Abstract: A material removal having a plurality of cartridges mounted on an active portion where a plurality of seating members mounted in each of the plurality of cartridges pivots about an axis between a retracted position and an extended position is disclosed. Alternative embodiments have a single pivotable seating member. The pivotable extending seating members operate to extend and retract in a scissors-like motion and enable compact and efficient machining operation, particularly for crank shaft bearing supports.

Abstract: A material removal tool with a cutting insert mounted in the seating pocket is disclosed. The translating bar is operably connected to the at least one radially pivotable arm by a mechanical linkage and translates under fluid pressure applied to one side of a piston head by an actuating fluid, where the actuating fluid is also coolant for the material removal tool. With the translating bar in a first position, the radially outermost edge of the cutting insert is radially inward from the first active volume, and with the translating bar in a second position, the radially outermost portion of the cutting insert is radially outward from the first active volume and the axially rearmost portion of the cutting insert is rearward of an axially rearmost portion of the arm. A method of removing material from a workpiece with the material removal tool, such as by backboring, is also disclosed.

Abstract: A method to adjust a modal property of a material removal tool without changing a projection length of the material removal tool is disclosed. Adjusting substantially aligns a characteristic frequency of the material removal tool with a rotation speed of a spindle of a machine tool. A material removal tool employing the method and a method to machine metal are also disclosed.

Abstract: A material removal tool including a housing body having an active portion, at least one seating surface for a cutting insert operatively positioned on the active portion, and a guide pad positioned in a cavity in a circumferential surface of the active portion is disclosed. The guide pad is radially adjustable between a first radial position and a second radial position by a differential pressure across the guide pad. The differential pressure is created by an actuation fluid supplied to one side of the guide pad. A method for removing material from a workpiece with the rotating material removal tool is also disclosed.

Abstract: Material removal tool with a translating bar having an actuation surface shaped as a cone or frustum, wherein an axial position of the cone or frustum along a length of the translating bar corresponds to a position of a push rod in operable contact with a first flexibly mounted cartridge on which a cutting insert is mounted is disclosed. The translating bar is actuated between a first and second position to place different combinations of flexibly mounted cutting inserts and fixedly mounted cutting inserts in a radially outermost position. The material removal tool optionally includes a support for the translating bar to reduce radial variation during machining operations. Various combinations of flexibly mounted cutting inserts and fixedly mounted cutting inserts are disclosed along with various methods for removing material using the disclosed material removal tool.

Abstract: Rotary material removal tool mounted to a shaft for rotational motion includes a body and a plurality of radially extending arms. Each arm includes a radially outward peripheral edge, and, relative to a direction of rotational motion of the body, a leading side and a trailing side. Radially outward peripheral edges include a cutting insert mounting structure that projects axially below a bottom side of the body. The rotary material removal tool includes at least one of the following features to reduce measured air pressure (P1): (i) a leading edge of the insert mounting structure includes an air-displacement structure, (ii) the radially extending arms include at least one through-opening extending from the leading side to the trailing side, and (iii) the bottom side of the body is spaced from a plane containing a bottommost surface of the projecting cutting insert mounting structure. The air-displacement structure can be generally wedge-shaped, cone-shaped or pyramid-shaped.

Abstract: An exemplary embodiment of a material removal tool has a housing at a mating end, an extension longitudinally extending from the housing to a distal end, a plurality of spacers arranged along the extension, and a nut at the distal end of the extension, wherein the plurality of spacers are formed from a material having a Young's modulus of greater than about 1.5 times that of steel. The spacers along the extension of the tool place the stiffer material of the spacer at a location of greatest resistance to bending moments (i.e. highest sectional modulus). Optionally preloading and “built-in” relief points contribute to improved performance of the material removal tool. A method of manufacturing a material removal tool and a method of machining a workpiece are also disclosed.

Abstract: Rotary material removal tool mounted to a shaft for rotational motion includes a body and a plurality of radially extending arms. Each arm includes a radially outward peripheral edge, and, relative to a direction of rotational motion of the body, a leading side and a trailing side. Radially outward peripheral edges include a cutting insert mounting structure that projects axially below a bottom side of the body. The rotary material removal tool includes at least one of the following features to reduce measured air pressure (P1): (i) a leading edge of the insert mounting structure includes an air-displacement structure, (ii) the radially extending arms include at least one through-opening extending from the leading side to the trailing side, and (iii) the bottom side of the body is spaced from a plane containing a bottommost surface of the projecting cutting insert mounting structure. The air-displacement structure can be generally wedge-shaped, cone-shaped or pyramid-shaped.

Abstract: A material removal having a plurality of cartridges mounted on an active portion where a plurality of seating members mounted in each of the plurality of cartridges pivots about an axis between a retracted position and an extended position is disclosed. Alternative embodiments have a single pivotable seating member. The pivotable extending seating members operate to extend and retract in a scissors-like motion and enable compact and efficient machining operation, particularly for crank shaft bearing supports.

Abstract: A material removal tool including a housing body having an active portion, at least one seating surface for a cutting insert operatively positioned on the active portion, and a guide pad positioned in a cavity in a circumferential surface of the active portion is disclosed. The guide pad is radially adjustable between a first radial position and a second radial position by a differential pressure across the guide pad. The differential pressure is created by an actuation fluid supplied to one side of the guide pad. A method for removing material from a workpiece with the rotating material removal tool is also disclosed.

Abstract: A material removal tool with a cutting insert mounted in the seating pocket is disclosed. The translating bar is operably connected to the at least one radially pivotable arm by a mechanical linkage and translates under fluid pressure applied to one side of a piston head by an actuating fluid, where the actuating fluid is also coolant for the material removal tool. With the translating bar in a first position, the radially outermost edge of the cutting insert is radially inward from the first active volume, and with the translating bar in a second position, the radially outermost portion of the cutting insert is radially outward from the first active volume and the axially rearmost portion of the cutting insert is rearward of an axially rearmost portion of the arm. A method of removing material from a workpiece with the material removal tool, such as by backboring, is also disclosed.

Abstract: An indexable insert has one or more recesses formed in a frontside or backside surface which receives a surface of the head of a locking screw. When mounted, the insert is forced against respective support surfaces of an insert pocket. The locking screw is threaded into a counterbored tap hole to engage the insert and provide side locating forces and clamping forces to secure the indexable insert in the insert pocket. More particularly, the indexable insert has a shaped surface recess that mates to a complimentarily-shaped surface on the head of a locking screw and secures the indexable insert in multiple dimensions to a seating surface. A material removal tool and a method of mounting the indexable insert are also disclosed.

Abstract: An indexable insert has one or more recesses formed in a frontside or backside surface which receives a surface of the head of a locking screw. When mounted, the insert is forced against respective support surfaces of an insert pocket. The locking screw is threaded into a counterbored tap hole to engage the insert and provide side locating forces and clamping forces to secure the indexable insert in the insert pocket. More particularly, the indexable insert has a shaped surface recess that mates to a complimentarily-shaped surface on the head of a locking screw and secures the indexable insert in multiple dimensions to a seating surface. A material removal tool and a method of mounting the indexable insert are also disclosed.

Abstract: A method to adjust a modal property of a material removal tool without changing a projection length of the material removal tool is disclosed. Adjusting substantially aligns a characteristic frequency of the material removal tool with a rotation speed of a spindle of a machine tool. A material removal tool employing the method and a method to machine metal are also disclosed.

Abstract: Material removal tool with a translating bar having an actuation surface shaped as a cone or frustum, wherein an axial position of the cone or frustum along a length of the translating bar corresponds to a position of a push rod in operable contact with a first flexibly mounted cartridge on which a cutting insert is mounted is disclosed. The translating bar is actuated between a first and second position to place different combinations of flexibly mounted cutting inserts and fixedly mounted cutting inserts in a radially outermost position. The material removal tool optionally includes a support for the translating bar to reduce radial variation during machining operations.

Abstract: A cutting tool is provided and includes a plurality of cutting inserts located in respective insert pockets. The cutting inserts each include a top cutting plane with at least one cutting edge and a bottom support plane. The top cutting plane includes an engagement portion for mating with a respective engagement portion located in the respective insert pocket. A clamping wedge clamps the cutting insert against the respective insert pocket. A shear resistance created between the engagement portions of the cutting insert and the respective insert pocket during operation of the tool is greater than a centrifugal force created during operation of the cutting tool. In an exemplary embodiment, the engagement portions are shown as a plurality of serrations. The cutting tool is particularly useful in high speed milling operations.

Abstract: A tool holder includes a plurality of portions arranged in end-to-end relationship and interconnected by friction weld to form a unitary assembly subjected to a heat treatment. The portions formed of different respective materials have different mass properties and/or different chemical compositions. A front-most one of the portions constitutes a cutter head portion, and a rear-most one of the portions constitutes a mounting portion. The cutter head portion can be in the form of an unfinished blank which is subsequently machined. A third portion, e.g. of aluminum, could be provided to minimize the weight of the tool holder.

Abstract: An eta-phase-free cemented carbide insert with improved surface hardness and wear resistance containing WC, and possibly cubic phases of a carbide and/or carbonitride, in a binder phase of Co, Ni, Fe or a combination thereof, with a binder phase gradient in the surface and near surface regions, is disclosed. The nominal binder phase content in the insert is 3-20 weight %. The surface, and near surface cobalt content is 50-100% of the binder phase content of the inner portion of the insert. The insert is formed by standard sintering practices, followed by the chemical removal of the binder phase from the surface and near surface regions of the insert. The insert is then heat treated at a temperature of 1300-1350° C. in a carburizing atmosphere, for a time of 5-400 minutes to cause diffusion of the binder phase from the interior into the binder depleted surface regions.

Abstract: An insert providing an improved wiper on cutting edges that form the surface finish of a workpiece, wherein the cutting edge is a curve in a plane of the flank that forms the finish cutting edge, the curve having an apex proximate the common corner, the curve forming a wiper on the finish cutting edge at or closely proximate to the apex.

Abstract: A rotatable cutting tool comprising a cutting tool body having at least one recess for receiving a replaceable insert. The recess has a wall defined by a deformable clamp extending radially from the tool body, the clamp comprising a leaf isolated from the tool body except at the base of the leaf by an isolating channel in the tool body. The tool further comprising adjustable clamping means for elastically deforming the leaf to retain a replaceable insert in the recess.