Abstract: A cutting tool including a toolholder and a round cutting insert for mounting on a pocket floor of the toolholder. The toolholder includes the toolholder pocket floor having a bore and a plurality of grooves in the pocket floor arranged radially about the bore, wherein adjacent grooves are radially offset by a groove offset angle, x. The round cutting insert includes an upper surface having a cutting edge, a lower surface opposite the upper surface, an exterior side surface between the upper surface and the lower surface, an interior side surface defining an aperture extending from the upper surface to the lower surface, and a plurality of lugs arranged radially about the aperture. In an alternate embodiment, the cutting tool includes an anti-rotation disc with a plurality of grooves instead of the toolholder pocket floor.

Abstract: A cutting tool includes a toolholder and a cutting insert. The toolholder includes a toolholder pocket having a pocket wall including a first anti-rotation engagement surface and a second anti-rotation engagement surface. The cutting insert is mounted in the toolholder pocket. The cutting insert includes: an upper surface, the upper surface having a plurality circular sinusoidal cutting edges; a lower surface opposite the upper surface; and an exterior sidewall between the upper surface and the lower surface. The first anti-rotation engagement surface and the second anti-rotation engagement surface of the pocket wall of the toolholder engage the exterior sidewall of the cutting insert to resist rotation of cutting insert.

Abstract: A cutting tool including a toolholder and a round cutting insert for mounting on a pocket floor of the toolholder. The toolholder includes the toolholder pocket floor having a bore therein and a plurality of grooves in the pocket floor arranged radially about the bore, wherein adjacent grooves are radially offset by a groove offset angle x. The round cutting insert includes an upper surface having a cutting edge, a lower surface opposite the upper surface, an exterior side surface between the upper surface and the lower surface, an interior side surface defining an aperture extending from the upper surface to the lower surface, and a plurality of lugs arranged radially about the aperture, wherein adjacent lugs are radially offset by a lug offset angle y, and wherein a ratio of y:x is an integer greater than or equal to 2.

Abstract: A cutting insert includes an upper surface having a circular cutting edge, a lower surface opposite the upper surface, an exterior sidewall between the upper surface and the lower surface, and an interior sidewall defining a hole extending from the upper surface to the lower surface. The interior sidewall includes an upper interior sidewall portion and a lower interior sidewall portion. The lower interior sidewall portion increases in radius with respect to a downward direction of the cutting insert. The lower interior sidewall portion includes a plurality of recessed portions positioned about a circumferential direction of the lower interior sidewall portion.

Abstract: A cutting tool including a toolholder and a round cutting insert for mounting on a pocket floor of the toolholder. The toolholder includes the toolholder pocket floor having a bore therein and a plurality of grooves in the pocket floor arranged radially about the bore, wherein adjacent grooves are radially offset by a groove offset angle x. The round cutting insert includes an upper surface having a cutting edge, a lower surface opposite the upper surface, an exterior side surface between the upper surface and the lower surface, an interior side surface defining an aperture extending from the upper surface to the lower surface, and a plurality of lugs arranged radially about the aperture, wherein adjacent lugs are radially offset by a lug offset angle y, and wherein a ratio of y:x is an integer greater than or equal to 2.

Abstract: A cutting tool includes a toolholder and a cutting insert. The toolholder includes a toolholder pocket having a pocket wall including a first anti-rotation engagement surface and a second anti-rotation engagement surface. The cutting insert is mounted in the toolholder pocket. The cutting insert includes: an upper surface, the upper surface having a plurality circular sinusoidal cutting edges; a lower surface opposite the upper surface; and an exterior sidewall between the upper surface and the lower surface. The first anti-rotation engagement surface and the second anti-rotation engagement surface of the pocket wall of the toolholder engage the exterior sidewall of the cutting insert to resist rotation of cutting insert.

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 to allow milling operations at relatively high feed rates. The cutting insert includes at least four convex cutting edges. Certain embodiments of square cutting inserts will have four convex cutting edges connected by nose corner regions. Each convex cutting edge includes a first curved cutting-edge region having a radius greater than or equal to two times a radius of the largest circle that may be inscribed on the top surface. Each convex cutting edge also includes a second curved cutting-edge region adjacent the first curved cutting-edge region and having a radius less than or equal to the diameter of the inscribed circle. Each convex cutting edge may also include one or more straight cutting-edge regions.

Abstract: A cutting insert includes an upper surface having a circular cutting edge, a lower surface opposite the upper surface, an exterior sidewall between the upper surface and the lower surface, and an interior sidewall defining a hole extending from the upper surface to the lower surface. The interior sidewall includes an upper interior sidewall portion and a lower interior sidewall portion. The lower interior sidewall portion increases in radius with respect to a downward direction of the cutting insert. The lower interior sidewall portion includes a plurality of recessed portions positioned about a circumferential direction of the lower interior sidewall portion.

Abstract: A cutting insert having two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. Each end surface has four corners with two lowered corners and two raised corners, the two lowered corners being diagonally opposite each other, the two raised corners being diagonally opposite each other. The cutting insert also includes a major cutting edge formed at an intersection of each major edge and the end surface. A first section of the major cutting edge proximate the raised corner constitutes a leading end of the major cutting edge, and a second section of the major cutting edge proximate the lowered corner constitutes a trailing end of the major cutting edge. An angled margin only partially extends along the leading end of the major cutting edge and segments the major cutting edge.

Abstract: A cutting insert having two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. Each end surface has four corners comprising two lowered corners and two raised corners, the two lowered corners being diagonally opposite each other, the two raised corners being diagonally opposite each other. The cutting insert also includes a major cutting edge formed at an intersection of each major edge and the end surface. A section of the major cutting edge proximate the raised corner constitutes a leading end of the major cutting edge, and a section of the major cutting edge proximate the lowered corner constitutes a trailing end of the major cutting edge. An angled margin only partially extends along the leading end of the major cutting edge and segments the major cutting edge.

Abstract: A double-sided tangential cutting insert, as well as a tool holder system that carries a plurality of the double-sided tangential cutting inserts, that has a peripheral side shape, as viewed from one of said cutting rake faces, that includes a pair of generally identical opposing main cutting edges wherein each of the main cutting edge comprises a substantially straight main cutting edge portion and an adjoining convex main cutting edge portion. The convex main cutting edge portion is truncated by an adjacent convex minor side face so as to define a generally sharp edge and a point of truncation. The peripheral side shape further includes a pair of opposing full nose cutting edges with a nose cutting radius; and a pair of opposing convex minor cutting edges with a minor cutting edge radius. The minor cutting edge radius is at least about four times greater than the nose cutting radius.

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 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 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: A double-sided tangential cutting insert, as well as a tool holder system that carries a plurality of the double-sided tangential cutting inserts, that has a peripheral side shape, as viewed from one of said cutting rake faces, that includes a pair of generally identical opposing main cutting edges wherein each of the main cutting edge comprises a substantially straight main cutting edge portion and an adjoining convex main cutting edge portion. The convex main cutting edge portion is truncated by an adjacent convex minor side face so as to define a generally sharp edge and a point of truncation. The peripheral side shape further includes a pair of opposing full nose cutting edges with a nose cutting radius; and a pair of opposing convex minor cutting edges with a minor cutting edge radius. The minor cutting edge radius is at least about four times greater than the nose cutting radius.

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.