Method for manufacturing an insert pocket of a cutter body

Abstract

A method for manufacturing an insert pocket of a cutter body is disclosed. First, the insert pocket of the cutter body a rough milling process. Then, the insert pocket is forged using a forging tool having a shape that generally conforms to the shape of the insert pocket. Then, the insert pocket undergoes a finish milling process to qualify the pocket geometry without removing the majority of the forge-enhanced pocket material. The insert pocket can be optionally heated prior to the forging step. The grain orientation of the inset pocket is compressed by the forging process to increase the impact and fatigue resistance of the insert pocket.

1 . A method for manufacturing an insert pocket of a cutter body, the method comprising:
 a) rough milling an insert pocket of a cutter body;   b) forging the insert pocket using a forging tool; and   c) finish milling the insert pocket.   
     
     
         2 . The method of  claim 1 , further comprising the step of heat treating the insert pocket after rough milling the insert pocket and prior to forging the insert pocket. 
     
     
         3 . The method of  claim 1 , wherein the forging tool has a shape that generally conforms to a bottom surface and side surfaces of the insert pocket. 
     
     
         4 . The method of  claim 1 , wherein the insert pocket is made of a steel alloy, and wherein the forging tool exerts a force that exceeds a yield stress of the insert pocket. 
     
     
         5 . The method of  claim 4 , wherein the tool holder is made of AISI 4340 steel, and wherein the forging tool exerts a force of at least 136000 psi against the insert pocket. 
     
     
         6 . The method of  claim 1 , wherein the forging tool includes a head portion and a body portion. 
     
     
         7 . The method of  claim 5 , wherein the insert pocket includes a bottom surface and a plurality of side support surfaces, and wherein the head portion has a shape that generally conforms to the shape of the insert pocket. 
     
     
         8 . A forging tool for manufacturing the insert pocket of the cutter body according to the method of  claim 1 .