Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: A coated cutting tool that comprises a body containing a pocket. The tool further includes a polycrystalline cubic boron nitride blank that is brazed into the pocket using a braze alloy. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade. There is a coating applied to the cutting tool.

Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a blaze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: A cutting assembly that includes a tool holder that contains a pocket therein. A shim and/or pocket insert along with a cutting insert are within the pocket of the tool holder. The shim may present an oxidation-resistant surface. Exemplary materials for the shim include ceramics and coated cemented carbides and cermets. The pocket may present an oxidation-resistant surface wherein the pocket may have an oxidation-resistant coating or an oxidation-resistant pocket insert may be positioned within the pocket.

Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.

Abstract: A coated cutting tool that comprises a body containing a pocket. The tool further includes a polycrystalline cubic boron nitride blank that is brazed into the pocket using a braze alloy. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade. There is a coating applied to the cutting tool.

Abstract: A cutting tool for removing material from a workpiece wherein the cutting tool is held in a pocket of a tool holder. The cutting tool includes a cutting tool substrate with a rake surface and flank surfaces, as well as a notch at the intersection of a pair of adjacent ones of the flank surfaces. The substrate includes opposite flank surfaces that are opposite from the notch and are disposed at a substrate disposition angle with respect to the rake surface of the cutting tool substrate. The cutting tool further includes a cutting blank that is within the notch. The cutting blank has a rake surface and a pair of exposed flank surfaces wherein a cutting edge is at the intersection of the rake surface and the exposed flank surfaces. The exposed flank surfaces of the cutting blank are disposed at a cutting clearance angle with respect to the rake surface of the cutting blank. The cutting clearance angle is not equal to the substrate disposition angle.

Abstract: A cutting tool for removing material from a workpiece wherein the cutting tool is held in a pocket of a tool holder. The cutting tool includes a cutting tool substrate with a rake surface and flank surfaces, as well as a notch at the intersection of a pair of adjacent ones of the flank surfaces. The substrate includes opposite flank surfaces that are opposite from the notch and are disposed at a substrate disposition angle with respect to the rake surface of the cutting tool substrate. The cutting tool further includes a cutting blank that is within the notch. The cutting blank has a rake surface and a pair of exposed flank surfaces wherein a cutting edge is at the intersection of the rake surface and the exposed flank surfaces. The exposed flank surfaces of the cutting blank are disposed at a cutting clearance angle with respect to the rake surface of the cutting blank. The cutting clearance angle is not equal to the substrate disposition angle.

Abstract: A cutting tool and method for machining hardened steel including a substrate of polycrystalline cubic boron nitride having one or more layers of a hard refractory coating containing aluminum. The coating may contain a titanium aluminum nitride layer applied by a physical vapor deposition (PVD). Alternatively, the coating may include a layer of aluminum oxide applied by chemical vapor deposition.

Abstract: A cutting assembly that includes a tool holder that contains a pocket therein. A shim and/or pocket insert along with a cutting insert are within the pocket of the tool holder. The shim may present an oxidation-resistant surface. Exemplary materials for the shim include ceramics and coated cemented carbides and cermets. The pocket may present an oxidation-resistant surface wherein the pocket may have an oxidation-resistant coating or an oxidation-resistant pocket insert may be positioned within the pocket.

Abstract: A polycrystalline diamond member and a method for making the same. The member includes a backing and a layer of polycrystalline diamond on the backing wherein the layer of polycrystalline diamond has a rake surface and a flank surface. The layer of polycrystalline diamond has an interior region adjacent to the backing and an exterior region adjacent to the interior region wherein the exterior region terminates at the rake surface. The interior region includes interior diamond particles and a catalyst with the interior diamond particles being bridged together so as to form interstices therebetween. The catalyst is at the interstices of the interior diamond particles. The exterior region includes exterior diamond particles bridged together so as to form interstices therebetween with the exterior region being essentially free of the catalyst. A chemical vapor deposition-applied hard material essentially surrounds the exterior diamond particles.

Abstract: A process for making a diamond-coated tool and the tool made thereby. The process includes a sintering step. In that step, the tool substrate is sintered in an atmosphere and for a time and at a temperature so that superficial, exaggerated grain growth is promoted that imparts a surface roughness which may serve as anchoring sites during a subsequent diamond coating step which is performed by a vapor deposition technique. The diamond-coated tool prepared by the process includes a large grain substrate surface, and an high bond strength between the diamond coating and the substrate surface.

Abstract: A cutting insert which includes a holder that contains a pocket and a hard insert that has a rake surface. The hard insert is contained within the pocket so as to present a cutting edge. The cutting insert also includes a chipbreaker which comprises a plate with a bottom surface. The chipbreaker is attached to the cutting insert (or optionally to the holder) so that the plate is spaced above the rake surface of the hard insert a first distance forming a conduit for passage of the chips away from the cutting insert. The conduit is defined at least in part by the rake surface of the cutting insert and the bottom surface of the chipbreaker plate.

Abstract: A cutting insert having a rake surface and a flank surface wherein there is a cutting edge at the intersection of the rake surface and the flank surface. The rake surface exhibits a sufficient degree of surface roughness so as to provide for microscopic chip control. The flank surface exhibits a sufficiently smooth (i.e., a mirror finish) so as to provide for a workpiece surface finish that approaches (or possibly reaches) the theoretical value attributable for the given cutting conditions.

Abstract: A cutting tool has a compressing segment for imparting a compressive force to produce a non-porous surface layer on a workpiece of porous material. The cutting tool also has a cutting segment to machine the non-porous surface layer for a desired surface finish. Furthermore, a method for machining a workpiece using such a cutting tool may be implemented to produce a non-porous surface layer on a workpiece of porous material and then to produce a desired surface finish.

Abstract: A coated cutting tool, and a method of producing the same, comprising a substrate which has a roughened surface that presents a surface roughness of between 15 microinches R.sub.a and 125 microinches R.sub.a. A coating is applied to the roughened surface of the substrate by physical vapor deposition. A coated cutting tool having a low cobalt substrate and experiencing long tool life is also discussed.

Abstract: A method of producing a cutting tool, comprising a substrate which has a roughened surface that presents a surface roughness of between 15 microinches R.sub.a and 125 microinches R.sub.a. A coating is applied to the roughened surface of the substrate by physical vapor deposition. A coated cutting tool having a low cobalt substrate and experiencing long tool life is also discussed.