Cutting tools for drilling concrete, aggregate, masonry or the like materials

Abstract

A cutting tool ( 500 ) has a longitudinally extending shaft portion ( 588 ) with a chucking part ( 509 ) and a cutting head ( 506 ). A pressed powder cutting insert ( 518 ) with a cutting edge ( 520 ) is on the cutting head ( 506 ). The cutting edge ( 520 ) includes at least one cutting portion. A rake surface ( 524 ) is formed adjacent to at least one of the cutting portions ( 520 ) with the rake face ( 524 ) being at a rake angle from about 0° to 10°. A clearance face ( 526 ) is formed adjacent to the at least one cutting portion opposite the rake face ( 524 ). The clearance face ( 526 ) is at a clearance angle from about 10° to 50°. An edge radius ( 540 ) between the rake face ( 524 ) and the clearance face ( 526 ) is at a radius of from about 0.0015 to about 0.004 inch. The edge radius 540 is formed during pressing of the powder to form the insert, thus, enabling the insert to be directly braised into the cutting head ( 506 ).

Claims:  
     
         1 . A cutting tool for boring concrete or the like material comprising: 
 a longitudinally extending shank portion defining a longitudinal axis having two ends;    a chucking part provided at one end of the shank portion;    a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge on said cutting insert, said cutting edge having at least one cutting edge portion, a rake face, formed during said pressing of said powder, adjacent said cutting edge, said rake face being at a rake angle from about 0° to about 10°.    
     
     
         2 . The cutting tool according to    claim 1   , wherein at least two cutting edge portions each include a rake surface.  
     
     
         3 . The cutting tool according to    claim 1   , wherein said rake face angle is preferably about 5°.  
     
     
         4 . The cutting tool according to    claim 1   , wherein said rake face angle is positive.  
     
     
         5 . A cutting tool for boring concrete or the like material comprising: 
 a longitudinally extending shank portion defining a longitudinal axis and having two ends;    a chucking part provided at one end of the shank portion;    a cutting head provided at the other end of said shank portion, a pressed powder cutting insert on said cutting head, a cutting edge on said cutting insert, said cutting edge including at least one cutting edge portion, a rake face formed adjacent said at least one cutting portion, a clearance face formed adjacent said at least one cutting portion opposing said rake face, said rake face and clearance face formed during pressing of the powder, and an edge radius between said rake face and clearance face, said edge radius having a radius of about 0.0015 to 0.004 inch.    
     
     
         6 . The cutting tool according to    claim 11   , including at least two cutting edge portions, both cutting edge portions include a rake surface.  
     
     
         7 . The cutting tool according to    claim 5   , wherein said clearance face is at an angle of about 30° to about 40°.  
     
     
         8 . The cutting tool according to    claim 5   , wherein said edge radius is preferably from about 0.002 to about 0.003.  
     
     
         9 . The cutting tool according to    claim 5   , wherein an egress face is adjacent said rake face.  
     
     
         10 . The cutting tool according to    claim 9   , wherein said egress face is at an angle of about 80° to about 100°.  
     
     
         11 . The cutting tool according to    claim 10   , wherein said egress face is at an angle of about 90°.  
     
     
         12 . A cutting tool for concrete, aggregate or the like material comprising: 
 a longitudinally extending shank portion defining a longitudinal axis and having two ends;    a chucking part provided at one end of the shank portion;    a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge formed on said cutting insert, said cutting edge having at least one cutting edge portion, a rake surface formed adjacent said cutting edge during pressing of the powder, said rake surface being at a positive rake angle.    
     
     
         13 . A method of boring a hole in concrete, aggregate or the like material comprising: 
 providing a cutting tool including a longitudinally extending shank portion defining a longitudinal axis and having two ends, a chucking part provided at one end of the shank portion, a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge on said cutting insert, said cutting edge having at least one cutting edge portion, a rake surface formed adjacent said cutting edge portion, said rake face being at a rake angle from about 0° to about 10°;    contacting said cutting edge with the material;    rotating said cutting tool to cut said material; and    forming a hole in said material.    
     
     
         14 . The method of    claim 13   , including applying a force along said longitudinal axis of said cutting tool.  
     
     
         15 . The method of    claim 14   , wherein said force is constant.  
     
     
         16 . The method of    claim 14   , wherein said force is sequentially repetitious to impact the material to chisel the material.  
     
     
         17 . A method of boring a hole in concrete, aggregate or the like material comprising: 
 providing a cutting tool including a longitudinally extending shank portion defining a longitudinal axis and having two ends, a chucking part provided at one end of the shank portion, a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge on said cutting insert, said cutting edge having at least one cutting edge portion, a rake surface formed adjacent said cutting edge portion, said rake face being at a rake angle from about 0° to about 10°;    contacting said cutting edge with the material;    impacting said cutting tool to chisel said material; and    forming a hole in said material.    
     
     
         18 . The method of    claim 17   , including rotating said cutting tool to cut the material.  
     
     
         19 . A method of boring a hole in concrete, aggregate or the like material comprising: 
 providing a cutting tool including a longitudinally extending shank portion defining a longitudinal axis and having two ends, a chucking part provided at one end of the shank portion, a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge on said cutting insert, said cutting edge including at least one cutting edge portion, a rake surface formed adjacent said at least one cutting portion, a clearance face formed adjacent said at least one cutting portion opposing said rake face, and an edge radius between said rake face and clearance face, said edge radius of from about 0.0015 to 0.004 inch;    contacting said cutting edge with the material;    rotating said cutting tool to cut said material; and    forming a hole in said material.    
     
     
         20 . The method of    claim 19   , including applying a force along said longitudinal axis of said cutting tool.  
     
     
         21 . The method of    claim 20   , wherein said force is constant.  
     
     
         22 . The method of    claim 21   , wherein said force is sequentially repetitious to impact the material to chisel the material.  
     
     
         23 . A method of boring a hole in concrete, aggregate or the like material comprising: 
 providing a cutting tool including a longitudinally extending shank portion defining a longitudinal axis and having two ends, a chucking part provided at one end of the shank portion, a cutting head provided at the other end of said shank portion, a pressed powder cutting insert in said cutting head, a cutting edge on said cutting insert, said cutting edge including at least one cutting edge portion, a rake surface formed adjacent said at least one cutting portion, a clearance face formed adjacent said at least one cutting portion opposing said rake face, and an edge radius between said rake face and clearance face, said edge radius having a radius of from about 0.0015 to 0.004 inch;    contacting said cutting edge with the material;    impacting said cutting tool to chisel said material; and    forming a hole in said material.    
     
     
         24 . The method of    claim 23   , including rotating said cutting tool to cut the material.  
     
     
         25 . A method of forming an insert comprising: 
 providing a mold with an insert cavity defining a longitudinal axis and having an opening along the longitudinal axis;    adding powder material into the mold;    compressing the material in the direction of the longitudinal axis;    forming the insert with a positive rake face.    
     
     
         26 . The method of forming an insert according to    claim 25    further comprising a V-shaped punch compressing said powder material.  
     
     
         27 . The method of forming an insert according to    claim 25    and forming a land on a face of said insert, said land being at an acute angle and counter clockwise with respect to an axis of the insert.  
     
     
         28 . The method of forming an insert according to    claim 25   , wherein said insert has a desired rake face, clearance face and edge radius.  
     
     
         29 . The method of forming an insert according to    claim 25    and ejecting the insert from the mold.