Abstract: A cutting tool assembly for use in controlled fracture machining includes a body having a rectilinear shape with a top end and bottom end and a tool holder attached to the bottom end of the body. A first cutting tool is configured at one lower end of the tool holder is to operate the tool in a forward direction of movement while a second cutting tool is configured at the opposite end of the tool holder to operate in a reverse direction of movement. The tool is shaped so an upper portion of the tool holder has a first diameter and the lower portion of the tool holder has a second diameter. The first diameter can smaller or larger than the second diameter depending on the size and type of workpiece and shape needed to produced.

Abstract: A miniaturized turbogenerator (200) to directly provide electrical propulsion (307 308, 309) to small land, air, and maritime vehicles without an intervening electricity storage battery (315). The invention comprises of a process of miniaturization (500) of a turbine engine core (100), in particular its compressors and turbines (400), by means of hyper-feed machining by linear force alone, i.e. without rotation of either the workpiece or the cutting tool (505), and a resulting apparatus of a miniaturized turbogenerator (200) that has sufficient power density to provide high-performance electrical propulsion (310) for commercially feasible automobiles, urban air mobility vehicles, and other small vehicles and vessels with greater performance than battery-electric vehicles (300).

Abstract: A method and apparatus for producing a hole in any material by means of controlled fracturing using non-spindle CNC machining includes the steps of: fixturing a workpiece to the table of a non-spindle CNC holemaking machine tool. The cutting tool is then secured to the column of the machine tool and the face of the cutting tool is positioned perpendicular to the centerline of the proposed hole. The surface of the workpiece is approached with the cutting tool to a predetermined clearance level. Thereafter, the cutting tool is driven with sufficient linear force to induce instantaneous strain in the material of the workpiece to a depth necessary to create a hole of a desired size and shape using a drive mechanism. The cutting tool is then repositioned so that the face of cutting tool is perpendicular to centerline of a subsequent hole to be produced.

Abstract: A split link (800C) includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device (807) to form a split link assembly. The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.

Abstract: A non-spindle multi-axis machining center (600) and method for forming a part using a non-rotating cutting tool (400) for removing material from a non-rotating workpiece within a three-dimensional work envelope. The non-spindle machining center makes obsolete the use of mills for profiling operations without the need to rotate the cutting tool to produce sufficient torque to remove material. Instead, the cutting tool (400) applies a linear cutting force to the workpiece along a one-, two-, or three-dimensional cutting path with sufficient impact to remove material by means of controlled fracturing instead of plastic deformation. Also, without the need to rotate, neither the cutting tool nor the part are constrained in shape by axial symmetry. Therefore, parts without restrictions in shape can be produced with higher material removal rates and finer surface finishes than by milling or turning.

Abstract: A non-rotary shaping method (700, 800, 900) and shaping center (600) for forming a part using a non-rotating cutting tool (400) for removing material from a non-rotating workpiece within a three-dimensional work envelope that obsoletes the use of mills for profiling operations. Without the need to rotate to produce sufficient surface footage to remove material, the cutting tool (400) applies constant cutting force to the workpiece along a one-, two-, or three-dimensional cutting path at a sufficiently high feed rate to remove material by means of controlled fracturing instead of plastic deformation. Also, without the need to rotate, neither the cutting tool nor the part are constrained in shape by axial symmetrical. Therefore, parts without any restriction in shape can be produced with finer surface finishes and higher material removal rates than by milling.