Cutting insert, cutting tool, and method of manufacturing machined product using the same

Abstract

A cutting insert with a first flat and major cutting edges in order in an intersection region of a first side surface and an upper surface, and a second flat and major cutting edges in order in an intersection region of a second side surface and upper surface. The first and second side surfaces include respective first and second chamfered side surfaces, respective first and second corner side surfaces, and respective first and second major side surfaces in order. The intersection region of the second side surface and upper surface includes a first intersection region of the second chamfered side surface and upper surface, and a second intersection region of the second corner side surface and upper surface. The second flat cutting edge is located from the first intersection region to the second intersection region, and has a lowermost portion in the first intersection region in a side view.

The invention claimed is: 
     
       1. A cutting insert, comprising:
 an upper surface; 
 a lower surface; 
 a side surface which is connected to the upper surface and the lower surface, and comprises a first side surface and a second side surface in order one after the other; and 
 a cutting edge comprises a first flat cutting edge and a first major cutting edge in order one after the other in an intersection region of the first side surface and the upper surface, and a second flat cutting edge and a second major cutting edge in order one after the other in an intersection region of the second side surface and the upper surface, 
 wherein the first side surface comprises a first chamfered curved side surface with a curved shape, a first corner side surface with a planar shape,; and a first major side surface in order one after the other, the second side surface comprises a second chamfered curved side surface with a curved shape, a second corner side surface with a planar shape, and a second major side surface in order one after the other, 
 the intersection region of the second side surface and the upper surface comprises a first intersection region of the second chamfered curved side surface and the upper surface, and a second intersection region of the second corner side surface and the upper surface, 
 the second flat cutting edge which is located from the first intersection region to the second intersection region, and has a downward convex curve with respect to a reference plane perpendicular to a central axis of the cutting insert in a side view and wherein the downward convex curve provides a lowermost portion in the first intersection region in a side view, and 
 the second flat cutting edge further comprises a first inclined cutting edge which is located in the second intersection region and is inclined upward with respect to the reference plane as the first inclined cutting edge separates in a direction away from the curved cutting edge downward convex curve in the side view. 
 
     
     
       2. The cutting insert according to  claim 1 , wherein a curve formed by the curved cutting edge the downward convex curve is a spline curve. 
     
     
       3. The cutting insert according to  claim 1 , wherein the cutting edge further comprises a second inclined cutting edge which is located in the second intersection region and is connected to the first inclined cutting edge, and is inclined upward with respect to the reference plane as the second inclined cutting edge separates from the first inclined cutting edge in a side view. 
     
     
       4. The cutting insert according to  claim 3 , wherein an upward inclination angle of the second inclined cutting edge with respect to the reference plane is decreased as the second inclined cutting edge separates from the first inclined cutting edge in a side view. 
     
     
       5. The cutting insert according to  claim 1 , wherein
 the second side surface further comprises a second intermediate side surface located between the second corner side surface and the second major side surface, 
 the intersection region of the second side surface and the upper surface further comprises a third intersection region of the second intermediate side surface and the upper surface, and 
 the cutting edge further comprises an intermediate cutting edge which is located in the third intersection region and has an upward convex curve with respect to the reference plane in a side view. 
 
     
     
       6. The cutting insert according to  claim 1 , wherein the first major cutting edge is located in an intersection region of the first major side surface and the upper surface in the intersection region of the first side surface and the upper surface, and is inclined downward with respect to the reference plane as the first major cutting edge approaches the second corner side surface in a side view. 
     
     
       7. The cutting insert according to  claim 6 , wherein the first major cutting edge is continuously inclined downward with respect to the reference plane as the first major cutting edge approaches the second corner side surface in a side view. 
     
     
       8. The cutting insert according to  claim 1 , wherein the cutting edge further comprises an auxiliary major cutting edge which is located between the first major cutting edge and the second flat cutting edge, and is inclined downward with respect to the reference plane as the auxiliary major cutting edge approaches from the major cutting edge to the second flat cutting edge in a side view. 
     
     
       9. The cutting insert according to  claim 8 , wherein the auxiliary primary cutting edge is continuously inclined downward with respect to the reference plane as the auxiliary primary cutting edge approaches from the first major cutting edge to the second flat cutting edge in a side view. 
     
     
       10. The cutting insert according to  claim 8 , wherein a downward inclination angle of the auxiliary primary cutting edge with respect to the reference plane is increased as the auxiliary primary cutting edge approaches from the first major cutting edge to the second flat cutting edge in a side view. 
     
     
       11. A cutting tool, comprising: a cutting insert according to  claim 1 ; and a holder configured to attach the cutting insert thereto. 
     
     
       12. The cutting tool according to  claim 11 , wherein the cutting insert which is attached to the holder and has a negative axial rake angle with respect to a rotation axis of the holder. 
     
     
       13. The cutting tool according to  claim 11 , wherein the second flat cutting edge is perpendicular to the rotation axis of the holder. 
     
     
       14. A method of manufacturing a machined product, comprising:
 rotating a cutting tool according to  claim 11 ; 
 bringing the cutting edge of the rotating cutting tool into contact with a workpiece; and 
 separating the cutting tool from the workpiece. 
 
     
     
       15. The cutting insert according to claim 1, wherein the first curved side surface comprises a first chamfered side surface and the second curved side surface comprises a second chamfered side surface. 
     
     
       16. A cutting insert, comprising:
 an upper surface;   a lower surface;   a side surface which is connected to the upper surface and the lower surface, and comprises a first side surface and a second side surface; and   a cutting edge comprises a first flat cutting edge and a first major cutting edge in an intersection region of the first side surface and the upper surface, and a second flat cutting edge, and a second major cutting edge in an intersection region of the second side surface and the upper surface,   wherein the first side surface comprises a first curved side surface, a first corner side surface, and a first major side surface, the second side surface comprises a second curved side surface, a second corner side surface, and a second major side surface,   the intersection region of the second side surface and the upper surface comprises a first intersection region of the second curved side surface and the upper surface, and a second intersection region of the second corner side surface and the upper surface, and   the first intersection region has a downward convex curve with respect to a reference plane perpendicular to a central axis of the cutting insert in a side view and wherein the downward convex curve provides a lowermost portion in the first intersection region in a side view,   and the second intersection region comprises a first inclined cutting edge that is inclined upward with respect to the reference plane in a direction away from the downward convex curve in the side view.   
     
     
       17. The cutting insert according to claim 16, wherein the first curved side surface comprises a first chamfered side surface and the second curved side surface comprises a second chamfered side surface. 
     
     
       18. The cutting insert according to claim 16, wherein the downward convex curve is a spline curve. 
     
     
       19. The cutting insert according to claim 16, wherein the second side surface further comprises a second intermediate side surface located between the second corner side surface and the second major side surface, the intersection region of the second side surface and the upper surface further comprises a third intersection region of the second intermediate side surface and the upper surface, and the cutting edge further comprises an intermediate cutting edge which is located in the third intersection region and has an upward convex curve with respect to the reference plane in a side view. 
     
     
       20. The cutting insert according to claim 16, wherein the first major cutting edge is located in the intersection region of the first side surface and the upper surface, and is inclined downward with respect to the reference plane as the first major cutting edge approaches the second corner side surface in a side view. 
     
     
       21. A cutting tool, comprising:
 a cutting insert according to claim 16; and   a holder configured to receive and hold the cutting insert therein.   
     
     
       22. The cutting tool according to claim 21, wherein the cutting insert comprises a negative axial rake angle with respect to a rotation axis of the holder. 
     
     
       23. A cutting insert, comprising:
 an upper surface;   a lower surface;   a side surface which is connected to the upper surface and the lower surface, and comprises a first side surface and a second side surface; and   a cutting edge comprises a first flat cutting edge and a first major cutting edge in an intersection region of the first side surface and the upper surface, and a second flat cutting edge, and a second major cutting edge in an intersection region of the second side surface and the upper surface,   wherein the first side surface comprises a first corner side surface, and a first major side surface, the second side surface comprises a second corner side surface, and a second major side surface,   the intersection region of the second side surface and the upper surface comprises a first intersection region and a second intersection region, and   the first intersection region has a downward convex curve with respect to a reference plane perpendicular to a central axis of the cutting insert in a side view and wherein the downward convex curve provides a lowermost portion in the first intersection region in a side view,   and the second intersection region comprises a first inclined cutting edge that is inclined upward with respect to the reference plane in a direction away from the downward convex curve in the side view.