Abstract: A rotary cutting tool includes a replaceable cutting insert, a pocket portion for holding the cutting insert, and a chip flute portion having a plurality of helical flutes. An internal coolant passage is formed in the chip flute portion and has both a twisted geometry and a “see-through” central portion. The internal coolant passage is polygonal in cross-sectional shape having a number of cusps equal to the number of flutes. The internal coolant passage greatly increases coolant flow area, while maintaining the stiffness and rigidity of the cutting tool. A method includes forming the internal coolant passage using additive manufacturing such that the internal coolant passage has a “see-through” central portion and a twisted geometry.

Abstract: A rotary cutting tool includes a replaceable cutting insert, a pocket portion for holding the cutting insert, and a chip flute portion having a plurality of helical flutes. An internal coolant passage is formed in the chip flute portion and has both a twisted geometry and a “see-through” central portion. The internal coolant passage is polygonal in cross-sectional shape having a number of cusps equal to the number of flutes. The internal coolant passage greatly increases coolant flow area, while maintaining the stiffness and rigidity of the cutting tool. A method includes forming the internal coolant passage using additive manufacturing such that the internal coolant passage has a “see-through” central portion and a twisted geometry.

Abstract: Cutting tool systems including a tool holder and tangential cutting inserts are disclosed. The tangential cutting inserts have indexable cutting edges that may be sinusoidal-shaped and helical-shaped. The tangential cutting inserts have integrated fan and base portions. The tool holders comprise a plurality of insert pockets structured and arranged to receive the indexable tangential cutting inserts. The cutting tool systems provide cutting tools with effectively longer sinusoidal and helical cutting edges at their cutting rake faces and a strong support when seating in insert-receiving pockets on the tool holder.

Abstract: Cutting tool systems including a tool holder and tangential cutting inserts are disclosed. The tangential cutting inserts have indexable cutting edges that may be sinusoidal-shaped and helical-shaped. The tangential cutting inserts have integrated fan and base portions. The tool holders comprise a plurality of insert pockets structured and arranged to receive the indexable tangential cutting inserts. The cutting tool systems provide cutting tools with effectively longer sinusoidal and helical cutting edges at their cutting rake faces and a strong support when seating in insert-receiving pockets on the tool holder.

Abstract: A cutting insert with internal coolant passageways is disclosed. The cutting insert includes at least one internal coolant inlet passageway having a first cross-sectional area, and at least one internal coolant exit passageway having a second cross-sectional area. The at least one internal coolant exit passageway is in fluid communication with the at least one internal coolant inlet passageway. The coolant enters the at least one internal coolant inlet passageway at a first surface of the cutting insert and exits the at least one coolant exit passageway at a second, different surface of the cutting insert. The second cross-sectional area of the at least one internal coolant exit passageway are less than the first cross-sectional area of the at least one internal coolant inlet passageway, thereby producing an increased streaming effect of the coolant to an insert-chip interface.

Abstract: A double-sided tangential cutting insert comprising a pair of cutting rake faces, a pair of major side surfaces and a pair of opposing minor side faces each having a twisted convex shape. Each of the cutting rake faces is defined between a pair of main cutting edges, a pair of full nose cutting edges, and a pair of opposing convex minor cutting edges. Each of the minor side faces is defined between one of the convex minor cutting edges at one of the rake faces and one of the convex minor cutting edges at the other one of the rake faces wherein, at each minor side face, a ridge line interconnects an apex of the convex minor edge at the one of the rake faces and an apex of the convex minor cutting edge at the other one of the rake faces. Other variants and embodiments are broadly contemplated herein.

Abstract: A double-sided tangential cutting insert comprising a pair of cutting rake faces, a pair of major side surfaces and a pair of opposing minor side faces each having a twisted convex shape. Each of the cutting rake faces is defined between a pair of main cutting edges, a pair of full nose cutting edges, and a pair of opposing convex minor cutting edges. Each of the minor side faces is defined between one of the convex minor cutting edges at one of the rake faces and one of the convex minor cutting edges at the other one of the rake faces wherein, at each minor side face, a ridge line interconnects an apex of the convex minor edge at the one of the rake faces and an apex of the convex minor cutting edge at the other one of the rake faces. Other variants and embodiments are broadly contemplated herein.

Abstract: A ballnose cutting insert has a top face, a bottom face, a plurality of side clearance faces, a first nose corner, a second nose corner, and a first elongate cutting edge at the top face, a second elongate cutting edge at the top face, and a fastener bore with a center. There is a first open-end notch below the first nose corner, and a second open-end notch below the second nose corner. The first open-end notch is defined at least in part by a first generally planar engaging surface, and the second open-end notch is defined at least in part by a second generally planar engaging surface. The first generally planar engaging surface is disposed at a disposition angle relative to the second engaging surface, and the disposition angle is not equal to zero degrees. The first generally planar engaging surface is disposed from the center of the fastener bore a first abutment distance as measured along a line perpendicular to the first generally planar engaging surface.

Abstract: A cutting tool system is designed to have a combined sinusoidal-shaped and helical-shaped cutting edge formed by an assembly of aligned common cutting inserts each having a sinusoidal and helical cutting edge.

Abstract: A double-sided cutting insert for a drilling tool includes a top side, a bottom side, and at least one side surface interconnecting the top side and the bottom side and forming at least one cutting edge. The top side and the bottom side comprise a different external profile and chip groove geometry and an identical inscribed circle, and each of the top side and the bottom side comprises four indexable cutting edges.

Abstract: An endmill having a longitudinal cutting axis includes a cutting edge portion having: a nose corner adjacent to a cutting periphery of the endmill; a convex cutting edge having an end adjacent to the nose corner and an opposing end closer to the longitudinal cutting axis; a straight cutting edge having a first end adjacent to the opposing end of the convex cutting edge and a second end closer to the longitudinal cutting axis; and a convex ramping edge adjacent to the second end of the straight cutting edge.

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: A double-sided cutting insert may generally comprise: a top surface; a bottom surface; at least one side surface interconnecting the top surface and the bottom surface and forming at least one cutting edge; a through hole extending between the top surface and bottom surface; and wherein each of the top surface and bottom surface comprise an anti-rotation element comprising a single recess comprising a generally cyclic conical periphery. Each of the top surface and bottom surface may comprise at least one cyclic conical face. The recess may comprise a geometry that is complementary to the at least one cyclic conical face of the projection in an insert receiving pocket in a tool holder. A cutting tool incorporating one or more of the cutting inserts, and methods of making and using the cutting inserts are also described.

Abstract: A ballnose cutting insert has a top face, a bottom face, a plurality of side clearance faces, a first nose corner, a second nose corner, and a first elongate cutting edge at the top face, a second elongate cutting edge at the top face, and a fastener bore with a center. There is a first open-end notch below the first nose corner, and a second open-end notch below the second nose corner. The first open-end notch is defined at least in part by a first generally planar engaging surface, and the second open-end notch is defined at least in part by a second generally planar engaging surface. The first generally planar engaging surface is disposed at a disposition angle relative to the second engaging surface, and the disposition angle is not equal to zero degrees. The first generally planar engaging surface is disposed from the center of the fastener bore a first abutment distance as measured along a line perpendicular to the first generally planar engaging surface.

Abstract: One non-limiting aspect of the present disclosure is directed to a multi-piece twist drill head. The multi-piece twist drill head includes a core piece formed from a first hard material, and a peripheral piece formed from a second hard material. The core piece and peripheral piece each comprise a cutting edge and are adapted to mate to provide a central region and a peripheral region, respectively, of the multi-piece twist drill head. A twist drill including the multi-piece twist drill head is also disclosed.

Abstract: A cutting insert fastener adapted to secure a cutting insert to a cutting tool holder. The fastener comprises a fastener head portion comprising at least one feature adapted to direct a coolant fluid to an insert cutting edge of a cutting insert when the cutting insert is secured to a cutting tool holder by the cutting insert fastener. Cutting tools comprising internal coolant systems and fastened with a cutting insert fastener comprising a fastener head portion with at least one feature adapted to direct a coolant fluid to an insert cutting edge are also disclosed.

Abstract: The present invention relates to embodiments of a cutting tool holder having at least one insert pocket, wherein at least one insert pocket comprises a side surface and at least one antirotation stop protruding from the side surface.

Abstract: Cutting inserts are described having at least two discontiguous clearance faces. Cutting tool systems including the cutting inserts are also described. An indexable cutting insert includes a top face, a bottom face, and at least two clearance faces connecting the top face and the bottom face at a periphery of the cutting insert. The at least two clearance faces include a primary clearance face contiguous with the top face and forming a cutting edge at an intersection of the primary clearance face and the top face, and a secondary clearance face discontiguous with the primary clearance face and separated from the primary clearance face by a bridge surface, and wherein a primary clearance angle formed by the primary clearance face is larger than a secondary clearance angle formed by the secondary clearance face.

Abstract: A double-sided cutting insert may generally comprise a top surface, a bottom surface, at least one side surface interconnecting the top surface and the bottom surface and forming at least one cutting edge, a through hole extending between the top surface and bottom surface, wherein each of the top surface and bottom surface comprise at least one anti-rotation element. The cutting insert may comprise a single anti-rotation element on the top surface and a single anti-rotation element on the bottom surface. The anti-rotation element may be proximate to the through hole. A cutting tool using the cutting inserts, as well as methods of making and using the same are also described.

Abstract: One non-limiting aspect of the present disclosure is directed to a multi-piece twist drill head. The multi-piece twist drill head includes a core piece formed from a first hard material, and a peripheral piece formed from a second hard material. The core piece and peripheral piece each comprise a cutting edge and are adapted to mate to provide a central region and a peripheral region, respectively, of the multi-piece twist drill head. A twist drill including the multi-piece twist drill head is also disclosed.