Abstract: A method of milling a profile of a railway rail comprises: rotating a milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof; milling a railway rail with cutting edges of the cutting inserts rotating in a predetermined plane corresponding to at least a portion of a desired rail profile while controlling the depth of cut of the cutting inserts; traversing the railway rail with the milling cutter while milling the railway rail; and controlling the speed of traverse of the milling cutter along the railway rail.

Abstract: A method of milling a profile of a railway rail comprises: rotating a milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof; milling a railway rail with cutting edges of the cutting inserts rotating in a predetermined plane corresponding to at least a portion of a desired rail profile while controlling the depth of cut of the cutting inserts; traversing the railway rail with the milling cutter while milling the railway rail; and controlling the speed of traverse of the milling cutter along the railway rail.

Abstract: A cutting tool includes a novel cutting insert retaining and adjusting mechanism. The cutting insert retaining and adjusting mechanism is associated with a recess in the cutting tool and includes a nest slidably mounted in the recess. The nest includes a cutting insert pocket. The cutting insert retaining and adjusting mechanism includes a first wedge adapted to selectively exert pressure on the nest to retain the nest in a desired position in the recess, and a second wedge adapted to selectively exert pressure on a cutting insert positioned in the cutting insert pocket to retain the cutting insert in a desired position. The mechanism further includes an adjustment screw including a first threaded portion and a second threaded portion. The first threaded portion is threadedly disposed in a threaded bore in the cutting tool body, and the second threaded portion is threadedly disposed in a threaded bore in the nest.

Abstract: A method of milling a profile of a railway rail comprises: rotating a milling cutter including a plurality of face mounted cutting inserts mounted about a periphery thereof; milling a railway rail with cutting edges of the cutting inserts rotating in a predetermined plane corresponding to at least a portion of a desired rail profile while controlling the depth of cut of the cutting inserts; traversing the railway rail with the milling cutter while milling the railway rail; and controlling the speed of traverse of the milling cutter along the railway rail.

Abstract: The present invention is directed to an insert, a slotting cutter assembly and a method for machining a plurality of slots in a metallic alloy part. The insert may comprise a cutting edge, at least one primary radius, at least two secondary radii and a clearance angle. The cutting edge may form a narrow outer end at a tip of the insert and a larger width region at a distance inward from the narrow outer end. The clearance angle may extend rearward from the cutting edge. The slotting cutter assembly may comprise a plurality of inserts and a cutter body. The cutter body may comprise a plurality of retaining slots and a plurality of support portions. The retaining slot may be configured to receive the insert. The support portion may provide support for the insert.

Abstract: The present invention is directed to an insert, a slotting cutter assembly and a method for machining a plurality of slots in a metallic alloy part. The insert may comprise a cutting edge, at least one primary radius, at least two secondary radii and a clearance angle. The cutting edge may form a narrow outer end at a tip of the insert and a larger width region at a distance inward from the narrow outer end. The clearance angle may extend rearward from the cutting edge. The slotting cutter assembly may comprise a plurality of inserts and a cutter body. The cutter body may comprise a plurality of retaining slots and a plurality of support portions. The retaining slot may be configured to receive the insert. The support portion may provide support for the insert.

Abstract: A cutting insert for a ball nose end mill includes a body including two opposed substantially flat retention surfaces. Each retention surface includes a chip control groove thereon extending from a point at or near an axial center of the body at an angle relative to the axial center of the body. The insert further includes a peripheral surface joining the two retention surfaces, wherein the peripheral surface includes a locating surface at a first end thereof and two arcuate surfaces at an opposed, second end thereof extending rearwardly from approximately the axial center of the second end and positioned on opposite sides of the insert symmetrically with respect to the centerline of the insert. The arcuate surfaces each including an arcuate cutting edge at the intersection of outer portion of a chip control groove and the arcuate surface. The arcuate surfaces are formed with a face clearance angle under the cutting edges.

Abstract: A cutting tool includes a novel cutting insert retaining and adjusting mechanism. The cutting insert retaining and adjusting mechanism is associated with a recess in the cutting tool and includes a nest slidably mounted in the recess. The nest includes a cutting insert pocket. The cutting insert retaining and adjusting mechanism includes a first wedge adapted to selectively exert pressure on the nest to retain the nest in a desired position in the recess, and a second wedge adapted to selectively exert pressure on a cutting insert positioned in the cutting insert pocket to retain the cutting insert in a desired position. The mechanism further includes an adjustment screw including a first threaded portion and a second threaded portion. The first threaded portion is threadedly disposed in a threaded bore in the cutting tool body, and the second threaded portion is threadedly disposed in a threaded bore in the nest.

Abstract: A cutting insert for a ball nose end mill includes a body including two opposed substantially flat retention surfaces. Each retention surface includes a chip control groove thereon extending from a point at or near an axial center of the body at an angle relative to the axial center of the body. The insert further includes a peripheral surface joining the two retention surfaces, wherein the peripheral surface includes a locating surface at a first end thereof and two arcuate surfaces at an opposed, second end thereof extending rearwardly from approximately the axial center of the second end and positioned on opposite sides of the insert symmetrically with respect to the centerline of the insert. The arcuate surfaces each including an arcuate cutting edge at the intersection of outer portion of a chip control groove and the arcuate surface. The arcuate surfaces are formed with a face clearance angle under the cutting edges.

Abstract: A method of treating a tool includes texturing at least a region of at least one surface of the tool to increase surface roughness and friction resistance. The tool may be in a variety of forms such as a cutting tool insert. The texturing process may be carried out by any suitable method such as laser beam impacting, grinding, sandblasting, molding, chemical etching, photolithography, and/or reactive ion etching. Tools made by the method also are disclosed.

Abstract: Improved formulations for ceramic materials for use as cutting tools are provided. The cutting tool includes a substrate of a ceramic matrix reinforced by ceramic whiskers, which substrate is coated with an adherent outer layer. The ceramic matrix is preferably formed from alumina and may contain toughening agents. The ceramic whiskers are preferably formed from silicon carbide and consist of 2-40% of the substrate. The cuter adherent coating is preferably alumina applied by a CVD process and provides an unexpected improvement in cutting tool longevity.