Combination tool and method for metal-cutting machining of a drill-hole and its hole surface as well as cutting insert for such a combination tool

A method of finishing an internal combustion engine part having several valve seat structures and valve stem structures using a plurality of combination tools connected to a machine tool, each combination tool of said plurality of combination tools comprising a tool body;

• said tool body being connected to and disposed to extend from said machine tool;
• said tool body comprising:
• a rotational axis;
• a central portion being disposed immediately about the rotational axis of said tool body;
• a reamer, comprising a shank portion and a cutting portion;
• at least a portion of said shank portion being disposed in and held by said central portion;
• said reamer being configured to be rotated by said tool body to finish a valve stem structure in a part;
• a plurality of inserts being disposed on said tool body adjacent to said reamer and being configured to finish a valve seat in a part of an internal combustion engine;
• said plurality of inserts being radially spaced about and from said rotational axis;
• a plurality of fastening structures;
• said plurality of fastening structures comprising a first fastening structure;
• said plurality of fastening structures being essentially operationally identical to said first fastening structure;
• said plurality of inserts comprising a first insert;
• said first fastening structure being configured and disposed to fasten said first insert to said tool body;
• said plurality of inserts being essentially operationally identical to said first insert;
• said first insert comprising:
• a first surface comprising:
• a fastening hole being disposed substantially in the middle of and substantially perpendicular to said first surface;
• said fastening hole having a central axis which central axis at least substantially intersects said rotational axis of said tool body;
• a plurality of peripheral edges, said plurality of peripheral edges comprising a first, cutting edge and at least a second edge;
• and a center disposed substantially equally from all said edges;
• a second surface being disposed opposite said first surface;
• said second surface comprising a plurality of peripheral edges;
• a plurality of side surfaces extending from said peripheral edges of said first surface to said peripheral edges of said second surface;
• said plurality of side surfaces comprising:
• a first, cutting, side surface extending from said first, cutting edge;
• and a portion of a second, side surface disposed away from said first, cutting, side surface and extending from said second edge;
• each of said first surface and said second surface having a greater area than a surface area of any one of said side surfaces;
• said first surface of said first insert being disposed away from said second surface by a first distance;
• said first, cutting, side surface being disposed away from said portion of said second, side surface by a second distance;
• said second distance being substantially greater than said first distance;
• said plurality of inserts being fastened by said plurality of fastening structures to said tool body, such that said second surface is disposed to face toward said central portion of said tool body and also is in contact with said tool body;
• said first surface of said first insert is disposed to face away from said central portion of said tool body;
• said second surface and said cutting surface being configured and disposed to together form a third edge disposed opposite said first, cutting edge;
• said third edge of said first insert being disposed closer to said tool body than said first, cutting edge;
• said cutting edge of said first insert being configured to be disposed at an angle substantially parallel to an angle of at least a portion of the valve seat to be cut;
• and said first distance being sufficiently short, upon said plurality of inserts being fastened by said tool body using said plurality of fastening structures, to minimize vibrations of said first insert and also sufficiently short to permit absorption of vibrations generated by said first insert by said tool body;
• a straight line, which is at least generally perpendicular to said first surface of said first cutting insert, is configured to extend through sad central portion of said combination tool upon assembly of said first cutting inserts in said combination tool:
• said tool body comprising a first abutment against which said second side surface of said first insert rests during operation;
• and
• a substantially flat surface against which said second surface abuts during operation;
• said first fastening structure holding said second surface of said first insert against said substantially flat surface of said tool body, thereby permitting the distance between said tool bodies in said plurality of combination tools being disposed at a minimal distance between one another;
• said method comprising the steps of:
• disposing said second surface of said first insert against said substantially flat surface of said tool body;
• disposing said second side surface against said first abutment;
• thereby disposing said first surface of said first insert a minimal distance from said rotational axis and disposing said cutting edge a minimal distance from said rotational axis to minimize vibrations of said first insert and to absorb vibrations generated by said first insert;
• fastening said plurality of inserts to said tool body with said plurality of fastening structures;
• turning on said combination tools;
• rotating said combination tools;
• advancing said combination tools into the preformed holes;
• finishing a plurality of valve stem structures with said reamers while substantially simultaneously finishing a plurality of valve seat structures with said plurality of inserts;
• and
• removing said combination tools from the finished holes.

A combination tool being configured to cut and finish a valve stem structure and substantially simultaneously a valve seat in a part of an internal combustion engine, said tool comprising:

• a tool body having a rotational axis;
• said tool body comprising a central portion being disposed immediately about the rotational axis of said tool body;
• a reamer, comprising a shank portion and a cutting portion;
• at least a portion of said shank portion being disposed in and held by said central portion;
• said reamer being configured to be rotated by said tool body to finish a valve stem structure in a part of an internal combustion engine;
• at least one insert being disposed on said tool body adjacent to said reamer and being configured to finish a valve seat in a part of an internal combustion engine;
• said inserts being radially spaced about and from said rotational axis;
• a fastening structure being configured and disposed to fasten said at least one insert to said tool body;
• said at least one insert comprising a first insert:
• said first insert comprising:
• a first surface comprising:
• a fastening hole being disposed substantially in the middle of and substantially perpendicular to said first surface;
• said fastening hold having a central axis which central axis at least substantially intersects said rotational axis of said tool body;
• a plurality of peripheral edges, said plurality of peripheral edges comprising a first, cutting edge and a second edge opposite said first, cutting edge;
• and
• a center disposed substantially equally from all said edges;
• a second surface being disposed opposite said first surface;
• said second surface comprising a plurality of peripheral edges;
• a plurality of side surfaces extending from said peripheral edges of said first surface to said peripheral edges of said second surface;
• said plurality of side surfaces comprising:
• a first, cutting, side surface extending from said first, cutting edge;
• and
• a second, side surface disposed opposite said first, cutting, side surface and extending from said second edge;
• each of said first surface and said second surface having a greater area than a surface area of any one of said side surfaces;
• a line perpendicular to a plane, in which said plurality of peripheral edges at least substantially lie, which perpendicular line passes through said center of said first surface of said insert also passes through said central portion of said tool;
• a straight line, which is at least generally perpendicular to said first surface of said first insert, is configured to extend through said central portion of said combination tool upon assembly of said cutting insert in said combination tool;
• said first surface of said first insert being disposed away from said second surface by a first distance;
• said first, cutting, side surface being disposed away from said second, side surface by a second distance;
• said second distance being substantially greater than said first distance;
• said at least one insert being fastened by said fastening structure to said tool body, such that said second surface is disposed to face toward said central portion of said tool body and also is in contact with said tool body;
• said first surface of said insert is disposed to face away from said central portion of said tool body;
• said second surface and said cutting surface being configured and disposed to together form a third edge disposed opposite said first, cutting edge;
• said third edge of said insert being disposed closer to said tool body than said first, cutting edge;
• said cutting edge of said first insert being configured to be disposed at an angle substantially parallel to an angle of at least a portion of the valve seat to be cut;
• and
• said first distance being sufficiently short, upon said first insert being fastened to said tool body using said fastening structure, to minimize vibrations of said first insert and also sufficiently short to permit absorption of vibrations generated by said tool body.

A combination tool being configured to cut and finish a valve stem structure and substantially simultaneously a valve seat in a part, said tool comprising:

• a tool body having a rotational axis;
• said tool body comprising a central portion being disposed immediately about the rotational axis of said tool body;
• a reamer, comprising a shank portion and a cutting portion;
• at least a portion of said shank portion being disposed in and held by said central portion;
• said reamer being configured to be rotated by said tool body to finish a valve stem structure in a part;
• at least one insert being disposed on said tool body adjacent to said reamer and being configured to finish a valve seat in a part of an internal combustion engine;
• said inserts being radially spaced around said rotational axis;
• a fastening structure being configured and disposed to fasten said at least one insert to said tool body;
• said at least one insert comprising a first insert;
• said first insert comprising:
• a first surface comprising:
• a plurality of peripheral edges, said plurality of peripheral edges comprising a first, cutting edge and at least a second edge;
• a center disposed substantially equally from all said edges of said first surface;
• and
• a fastening hole being disposed substantially in the middle of and substantially perpendicular to said first surface;
• said fastening hole having a central axis which central axis at least substantially intersects said rotational axis of said tool body;
• a second surface being disposed opposite said first surface;
• said second surface comprising a plurality of peripheral edges;
• a plurality of side surfaces extending from said peripheral edges of said first surface to said peripheral edges of said second surface;
• said plurality of side surfaces comprising:
• a first, cutting, side surface extending from said first, cutting edge;
• and
• a first portion of a second, side surface disposed farthest away from said first, cutting, side surface;
• said first portion of a second, side surface extending from said second edge;
• each of said first surface and said second surface having a greater area than a surface area of any one of said side surfaces;
• said first surface of said first insert being disposed away from said second surface by a first distance;
• said first, cutting, side surface being disposed away from said portion of said second, side surface by a second distance;
• said second distance being substantially greater than said first distance;
• said at least one insert being fastened by said fastening structure to said tool body, such that said second surface is disposed to face toward said central portion of said tool body and also is in contact with said tool body;
• said first surface of said insert is disposed to face away from said central portion of said tool body;
• said second surface and said cutting surface being configured and disposed to together form a third edge disposed opposite said first, cutting edge;
• said third edge of said insert being disposed closer to said tool body than said first, cutting edge;
• a straight line, which is at least generally perpendicular to said first surface of said first insert, extends through said central portion of said tool body upon assembly of said cutting insert in said combination tool;
• and
• said first distance being sufficiently short, upon said first insert being fastened to said tool body using said fastening structure, to minimize vibrations of said first insert and also sufficiently short to permit absorption of vibrations by said tool body generated by said first insert.

An internal combustion engine valve seat cutting insert configured to be mounted on a combination tool being configured to cut and finish a valve stem structure and substantially simultaneously form a valve seat in a part of an internal combustion engine;

• said internal combustion engine valve seat cutting insert comprising:
• a cutting insert body;
• a first large surface comprising:
• a plurality of peripheral edges, said plurality of peripheral edges comprising a first, cutting, edge and a second edge opposite said first, cutting, edge;
• and
• a center disposed substantially equally from all said edges;
• a second large surface being disposed opposite said first large surface;
• said second large surface comprising a plurality of peripheral edges;
• a plurality of side surfaces extending from said peripheral edges of said first large surface to said peripheral edges of said second large surface;
• said plurality of side surfaces comprising:
• a first, cutting, side surface extending from said first, cutting, edge;
• and
• a second, side surface disposed opposite said first, cutting, side surface and extending from said second edge;
• each of said first large surface and said second large surface having a greater area than a surface area of any one of said side surfaces;
• said first large surface of said engine valve seat cutting insert being disposed away from said second large surface by a first distance;
• said first, cutting, side surface being disposed away from said second, side surface by a second distance;
• said second distance being substantially greater than said first distance;
• said engine valve seat cutting insert being fastenable by a fastening structure to a combination tool, such that said second large surface is disposed to face toward a combination tool and also is in contact with a combination tool;
• said first large surface of said engine valve seat cutting insert being configured to face away from a combination tool;
• said second large surface and said cutting surface being configured and disposed to together form a third edge disposed opposite said first, cutting, edge;
• said third edge of said engine valve seat cutting insert being configured to be disposed closer to a combination tool than said first, cutting, edge;
• said first distance being sufficiently short, upon said internal combustion engine valve seat cutting insert being fastened to a combination tool using a fastening structure such that said second large surface faces toward a combination tool, to minimize vibrations of said engine valve seat cutting insert and also sufficiently short to permit absorption of vibrations generated by a combination tool in which said engine valve seat cutting insert is installed;
• said first, cutting, edge comprises an outer layer which outer layer forms part of said first large surface and part of said first, cutting, side surface;
• and
• an additional layer being disposed between and at least adjacent to both said outer layer and said cutting insert body;
• said outer layer comprises a material harder than said additional layer;
• and
• a straight line, which is at least generally perpendicular to said first large surface of said internal combustion engine valve seat cutting insert, is configured to extend through a central portion of a combination tool upon assembly of said cutting insert in a combination tool.

A cutting insert comprising:

• a cutting insert body;
• a first large surface;
• a plurality of peripheral edges disposed about the periphery of said first large surface thereof;
• a second large surface being disposed opposite said first large surface;
• a plurality of peripheral edges disposed about the periphery of said second large surface thereof;
• a plurality of peripheral side surfaces extending from said plurality of peripheral edges of said first large surface to said plurality of peripheral edges of said second large surface;
• at least one cutting edge being configured and disposed at the intersection of said first large surface and at least one of said plurality of peripheral side surfaces;
• said plurality of peripheral side surfaces comprising a first side surface;
• said at least one cutting edge comprising a first layer and a second layer;
• said first layer being disposed on said cutting insert body;
• said first layer comprising a first surface and a second surface;
• said first surface of said first layer forming part of said first large surface of said engine valve seat cutting insert;
• said second surface of said first layer being disposed on said first side surface;
• said at least one cutting edge comprising a first cutting edge;
• said first surface of said first layer and said second surface of said first layer forming an acute angle with respect to one another as measured through said first layer to form said first cutting edge;
• said second layer being disposed between said first layer and said cutting insert body;
• said second layer being exposed to said first side surface of said engine valve seat cutting insert;
• and
• a straight line, which is at least generally perpendicular to said first large surface of said internal combustion engine valve seat cutting insert, is configured to extend through a central portion of a combination tool.