Abstract: A rotary burr comprising cemented carbide for removing material from a workpiece includes a shank and a working portion and a shank. A surface of the working portion includes a plurality of right-handed helically oriented flutes that define a plurality of cutting teeth on the working portion. Each of the plurality of cutting teeth defined by the right-handed flutes includes a front face, a back face, a tip, and a positive front face angle, and lacks a radial land adjacent the tooth tip and at the periphery of the working portion.

Abstract: A cutting insert for milling operations, such as, face milling, slot milling, plunge milling, and ramping operations. The cutting insert exhibits a combination of favorable cutting edge strength, and unique cutting edge geometry, thus, allowing milling operations at relatively high feed rates. The cutting insert includes at least four cutting edges, wherein at least one of the cutting edges is a convex cutting edge. Certain embodiments of square cutting inserts will have four convex cutting edges which may be connected by nose corners. The convex cutting edge may comprise at least one of a circular arc, a portion of an ellipse, a portion of a parabola, a multi-segment spline curve, a straight line, or combinations of these. Wherein the convex cutting edge comprises a circular arc, the circular arc may have a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface.

Abstract: This invention relates to cutting inserts for earth boring bits comprising a cutting zone, wherein the cutting zone comprises first cemented hard particles and a body zone, wherein the body zone comprises second cemented hard particles. The first cemented hard particles may differ in at least one property from the second cemented hard particles. As used herein, the cemented hard particles means a material comprising hard particles in a binder. The hard particles may be at least one of a carbide, a nitride, a boride, a silicide, an oxide, and solid solutions thereof and the binder may be at least one metal selected from cobalt, nickel, iron and alloys of cobalt, nickel or iron.

Abstract: Embodiments of the present invention include methods of producing a composite article. A method comprises introducing a first powdered metal grade from a feed shoe into a first portion of a cavity in a die and a second powdered metal grade from the feed shoe into a second portion of the cavity, wherein the first powder metal grade differs from the second powdered metal grade in chemical composition or particle size. Further methods are also provided. Embodiments of the present invention also comprise composite inserts for material removal operations. The composite inserts may comprise a first region and a second region, wherein the first region comprises a first composite material and the second region comprises a second composite material.

Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and at least one melting point-reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.

Abstract: A composite article includes a first composite material and a second composite material. The first composite material and the second composite material individually comprise hard particles in a binder. A concentration of ruthenium in the binder of the first composite material is different from a concentration of ruthenium in the binder of the second composite material.

Abstract: Cutting tools and cutting inserts having a wear resistant coating on a substrate comprising a metal carbide particle and a binder. For certain applications, a cutting insert having a wear resistant coating comprising hafnium carbon nitride and a binder comprising ruthenium may provide a greater service life. The wear resistant coating comprising hafnium carbon nitride may have a thickness of from 1 to 10 microns. In another embodiment, the cutting tool comprises a cemented carbide substrate with a binder comprising at least one of iron, nickel and cobalt.

Abstract: A generally parallelogram-shaped cutting insert includes a top face; first and second main radial clearance faces, each intersecting the top face; first and second minor axial clearance faces each intersecting the top face and connecting the first and second main radial clearance faces; and a main cutting edge at the intersection of the top face and the first main radial clearance face. According to one non-limiting embodiment, the main cutting edge comprises a variable radial rake angle including a portion having a positive radial rake angle and a portion having a negative radial rake angle.

Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.

Abstract: Embodiments of the present invention include hybrid composite materials comprising a cemented carbide dispersed phase and a cemented carbide continuous phase. The contiguity ratio of the dispersed phase of embodiments may be less than or equal to 0.48. The hybrid composite material may have a hardness of the dispersed phase that is greater than the hardness of the continuous phase. For example, in certain embodiments of the hybrid composite material, the hardness of the dispersed phase is greater than or equal to 88 HRA and less than or equal to 95 HRA and the hardness of the continuous phase is greater than or equal to 78 and less than or equal to 91 HRA. Additional embodiments may include hybrid composite materials comprising a first cemented carbide dispersed phase wherein the volume fraction of the dispersed phase is less than 50 volume percent and a second cemented carbide continuous phase, wherein the contiguity ratio of the dispersed phase is less than or equal to 1.

Abstract: The present invention relates to ceramic cutting tools, such as, a aluminum oxide with zirconium oxide ceramic cutting tool with diffusion bonding enhanced layer and CVD coatings, particularly useful for machining modem metal materials. The method comprises a chemical reaction with a mixture including nitrogen and aluminum chloride introduced to form a diffusion bonding enhanced layer between the ceramic substrate and the CVD coatings. Thus formed diffusion bonding is highly adherent to the aluminum oxide with zirconium oxide ceramic substrate and significantly enhances the CVD coating properties, and thus improving the machining performance in terms of the tool life of zirconium-based aluminum oxide with zirconium oxide ceramic cutting tools.

Abstract: Embodiments of a radiation shield are disclosed. One non-limiting embodiment of the radiation shield may comprise a first layer, a second layer, and a third layer. The first layer may include a neutron moderating material. The second layer may be adjacent the first layer and may include a neutron absorbing material. The third layer may be adjacent the second layer, and may include a photonic radiation attenuating material. At least the first layer and the second layer may be removable from the radiation shield.

Abstract: A modular fixed cutter earth-boring bit body includes a blade support piece and at least one blade piece fastened to the blade support piece. A modular fixed cutter earth-boring bit and methods of making modular fixed cutter earth-boring bit bodies and bits also are disclosed.

Abstract: A cutting insert for milling operations, such as, face milling, slot milling, plunge milling, and ramping operations. The cutting insert exhibits a combination of favorable cutting edge strength, and unique cutting edge geometry, thus, allowing milling operations at relatively high feed rates. The cutting insert includes at least four cutting edges, wherein at least one of the cutting edges is a convex cutting edge. Certain embodiments of square cutting inserts will have four convex cutting edges which may be connected by nose corners. The convex cutting edge may comprise at least one of a circular arc, a portion of an ellipse, a portion of a parabola, a multi-segment spline curve, a straight line, or combinations of these. Wherein the convex cutting edge comprises a circular arc, the circular arc may have a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface.

Abstract: The present invention relates to the PVD coated tungsten carbide (WC) based cemented cutting inserts with ruthenium (Ru) as a key chemical element, or a key feature, in the cobalt (Co)-based binder phase, particularly useful for machining today's mold & die materials. In the Ru—Co mixed binder phase in the tungsten carbide substrate, the ratio of Ru/Co is at least 3%, by weight. The Ru-featured carbide cutting insert provided in this invention is PVD coated with one or more layers by a modern PVD coating technology. The development of the PVD coated Ru-featured carbide cutting inserts provided in this invention is based on a discovery that the unique combination of PVD coating techniques and Ru-featured carbide cutting inserts demonstrates superior machining performance in today's mold & die machining applications.

Abstract: The invention is directed towards cutting inserts having a top surface, a bottom surface, at least three side surfaces extending from the top surface to the bottom surface, and a nose corner connecting two adjacent side surfaces. The intersection of the cutting insert may include an intersection of the nose corner and the top surface wherein at least a portion of the intersection defined by a multi-segment spline curve. The multi-segment spline curve may be a B-spline curve. The intersection may also be defined by two arcs at each end of the B-spline curve. The invention also includes a method of designing a turning insert having the steps of designing a nose corner with multi-segment spline curve. The multi-segment spline curve may be a B-spline curve.

Abstract: A cutting insert for milling operations, such as, face milling, slot milling, plunge milling, and ramping operations. The cutting insert exhibits a combination of favorable cutting edge strength, and unique cutting edge geometry, thus, allowing milling operations at relatively high feed rates. The cutting insert includes at least four cutting edges, wherein at least one of the cutting edges is a convex cutting edge. Certain embodiments of square cutting inserts will have four convex cutting edges which may be connected by nose corners. The convex cutting edge may comprise at least one of a circular arc, a portion of an ellipse, a portion of a parabola, a multi-segment spline curve, a straight line, or combinations of these. Wherein the convex cutting edge comprises a circular arc, the circular arc may have a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface.

Abstract: The present invention relates to embodiments of a cutting tool holder (10) having at least one insert pocket (13), wherein at least one insert pocket comprises a side surface (15) and at least one antirotation stop (16) protruding from the side surface. The antirotation stop may comprise at least two substantially planar surfaces. In certain embodiments, the cutting tool holder may have a pocket which comprises a bottom surface and an antirotation stop having three substantially planar surfaces that are substantially perpendicular to the bottom surface. The antirotation stop may be integral to the tool holder or may be produced separately and attached, either permanently or temporarily, to the tool holder. Embodiments may further comprise additional antirotation stops is desired by the machining application.

Abstract: Method for removing a portion of the binder phase from the surface of a substrate that is composed of particles of at least a first phase joined together by the binder phase, and wherein the surface is etched by contacting it with a gas flow of an etchant gas and a second gas. The second gas is one or more gases that will not react with the substrate or the removed binder phase and will not alter the oxidation state of the substrate during etching.

Abstract: Methods of coating cutting tool inserts including a hard substrate and a plurality of coatings are disclosed. In one embodiment, the method comprises applying a first coating of at least 2 microns to at least a portion of the hard substrate and applying a second coating. The first coating can comprise at least one of a metal carbide, a metal nitride, and a metal carbonitride of at least one metal selected from zirconium and hafnium. The second coating can comprise at least one of a metal carbide, a metal boride, a metal nitride, and a metal oxide of a metal selected from groups IIIA, IVB, VB, and VIB of the periodic table. Optionally, third and fourth coatings are also applied to the cutting tool inserts.