Abstract: A cutting insert includes a body made of a ceramic material. The body has a first surface, a second surface and at least one flank surface extending between the first surface and the second surface. The first surface includes a chip forming feature extending in a radially outwardly direction to a cutting edge and extending in a radially inwardly direction to an inner edge. The chip forming feature includes a front wall that slopes downward from the cutting edge radially inward toward a rounded bottom surface and a back wall that slopes upward from the rounded bottom surface radially inward to the inner edge. The chip forming feature can include an optional land surface between the cutting edge and the front wall.

Abstract: A double-sided, trigon cutting insert has three three major cutting edges formed at an intersection between a first planar side surface portion and first and second surfaces, and three minor cutting edges formed at an intersection between a second planar side surface portion and first and second surfaces. A planar rake surface extends radially inward and downward from each major cutting edge, and a rounded rake surface extends radially inward and downward from each minor cutting edge. An insert-receiving pocket of a cutting tool includes a planar bottom support surface, a first planar side support surface, a second planar side support surface, and a third planar side support surface. Each rounded rake surface is formed with a radius, R, that causes only a high point of each minor cutting edge to contact a workpiece during a machining operation.

Abstract: A cutting insert includes a body made of a ceramic material. The body has a first surface, a second surface and at least one flank surface extending between the first surface and the second surface. The first surface includes a chip forming feature extending in a radially outwardly direction to a cutting edge and extending in a radially inwardly direction to an inner edge. The chip forming feature includes a front wall that slopes downward from the cutting edge radially inward toward a rounded bottom surface and a back wall that slopes upward from the rounded bottom surface radially inward to the inner edge. The chip forming feature can include an optional land surface between the cutting edge and the front wall.

Abstract: A cutting insert for a cutting tool is described. The cutting inserts generally square-shaped with two opposing surfaces and four peripheral side surfaces. Cutting edges are formed at the intersection between the first and second surfaces and the peripheral side surfaces. Each cutting edge is divided into a first portion, a second portion and a radius blend. The first portion has a length, L1, and the second portion has a length, L2, that is shorter than the first portion such that the radius blend is not located at a midpoint of the cutting edge, thereby increasing a height of the ninety-degree shoulder that can be cut by the cutting insert.

Abstract: A double-sided, trigon cutting insert has three three major cutting edges formed at an intersection between a first planar side surface portion and first and second surfaces, and three minor cutting edges formed at an intersection between a second planar side surface portion and first and second surfaces. A planar rake surface extends radially inward and downward from each major cutting edge, and a rounded rake surface extends radially inward and downward from each minor cutting edge. An insert-receiving pocket of a cutting tool includes a planar bottom support surface, a first planar side support surface, a second planar side support surface, and a third planar side support surface. Each rounded rake surface is formed with a radius, R, that causes only a high point of each minor cutting edge to contact a workpiece during a machining operation.

Abstract: A composite cutting insert includes a first portion made of a first composite material, a second portion made of a second composite material, and an intermediate portion interposed between the first and second portions and made of a third material. The intermediate portion has a two dimensional interlocking geometric shape. In one embodiment, the two-dimensional interlocking geometric shape is in the form of a mesh of interlocking links with evenly spaced, uniform small openings between the links. The interlocking geometric shape prevents movement of the first portion relative to the second portion. In addition, the openings allow the first and second composite materials to bond directly to each other.

Abstract: A wedge clamp includes a top wall, a bottom wall, a front wall, a rear wall opposite the front wall, and a fluid port traversing from the front wall to the rear wall. The fluid port has a front opening and a rear opening to allow cooling fluid to pass therethrough. In one embodiment, the front opening is a rounded isosceles trapezoid in shape with a pair of parallel substantially planar side walls of different length and a pair of arcuate side walls connecting the pair of planar side walls. The rear opening has a greater surface area proximate the rear wall and a smaller surface area proximate the front opening, resulting in a funnel-shaped opening to cause an increase in velocity of the cooling fluid passing through the fluid port.

Abstract: A cutting insert for a cutting tool is described. The cutting inserts generally square-shaped with two opposing surfaces and four peripheral side surfaces. Cutting edges are formed at the intersection between the first and second surfaces and the peripheral side surfaces. Each cutting edge is divided into a first portion, a second portion and a radius blend. The first portion has a length, L1, and the second portion has a length, L2, that is shorter than the first portion such that the radius blend is not located at a midpoint of the cutting edge, thereby increasing a height of the ninety-degree shoulder that can be cut by the cutting insert.

Abstract: A cutting insert with a serrated topography includes a top surface terminating in a circular cutting edge, a bottom surface and a frusto-conical sidewall interconnecting the top surface and the bottom surface, and a plurality of serrations on the top surface uniformly disposed around the circular cutting edge and extending radially inward from the cutting edge in such a way that a bisector through each serration passes through a central axis of the cutting insert. The plurality of serrations are positioned in a cutting tool in such a way so as to reduce regenerative chatter during a cutting operation. A method of reducing generative chatter by positioning the cutting inserts in a particular fashion in a cutting tool is also disclosed.

Abstract: A wedge clamp includes a top wall, a bottom wall, a front wall, a rear wall opposite the front wall, and a fluid port traversing from the front wall to the rear wall. The fluid port has a front opening and a rear opening to allow cooling fluid to pass therethrough. In one embodiment, the front opening is a rounded isosceles trapezoid in shape with a pair of parallel substantially planar side walls of different length and a pair of arcuate side walls connecting the pair of planar side walls. The rear opening has a greater surface area proximate the rear wall and a smaller surface area proximate the front opening, resulting in a funnel-shaped opening to cause an increase in velocity of the cooling fluid passing through the fluid port.

Abstract: A composite cutting insert includes a first portion made of a first composite material, a second portion made of a second composite material, and an intermediate portion interposed between the first and second portions and made of a third material. The intermediate portion has a two dimensional interlocking geometric shape. In one embodiment, the two-dimensional interlocking geometric shape is in the form of a mesh of interlocking links with evenly spaced, uniform small openings between the links. The interlocking geometric shape prevents movement of the first portion relative to the second portion. In addition, the openings allow the first and second composite materials to bond directly to each other.

Abstract: A cutting tool includes a pocket with a top wall, a bottom wall, a first side wall for engaging an insert cartridge, a second side wall, a first rear wall, and a second rear wall. The top wall and the bottom wall are formed at a negative angle with respect to each other to provide a closed pocket design that resists centrifugal forces when the insert cartridge and the clamp wedge are in a locked condition during a cutting operation.

Abstract: An anti-rotation mounting mechanism is provided between an indexable insert and an insert-receiving pocket in the body of a machine tool, such as a milling cutter. The mechanism includes a plurality of curved stop surfaces uniformly disposed around the side surface of the insert, a portion of which is obliquely oriented with respect to the side surface of the insert, and an anti-rotation feature in the pocket of the tool body having a pair of engagement portions that are substantially complementary in shape to that of the stop surfaces for forming an interference joint between the pocket and the insert. The anti-rotation feature further includes a central planar portion that does not engage the stop surfaces. The mechanism effectively prevents rotation between the insert and pocket without the formation of point-type, localized stresses which can chip or break the insert.

Abstract: A hydraulic coupling system includes an adapter, a shell mill, a threaded member, and a chucking membrane. The adapter includes a tapered pilot disposed on and extending from an end face. The shell mill includes a central counter bore for enabling the pilot of the adapter to be inserted therein. The threaded member includes at least one sealing member and is capable of being threaded into a threaded bore of the shell mill. The chucking membrane includes an intermediate portion disposed between two flanges and forms a fluid-tight channel for hydraulic fluid. The chucking member has a tapered inside surface. When the threaded member is threaded into the shell mill, the tapered surfaces of the pilot and the chucking membrane cause an axial force to seat the end face of the shell mill firmly against the end face of the adapter.

Abstract: A cutting insert with a serrated topography includes a top surface terminating in a circular cutting edge, a bottom surface and a frusto-conical sidewall interconnecting the top surface and the bottom surface, and a plurality of serrations on the top surface uniformly disposed around the circular cutting edge and extending radially inward from the cutting edge in such a way that a bisector through each serration passes through a central axis of the cutting insert. The plurality of serrations are positioned in a cutting tool in such a way so as to reduce regenerative chatter during a cutting operation. A method of reducing generative chatter by positioning the cutting inserts in a particular fashion in a cutting tool is also disclosed.