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: 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: 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 high-speed milling cutter (10) includes a shank (12), a front portion (14), and a transition surface (16) between the shank (12) and the front portion (14). The cutter (10) also includes an insert pocket (20) having a bottom surface (22) and side surfaces (24, 26). The bottom surface (22) includes a raised boss (28) for supporting a cutting insert (30). The cutting insert (30) has a top surface (32), a bottom surface (34) and side surfaces (36, 38, 40, 42). The cutting insert (30) includes a primary cutting edge (44, 46) formed at an intersection between the top surface (32) and two of the side surfaces (36, 38, 40, 42). The top surface (32) of the cutting insert (30) includes a concave or dish-shaped topography that is designed for high-speed milling operations of a metallic work piece.