Abstract: A method for manufacturing machining tools out of composite powdered metal which is first formed to approximate the desired shape of the machining tool; then bonded metallurgically; and machined to the desired finished shape. Desirably, the forming step employs at least two distinct powdered metals, the first formed to the outer shape over the portion of the tool that interfaces with the work piece and selected to exhibit the desired hardness and wear-resistance properties. The second material supports the hollow form of the first material and includes a shank to interface with the machine that the tool will be employed with. The second material is chosen to exhibit the desired ductility, surface hardness, abrasion resistance and reduced cost. Additional materials can be used for different facets of the tool to obtain an optimum balance of long life, efficient operation and low cost.

Abstract: A cutting tool for machining a work piece to form a turbine rotor having a longitudinal axis includes a plurality of curved splines extending from a back of the tool to a front of the tool. Each spline is curved so that it is not parallel to a plane perpendicular to the longitudinal axis of the tool. Preferably, each spline is curved in a helical shape in the axial direction. Disposed along each spline are a plurality of cutting teeth. Each tooth has a cutting face that is helical in shape. Due to this helical shape of the cutting face of each tooth, a positive radial rake angle is formed for each tooth and a positive axial rake angle is formed for each tooth. These positive rake angles enhance the characteristics of the cutting process. The top of each tooth is also curved to form radial relief for each tooth. Furthermore, each tooth disposed axially forward of another tooth along a spline has a radial height that is less than the other tooth to provide cutting relief in the axial direction for each tooth.

Abstract: A method and a system for creating an improved cutting tool having a helical shaped cutting surface includes a computer, a computer numerically controlled milling machine and an electric discharge machine. The computer can be programmed to form the female shape of a helical spline of a cutting tool that extends longitudinally from the back of the tool to the front of the tool so that it is not parallel to a plane perpendicular to a longitudinal axis of the tool. Disposed along the spline may be a plurality of cutting teeth that each extend outward from the curved spline and have a cutting face that is curved in both a radial direction and in an axial direction with respect to the cutting tool. After forming the female shape of this spline, the computer can develop a cutting path for a tool of a numerically controlled milling machine and operate the milling machine to create an electrode having the female shape of the spline of the cutting tool.