Abstract: A cutting tool includes a cartridge-receiving pocket, and an adjustable cartridge assembly mounted in the cartridge-receiving pocket. The adjustable cartridge assembly includes a cartridge with an insert-receiving pocket and a wedge. The wedge has planar surfaces formed at taper angles of between greater than zero degrees and less than or equal to about five degrees that contact the bottom wall of the cartridge to move a cutting insert mounted in the insert-receiving pocket of the cartridge in a direction of a central axis of the cutting tool. The planar surfaces are at different distances from a central axis of the wedge to place the wedge in a minus, nominal or plus orientation, respectively.

Abstract: A cutting tool includes a cartridge-receiving pocket, and an adjustable cartridge assembly mounted in the cartridge-receiving pocket. The adjustable cartridge assembly includes a cartridge with an insert-receiving pocket and a wedge. The wedge has planar surfaces formed at taper angles of between greater than zero degrees and less than or equal to about five degrees that contact the bottom wall of the cartridge to move a cutting insert mounted in the insert-receiving pocket of the cartridge in a direction of a central axis of the cutting tool. The planar surfaces are at different distances from a central axis of the wedge to place the wedge in a minus, nominal or plus orientation, respectively.

Abstract: A rotary cutting tool, such as a slotting cutter, includes a cutter body rotatable in a predetermined direction on a central axis perpendicular to a plane of the cutter body. A plurality of cutting insert-receiving pockets are formed at predetermined locations about the cutter body. A cantilevered member can be integrally formed in the cutter body or attached to the cutter body as a separate component. A tip of the cantilevered member at least partially extends into each insert-receiving pocket such that the cantilevered member exerts a biasing force against a cutting insert at a location so as to counteract a tendency of the cutting insert to rotate within the insert-receiving pocket during a cutting operation.

Abstract: A rotary cutting tool includes a cutter body having a head, a shank, and a cavity extending along a central, longitudinal axis of the cutter body. The head includes at least one cutting insert mounted in a pocket adjacent to a chip groove. A stiffening device includes a plurality of slugs with high compressive strength disposed within the cavity, and a first compression screw threaded into a rearward end of the cutting tool. In another embodiment, a second compression screw is threaded into a forward end of the cutter body. In another embodiment, each slug includes a coolant hole, circumferential grooves and axial grooves on its outer diameter, and a plurality of radial grooves on each end, and the first compression screw has a coolant hole for allowing coolant to pass therethrough.

Abstract: A method for manufacturing a sidewall support surface of an insert-receiving pocket with a compound radius includes the steps of: 1) tilting a cutting tool at a primary tilt angle with respect to a first plane (x-z); 2) tilting the cutting tool at a secondary tilt angle with respect to a second plane (y-z), the second plane different than the first plane; and 3) rotating the cutting tool about an axis (z-axis) perpendicular to a pocket floor of the insert-receiving pocket while maintaining the first and second tilt angles. A cutting tool including a toolholder with the insert-receiving pocket having a pocket floor and the sidewall support surface formed with a compound radius is also described.

Abstract: A cutting insert for a cutting tool is described. The cutting insert includes a front surface, a generally planar rear surface opposite the front surface, a generally planar first end surface, a generally planar second end surface opposite the first end surface, a generally planar first side surface, a generally planar second side surface opposite the first side surface. The front surface is continuously convex extending entirely between the first and second surfaces and entirely between the first and second side surfaces. At least one end surface is formed with a clearance angle (A1, A2, A3) to produce a cutting edge that is elliptical in shape having a relatively small depth-of-cut (DOC) to produce an extremely fine finish on a workpiece.

Abstract: A rotary cutting tool, such as a slotting cutter, includes a cutter body rotatable in a predetermined direction on a central axis perpendicular to a plane of the cutter body. A plurality of cutting insert-receiving pockets are formed at predetermined locations about the cutter body. A cantilevered member can be integrally formed in the cutter body or attached to the cutter body as a separate component. A tip of the cantilevered member at least partially extends into each insert-receiving pocket such that the cantilevered member exerts a biasing force against a cutting insert at a location so as to counteract a tendency of the cutting insert to rotate within the insert-receiving pocket during a cutting operation.

Abstract: A cutting insert for a cutting tool is described. The cutting insert includes a front surface, a generally planar rear surface opposite the front surface, a generally planar first end surface, a generally planar second end surface opposite the first end surface, a generally planar first side surface, a generally planar second side surface opposite the first side surface. The front surface is continuously convex extending entirely between the first and second surfaces and entirely between the first and second side surfaces. At least one end surface is formed with a clearance angle (A1, A2, A3) to produce a cutting edge that is elliptical in shape having a relatively small depth-of-cut (DOC) to produce an extremely fine finish on a workpiece.

Abstract: A rotary cutting tool includes a cutter body having a head, a shank, and a cavity extending along a central, longitudinal axis of the cutter body. The head includes at least one cutting insert mounted in a pocket adjacent to a chip groove. A stiffening device includes a plurality of slugs with high compressive strength disposed within the cavity, and a first compression screw threaded into a rearward end of the cutting tool. In another embodiment, a second compression screw is threaded into a forward end of the cutter body. In another embodiment, each slug includes a coolant hole, circumferential grooves and axial grooves on its outer diameter, and a plurality of radial grooves on each end, and the first compression screw has a coolant hole for allowing coolant to pass therethrough.

Abstract: A slotting cutter includes a disc-like cutter body rotatable in a predetermined direction on a central axis perpendicular to a plane of the cutter body. The cutter body includes a stop slot, an upper cam slot and a lower slot. A plurality of pockets adapted to receive a cutting inset are formed about a perimeter of the body. A cantilevered clamping member includes a bottom surface with a pair of clamping surfaces that engage a pair of angled clamping surfaces on a top surface of the cutting insert during operation. A wrench is provided to lift the cantilevered clamping member for inserting, indexing or removing the cutting insert from the slotting cutter. The wrench includes two fixed pins and a floating pin that prevents the cantilevered clamping member from bending too far and limiting the useful life of the slotting cutter.

Abstract: A method for manufacturing a sidewall support surface of an insert-receiving pocket with a compound radius includes the steps of: 1) tilting a cutting tool at a primary tilt angle with respect to a first plane (x-z); 2) tilting the cutting tool at a secondary tilt angle with respect to a second plane (y-z), the second plane different than the first plane; and 3) rotating the cutting tool about an axis (z-axis) perpendicular to a pocket floor of the insert-receiving pocket while maintaining the first and second tilt angles. A cutting tool including a toolholder with the insert-receiving pocket having a pocket floor and the sidewall support surface formed with a compound radius is also described.

Abstract: A hydraulic coupling system includes an adapter, a shell mill, a threaded member, and a chucking membrane. The adapter includes a tapered pilot disposed on and extending from an end face. The shell mill includes a central counter bore for enabling the pilot of the adapter to be inserted therein. The threaded member includes at least one sealing member and is capable of being threaded into a threaded bore of the shell mill. The chucking membrane includes an intermediate portion disposed between two flanges and forms a fluid-tight channel for hydraulic fluid. The chucking member has a tapered inside surface. When the threaded member is threaded into the shell mill, the tapered surfaces of the pilot and the chucking membrane cause an axial force to seat the end face of the shell mill firmly against the end face of the adapter.

Abstract: A rotary cutting tool includes a cutter body having a head, a shank, and a cavity extending along a central, longitudinal axis of the cutter body. The head includes at least one cutting insert mounted in a pocket adjacent to a chip groove. A vibration damping device is disposed within the cavity. The vibration damping device includes a stop member, a threaded fastener, weight elements, and a biasing member. At least one, if not all of the weight elements have different outside diameters to cause the weight elements to vibrate in the cavity at different frequencies. At least some of the frequencies of the weight elements are different than a fundamental chatter frequency of the cutting tool, thereby dampening vibration of the rotary cutting tool during a machining operation.

Abstract: A combination cutter body and a locking screw for mounting the cutter body to an adapter is disclosed. The cutter body includes a plurality of threaded bores that extend radially through a sidewall of the cutting body. The threaded bores are adapted to receive a corresponding threaded setscrew. The locking screw includes a head having a plurality of indentations around a circumference of the head. A central axis of each threaded bore is offset by a distance from a central axis of each indentation to cause an axial force to be exerted on the cutter body when an end of the setscrew engages a respective indentation to tightly seat the cutter body against the adapter.

Abstract: A slotting cutter includes a disc-like cutter body rotatable in a predetermined direction on a central axis perpendicular to a plane of the cutter body. The cutter body includes a stop slot, an upper cam slot and a lower slot. A plurality of pockets adapted to receive a cutting inset are formed about a perimeter of the body. A cantilevered clamping member includes a bottom surface with a pair of clamping surfaces that engage a pair of angled clamping surfaces on a top surface of the cutting insert during operation. A wrench is provided to lift the cantilevered clamping member for inserting, indexing or removing the cutting insert from the slotting cutter. The wrench includes two fixed pins and a floating pin that prevents the cantilevered clamping member from bending too far and limiting the useful life of the slotting cutter.

Abstract: A slotting cutter includes a disc-like cutter body rotatable in a predetermined direction on a central axis perpendicular to a plane of the cutter body. A plurality of cutting insert receiving pockets and a corresponding number of wedge receiving pockets are formed about a perimeter of the body. A cutting insert is replaceably mounted in each insert receiving pocket of the cutter body, and a clamping wedge is replaceably mounted in each wedge receiving pocket of the cutter body. A cantilevered member is disposed between each insert receiving pocket and a respective wedge receiving pocket to securely hold the cutting insert in the cutter body.

Abstract: A hydraulic coupling system includes an adapter, a shell mill, a threaded member, and a chucking membrane. The adapter includes a tapered pilot disposed on and extending from an end face. The shell mill includes a central counter bore for enabling the pilot of the adapter to be inserted therein. The threaded member includes at least one sealing member and is capable of being threaded into a threaded bore of the shell mill. The chucking membrane includes an intermediate portion disposed between two flanges and forms a fluid-tight channel for hydraulic fluid. The chucking member has a tapered inside surface. When the threaded member is threaded into the shell mill, the tapered surfaces of the pilot and the chucking membrane cause an axial force to seat the end face of the shell mill firmly against the end face of the adapter.

Abstract: A rotary cutting tool includes a cutter body having a head, a shank, and a cavity extending along a central, longitudinal axis of the cutter body. The head includes at least one cutting insert mounted in a pocket adjacent to a chip groove. A vibration damping device is disposed within the cavity. The vibration damping device includes a stop member, a threaded fastener, weight elements, and a biasing member. At least one, if not all of the weight elements have different outside diameters to cause the weight elements to vibrate in the cavity at different frequencies. At least some of the frequencies of the weight elements are different than a fundamental chatter frequency of the cutting tool, thereby dampening vibration of the rotary cutting tool during a machining operation.

Abstract: A method for manufacturing an insert pocket of a cutter body is disclosed. First, the insert pocket of the cutter body a rough milling process. Then, the insert pocket is forged using a forging tool having a shape that generally conforms to the shape of the insert pocket. Then, the insert pocket undergoes a finish milling process to qualify the pocket geometry without removing the majority of the forge-enhanced pocket material. The insert pocket can be optionally heated prior to the forging step. The grain orientation of the inset pocket is compressed by the forging process to increase the impact and fatigue resistance of the insert pocket.

Abstract: A combination cutter body and a locking screw for mounting the cutter body to an adapter is disclosed. The cutter body includes a plurality of threaded bores that extend radially through a sidewall of the cutting body. The threaded bores are adapted to receive a corresponding threaded setscrew. The locking screw includes a head having a plurality of indentations around a circumference of the head. A central axis of each threaded bore is offset by a distance from a central axis of each indentation to cause an axial force to be exerted on the cutter body when an end of the setscrew engages a respective indentation to tightly seat the cutter body against the adapter.