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: 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: One non-limiting aspect of the present disclosure is directed to a multi-piece spade drill head for a spade drill, wherein the spade drill includes an elongate body portion and a cutting portion removably secured to an end of the body portion. The multi-piece spade drill head includes at least two insert pieces, each piece including a cutting edge. The at least two insert pieces are configured to be removably secured to the body portion of the spade drill adjacent one another and with the cutting edges of the insert pieces aligned to together form a cutting edge on an end of the spade drill.

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: Insert pockets of tool holders configured to accommodate multiple differently-shaped cutting inserts are disclosed. Cutting tool holders and cutting tool systems are also disclosed.

Abstract: A method of forming a composite article by injecting at least two composite materials comprising metal carbides into a mold to form a green compact is disclosed. The composite materials may be metal powders comprising a binder metal, a hard particle. The composite material may further comprise a plastic binder. The two different composite materials are injected into the mold to form the green compact. Additionally, the composite materials may be injected through a die before entering the mold. In a specific embodiment, the die forms at least one internal channel within the green compact.

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: One non-limiting aspect of the present disclosure is directed to a multi-piece spade drill head for a spade drill, wherein the spade drill includes an elongate body portion and a cutting portion removably secured to an end of the body portion. The multi-piece spade drill head includes at least two insert pieces, each piece including a cutting edge. The at least two insert pieces are configured to be removably secured to the body portion of the spade drill adjacent one another and with the cutting edges of the insert pieces aligned to together form a cutting edge on an end of the spade drill.

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 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 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: Embodiments of the present invention include methods of producing a composite article. A method comprises introducing a first powdered metal grade from a feed shoe into a first portion of a cavity in a die and a second powdered metal grade from the feed shoe into a second portion of the cavity, wherein the first powder metal grade differs from the second powdered metal grade in chemical composition or particle size. Further methods are also provided. Embodiments of the present invention also comprise composite inserts for material removal operations. The composite inserts may comprise a first region and a second region, wherein the first region comprises a first composite material and the second region comprises a second composite material.

Abstract: A cutting tool comprises a cutting insert, a tool holder, and a fastener. The cutting insert comprises a cutting edge and a fastener bore adapted to accept a fastener for fastening together the cutting tool and tool holder. A coolant flow recess in the fastener bore is adapted to direct coolant through the coolant flow recess and toward a head portion of the fastener. The tool holder comprises an insert pocket adapted to removably fasten the cutting insert and fastener to the tool holder, and a coolant bore adapted to direct the coolant from the tool holder to the coolant flow recess of the fastener bore. The head portion of the fastener and the coolant flow recess of the fastener bore define a gap that directs the coolant to the cutting edge of the cutting insert.

Abstract: The present disclosure is directed to cutting tools. The disclosed cutting tools may have a wear resistant coating on a substrate. The substrate may have hard particles cemented in a binder phase. The binder may have a near-surface concentration gradient of at least one platinum group element and/or rhenium. Processes for producing cutting tools are also disclosed.

Abstract: Cutting tools and cutting inserts having a wear resistant coating on a substrate comprising a metal carbide particle and a binder. For certain applications, a cutting insert having a wear resistant coating comprising hafnium carbon nitride and a binder comprising ruthenium may provide a greater service life. The wear resistant coating comprising hafnium carbon nitride may have a thickness of from 1 to 10 microns. In another embodiment, the cutting tool comprises a cemented carbide substrate with a binder comprising at least one of iron, nickel and cobalt.

Abstract: A double-sided cutting insert with a plurality of indexable convex cutting edges can have a top face and a bottom face, at least three convex cutting edges on each face connected by at least three nose corners, at least three peripheral side surfaces extending from each face toward a virtual middle plane; and a common lateral seating surface on each peripheral side surface. Each convex cutting edge can have at least a curved cutting edge region, and can further have a primary substantially straight cutting edge region intermediate the curved cutting edge region and the nose corner. Each peripheral side surface can further have a primary planar facet associated with the primary substantially straight cutting edge, and each face may also be single-handed in same direction. Additionally, in various embodiments, the top and bottom faces of the cutting insert may be formed such that they are twisted or rotated with respect to each other.

Abstract: Cutting tools and cutting inserts having a wear resistant coating on a substrate comprising a metal carbide particle and a binder. For certain applications, a cutting insert having a wear resistant coating comprising hafnium carbon nitride and a binder comprising ruthenium may provide a greater service life. The wear resistant coating comprising hafnium carbon nitride may have a thickness of from 1 to 10 microns. In another embodiment, the cutting tool comprises a cemented carbide substrate with a binder comprising at least one of iron, nickel and cobalt.

Abstract: An improved design of a cutting insert system includes a plurality of indexable peripheral milling cutting inserts adapted to be mounted on a peripheral milling tool holder. Each of the cutting inserts includes an insert width that is the same for each cutting insert. Each of the cutting inserts also includes a corner nose having a corner nose radius dimension that is different for each cutting insert, and an axial alignment clearance face that defines an equivalent face location and an equivalent clearance angle for each of the plurality of cutting inserts when the insert is detachably mounted on the tool holder.

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, 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.

Abstract: The present disclosure is directed to cutting tools. The disclosed cutting tools may have a wear resistant coating on a substrate. The substrate may have hard particles cemented in a binder phase. The binder may have a near-surface concentration gradient of at least one platinum group element and/or rhenium. Processes for producing cutting tools are also disclosed.