Abstract: A method of forming deep holes and a gundrill therefore is disclosed. The gundrill has an elongate tubular shank and a cutting tip, each provided with a tubular central region supplying pressurized drilling fluid and a non-circular fluid cross-section defining a drilling fluid return path in conjunction with the hole being formed. The cutting tip flute defines a primary rake surface terminating in an offset point, and a secondary flank surface for forming an outlet with the hole being drilled, sized to maintain fluid pressure in the bottom end space to cool the cutting surfaces and to effectively remove chips as they are formed. A localized relief passage, sized relative to the outlet passage to cause a significant amount of drilling fluid to flow therethrough, is formed behind a peripheral rake edge of the primary rake surface for drilling fluid to exit the end space and cool the tip.

Abstract: A method of forming deep holes and a gundrill therefore is disclosed. The gundrill has an elongate tubular shank and a cutting tip, each provided with a tubular central region supplying pressurized drilling fluid and a non-circular fluid cross-section defining a drilling fluid return path in conjunction with the hole being formed. The cutting tip flute defines a primary rake surface terminating in an offset point, and a secondary flank surface for forming an outlet with the hole being drilled, sized to maintain fluid pressure in the bottom end space to cool the cutting surfaces and to effectively remove chips as they are formed. The drilling fluid exiting an orifice of the cutting tip, forms a maximum angle ? relative to the hole axis when viewed radially, which is greater than sixty-six degrees in order to minimize drilling fluid stagnation in an elongate fluid return path.

Abstract: A method of forming deep holes and a gundrill therefore is disclosed. The gundrill has an elongate tubular shank and a cutting tip, each provided with a tubular central region supplying pressurized drilling fluid and a non-circular fluid cross-section defining a drilling fluid return path in conjunction with the hole being formed. The cutting tip flute defines a primary rake surface terminating in an offset point, and a secondary flank surface for forming an outlet with the hole being drilled, sized to maintain fluid pressure in the bottom end space to cool the cutting surfaces and to effectively remove chips as they are formed. The drilling fluid exiting an orifice of the cutting tip, forms a maximum angle &bgr; relative to the hole axis when viewed radially, which is greater than sixty-six degrees in order to minimize drilling fluid stagnation in an elongate fluid return path.

Abstract: A method of forming deep holes and a gundrill therefore is disclosed. The gundrill has an elongate tubular shank and a cutting tip, each provided with a tubular central region supplying pressurized drilling fluid and a non-circular fluid cross-section defining a drilling fluid return path in conjunction with the hole being formed. The cutting tip flute defines a primary rake surface terminating in an offset point, and a secondary flank surface for forming an outlet with the hole being drilled, sized to maintain fluid pressure in the bottom end space to cool the cutting surfaces and to effectively remove chips as they are formed. A localized relief passage, sized relative to the outlet passage to cause a significant amount of drilling fluid to flow therethrough, is formed behind a peripheral rake edge of the primary rake surface for drilling fluid to exit the end space and cool the tip.

Abstract: A method that eliminates or reduces chatter when plunge cutting with boring cutters at different diameters, different tool geometries, different chip loads and different cutting depths, by computing optimal cutting insert locations and relocating such inserts to such optimal cutting locations with different phase angles therebetween; this minimizes the resultant radial force of the combined cutters.

Abstract: A method of designing a cutting tool uses finite element numerical models to predict a response of the tool during a simulated cutting operation on a workpiece, and to simulate a chip-flow phenomenon occurring during the cutting operation. The chip-flow model incorporates representations of a fracture mechanism describing a chip separation phenomenon, a heat-generating mechanism describing a thermal coupling phenomenon, and a shear localization mechanism describing a shearing phenomenon wherein these phenomena occur during the cutting operation. The predicted tool response and the chip-flow simulation are evaluated by an artificial intelligence system to render rule-based judgments which are embodied in recommendations for continuously modifying the models and input design variables until the simulation and response converge to an optimal result.

Abstract: A polygonal lay down indexable insert having radial projection is described. The insert reduces the force required to machine by reducing the friction forces encountered in machining operations.

Abstract: Chip control insert having parallel face central aperture diamond configuration, cutting edges extending above a planar recess, annular and discrete corner island locating surfaces, each with radially outward pointed chip breaking projections extending from the annular locating surface toward the center of each cutting edge and from each of the islands toward its respective acute and obtuse corner. Islands at the acute corners are larger than islands at the obtuse corners.

Abstract: A cutting insert having a particular configuration for cutting tough metals such as encountered in the turning of railway wheels is provided with a specific chip breaker configuration which tends to strengthen the negative rake cutting land.

Abstract: An indexable cutting insert of the type having a corner radius and a corner angle adapted for finishing operations comprises a pair of substantially parallel spaced apart faces and at least one peripheral side surface being substantially normal to said faces. A pair of straight cutting edge extend away from the corner at the juncture of the peripheral side surface and a plane positioned closely adjacent and below the juncture of a respective face. To break the chips formed during cutting, a chip breaker recess extents rearwardly and along the cutting edges. The chip breaker recess includes a descending control surface leading to the bottom of the recess followed by an ascending control surface. The descending control surface comprises a first and second planar descending control surface with the first surface being at a shallow angle and the second surface being at a steep angle.

Abstract: In a ceramic indexable cutting insert, an edge strengthening land extends rearwardly of a beveled cutting edge at an angle of from about 80 to about 100 degrees with respect to the peripheral side surface, and a grooved recess extents rearwardly and along the edge strengthening land to direct chips upwardly and outwardly away from the insert and the cutting edge. In one embodiment of the present invention intended for conditions of heavy depth of cut, enhanced edge strength is sacrificed and an edge strengthened land is not provided.

Abstract: A polygonal indexable cutting insert has a chip breaker with a backwall having a main portion spaced from the cutting edge and including a plurality lands as to deflect chips in a direction toward the center of the insert.

Abstract: A polygonal indexable cutting insert has a chip breaker with a backwall arranged in a sinuous path with the portion approaching the corner having a shallower slope than the main portion.

Abstract: A polygonal indexable cutting insert has a chip breaker with a backwall arranged in a sinuous path so as to deflect chips in a direction toward the center of the insert.