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.

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 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, 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: 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 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: 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: 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.