Cutting tools for cutting curved and complex features

• US 9,302,334 B2
• Filed: 03/15/2013
• Issued: 04/05/2016
• Est. Priority Date: 05/29/2012
• Status: Expired due to Fees

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Tan, Napthaneal Y., Huang, Chien-Ming, Yundi, Yu, Lu, Zhoujun
• Primary Examiner(s): Howell, Daniel
• Assistant Examiner(s): Ramos, Nicole N
• Application Number:
  US13/840,335
• Publication Number:
  US 20140069245A1
• Time in Patent Office: 1,117 Days
• Field of Search: 409131-174, 409183-218, 29/900.1, 407/33, 407/40, 407/43, 407/46, 407/53, 407/51
• US Class Current: 1/1
• CPC Class Codes: B23B 2270/26 Burnishing
• CPC Class Codes: B23C 2210/0407 Cutting angles
• CPC Class Codes: B23C 2226/31 Diamond
• CPC Class Codes: B23C 2226/315 polycrystalline [PCD]
• CPC Class Codes: B23C 2240/08 Brazed connections
• CPC Class Codes: B23C 3/12 Trimming or finishing edges, e.g. deburring welded corners
• CPC Class Codes: B23C 5/10 Shank-type cutters, i.e. with an integral shaft
• CPC Class Codes: B23C 5/12 Cutters specially designed for producing particular profiles B23C5/10 takes precedence
• CPC Class Codes: B23C 5/18 with permanently-fixed cutter-bits or teeth
• CPC Class Codes: C25D 11/12 Anodising more than once, e.g. in different baths
• CPC Class Codes: C25D 11/18 After-treatment, e.g. pore-sealing
• CPC Class Codes: H04M 1/0249 Details of the mechanical connection between the housing parts or relating to the method of assembly
• CPC Class Codes: Y10T 407/1906 including holder [i.e., head] having seat for inserted tool
• CPC Class Codes: Y10T 409/300896 with sensing of numerical information and regulation without mechanical connection between sensing means and regulated means [i.e., numerical control]
• CPC Class Codes: Y10T 409/303752 Process
• CPC Class Codes: Y10T 409/304144 Means to trim edge
• CPC Class Codes: Y10T 83/05 With reorientation of tool between cuts
• CPC Class Codes: Y10T 83/0524 Plural cutting steps

Abstract

The embodiments described herein relate to methods, systems, and structures for cutting a part to form a highly reflective and smooth surface. In some embodiments, the part includes substantially horizontal and vertical surfaces with edges and corners. In described embodiments, a diamond cutter can be used to cut a surface of the part during a milling operation where the diamond cutter contacts the part a number of times with each rotation of the spindle of a milling machine. In some embodiments, a complex feature having planar and curved surfaces is cut into a part.

Claims

1. A cutting tool assembly arranged to perform a cutting operation along an edge of a part, comprising:

a tool holder configured to rotate about an axis;

a first cutting tool attached to the tool holder and comprising a first cutting edge, the first cutting edge having a straight cutting surface configured to cut a planar surface along the edge of the part, the planar surface meeting an adjacent surface at a junction region; and

a second cutting tool attached to the tool holder and comprising a second cutting edge having a curved cutting surface, the curved cutting surface configured to round the junction region between the planar surface and the adjacent surface.

2. The cutting tool assembly of claim 1, wherein at least one of the first cutting tool or the second cutting tool is comprised of mono crystalline diamond.

3. The cutting tool assembly of claim 1, wherein at least one of the first cutting tool or the second cutting tool is comprised of poly crystalline diamond.

4. The cutting tool assembly of claim 1, further comprising:

a third cutting tool attached to the tool holder and comprising a third cutting edge having a second curved cutting surface, the second curved cutting surface configured to round a second junction region between the planar surface and a second adjacent surface of the part.

5. The cutting tool assembly of claim 4, wherein the curved cutting surface of the second cutting tool is characterized as having a first radius of curvature and the second curved cutting surface of the third cutting tool is characterized as having a second radius of curvature, wherein the first radius of curvature is the same as the second radius of curvature.

6. The cutting tool assembly of claim 1, wherein the first cutting tool comprises a first shank and a first cutter, wherein the second cutting tool comprises a second shank and a second cutter, wherein the first cutter is attached to the first shank and the second cutter is attached to the second shank.

7. The cutting tool assembly of claim 1, wherein the first cutting tool is at a first radial distance from the axis and the second cutting tool is at a second radial distance from the axis, the first radial distance is the same as the second radial distance.

8. The cutting tool assembly of claim 1, wherein the first cutting tool is at a first radial distance from the axis and the second cutting tool is at a second radial distance from the axis, the first radial distance is different than the second radial distance.

9. The cutting tool assembly of claim 1, wherein the cutting tool assembly is configured to operate with a computer numerical control (CNC) milling machine.

10. The cutting tool assembly of claim 1, wherein the first cutting tool and the second cutting tool are positioned at equidistant locations along a circumference of the tool holder.

11. A method of cutting along an edge of a part using a cutting tool assembly comprising a tool holder and a first cutting tool and a second cutting tool attached to the tool holder, the tool holder configured to rotate about an axis, the method comprising rotating the first cutting tool and second cutting tool about the axis such that:

the first cutting tool cuts a planar surface along the edge of the part the first cutting tool having a first cutting edge having a straight cutting surface, the planar surface meeting an adjacent surface at a junction region; and

the second cutting tool rounds the junction region between the planar surface and the adjacent surface, the second cutting tool having a second cutting edge having a curved cutting surface.

12. The method of claim 11, wherein one or both of the first cutting tool and the second cutting tool is a mono crystalline diamond cutter.

13. The method of claim 11, wherein one or both of the first cutting tool and the second cutting tool is a poly crystalline diamond cutter.

14. The method of claim 11, wherein the first cutting tool is at a first radial distance from the axis and the second cutting tool is at a second radial distance from the axis, the first radial distance is the same as the second radial distance.

15. The method of claim 11, wherein the first cutting tool is at a first radial distance from the axis and the second cutting tool is at a second radial distance from the axis, the first radial distance is different than the second radial distance.

16. The method of claim 11, wherein cutting along the edge comprises translating the cutting tool assembly along the edge of the part.

17. The method of claim 11, wherein the cutting tool assembly further comprises a third cutting tool attached to the tool holder, the method further comprising rotating the third cutting tool about the axis such that:

the third cutting tool rounds a second junction region between the planar surface and a second adjacent surface of the part, the third cutting tool having a third cutting edge having a second curved cutting surface.

18. The method of claim 17, wherein the curved cutting surface of the second cutting tool is characterized as having a first radius of curvature and the second curved cutting surface of the third cutting tool is characterized as having a second radius of curvature, wherein the first radius of curvature is the same as the second radius of curvature.

19. The method of claim 17, wherein cutting along the edge of the part forms a curved chamfer along the edge of the part.

20. A cutting tool assembly arranged to form a rounded chamfer along an edge of a part, comprising:

a tool holder that rotates a first cutter and a second cutter about an axis, the first cutter having a straight cutting edge and the second cutter having a curved cutting edge, wherein when the tool holder is rotated about the axis and translated along the edge of the part;

the first cutter cuts a planar surface along the edge, the planar surface meeting an adjacent surface at a junction region, and

the second cutter rounds the junction region between the planar surface and the adjacent surface.

21. The cutting tool assembly of claim 20, wherein the second cutter has a concave shaped cutting edge.

22. The cutting tool assembly of claim 20, wherein the second cutter is affixed to a shank that is adjustably coupled to the tool holder such that a radial distance of the second cutter with respect to the axis is adjustable.

23. The cutting tool assembly of claim 22, wherein adjusting the radial distance corresponds to adjusting an amount of rounding of the junction region.