture is formed in the bottom face and the coolant outlet aperture is formed in one of the top face and the at least one flank face of the cutting insert. 
     
     
         6 . The toolholder assembly of  claim 1 , wherein the coolant inlet aperture is formed in the at least one flank face and the coolant outlet aperture is formed in one of the top face and the bottom face of the cutting insert. 
     
     
         7 . The toolholder assembly of  claim 1 , wherein the coolant inlet aperture, the coolant passage and the coolant outlet aperture have a diameter of between 5 microns and 100 microns. 
     
     
         8 . The toolholder assembly of  claim 1 , wherein the cutting insert is symmetric with respect to the x-axis, y-axis, and z-axis. 
     
     
         9 . The toolholder assembly of  claim 8 , wherein the cutting insert is generally diamond in shape. 
     
     
         10 . The toolholder assembly of  claim 8  further comprising a plurality of flank faces, and wherein one of the flank faces is substantially identical to an opposite flank face, and another one of the flank faces is substantially identical to an opposite flank face. 
     
     
         11 . The toolholder assembly of  claim 8  further comprising a cutting edge defined at an intersection between the top face and the at least one flank face, and a cutting edge defined at an intersection between the bottom face ant the at least one flank face.