Abstract: A rotary cutting tool includes a cutting head having a plurality of insert-receiving pockets for radially mounting a first type of cutting insert in a first cutting region and for tangentially mounting a second type of cutting insert in a second cutting region. The first cutting region has a first length, L1, and the second cutting region has a second length, L2, that is greater in magnitude than the first length, L1. The two types of cutting inserts provides a hybrid cutting insert design in which the first type of cutting inserts provide an increased chip gash volume for effective chip evacuation, and the second type of cutting inserts provide an increased core diameter to minimize deflection of the rotary cutting tool.

Abstract: A rotary cutting tool includes a cutting head having a plurality of insert-receiving pockets for radially mounting a first type of cutting insert in a first cutting region and for tangentially mounting a second type of cutting insert in a second cutting region. The first cutting region has a first length, L1, and the second cutting region has a second length, L2, that is greater in magnitude than the first length, L1. The two types of cutting inserts provides a hybrid cutting insert design in which the first type of cutting inserts provide an increased chip gash volume for effective chip evacuation, and the second type of cutting inserts provide an increased core diameter to minimize deflection of the rotary cutting tool.

Abstract: A milling insert includes a first axial face, a second axial face, a first radial face, a second radial face parallel with the first radial face, a cutting face, and a generally V-shaped seating face formed with a first seating surface and a second seating surface. The first axial face defines a secondary clearance surface that is at least partially axially recessed from the first axial face and oblique to the first radial face. The first seating surface and the second seating surface are formed at an angle substantially equal to a radial rake angle when the cutting insert is mounted in the insert seat of the milling cutter. As a result, the seating face produces at least one seating surface that is substantially perpendicular to the tangential cutting force, FT, thereby reducing movement of the insert when tangentially mounted in the insert seat of the milling cutter.

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 of the insert has a concave-shaped seating surface for contacting the insert pocket the insert pocket along an entire length of the cutting insert. The minor side surfaces are convex-shaped. The concave-shaped seating surface and the convex-shaped minor side surfaces enable the cutting insert to be accurately tangentially mounted in the insert pocket.

Abstract: A round cutting insert has a seating surface with a plurality of projections formed on the seating surface proximate a central opening. The projections do not extend to an outer perimeter of the seating surface such that the outer perimeter is continuous and uninterrupted a full 360 degrees. An insert-receiving pocket includes a seating surface with a plurality of dimples for receiving the plurality of projections to prevent rotation of the cutting insert when mounted in the insert-receiving pocket. The plurality of dimples do not extend to an outer perimeter of the seating surface such that the outer perimeter is continuous and uninterrupted a full 360 degrees, thereby maximizing contact between the cutting insert and the pocket.

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 cutting insert includes a body made of a ceramic material. The body has a first surface, a second surface and at least one flank surface extending between the first surface and the second surface. The first surface includes a chip forming feature extending in a radially outwardly direction to a cutting edge and extending in a radially inwardly direction to an inner edge. The chip forming feature includes a front wall that slopes downward from the cutting edge radially inward toward a rounded bottom surface and a back wall that slopes upward from the rounded bottom surface radially inward to the inner edge. The chip forming feature can include an optional land surface between the cutting edge and the front wall.

Abstract: A milling insert includes a first axial face, a second axial face, a first radial face, a second radial face parallel with the first radial face, a cutting face, and a generally V-shaped seating face formed with a first seating surface and a second seating surface. The first axial face defines a secondary clearance surface that is at least partially axially recessed from the first axial face and oblique to the first radial face. The first seating surface and the second seating surface are formed at an angle substantially equal to a radial rake angle when the cutting insert is mounted in the insert seat of the milling cutter. As a result, the seating face produces at least one seating surface that is substantially perpendicular to the tangential cutting force, FT, thereby reducing movement of the insert when tangentially mounted in the insert seat of the milling cutter.

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 of the insert has a concave-shaped seating surface for contacting the insert pocket the insert pocket along an entire length of the cutting insert. The minor side surfaces are convex-shaped. The concave-shaped seating surface and the convex-shaped minor side surfaces enable the cutting insert to be accurately tangentially mounted in the insert pocket.

Abstract: A double-sided, trigon cutting insert has three three major cutting edges formed at an intersection between a first planar side surface portion and first and second surfaces, and three minor cutting edges formed at an intersection between a second planar side surface portion and first and second surfaces. A planar rake surface extends radially inward and downward from each major cutting edge, and a rounded rake surface extends radially inward and downward from each minor cutting edge. An insert-receiving pocket of a cutting tool includes a planar bottom support surface, a first planar side support surface, a second planar side support surface, and a third planar side support surface. Each rounded rake surface is formed with a radius, R, that causes only a high point of each minor cutting edge to contact a workpiece during a machining operation.

Abstract: A cutting insert includes a body made of a ceramic material. The body has a first surface, a second surface and at least one flank surface extending between the first surface and the second surface. The first surface includes a chip forming feature extending in a radially outwardly direction to a cutting edge and extending in a radially inwardly direction to an inner edge. The chip forming feature includes a front wall that slopes downward from the cutting edge radially inward toward a rounded bottom surface and a back wall that slopes upward from the rounded bottom surface radially inward to the inner edge. The chip forming feature can include an optional land surface between the cutting edge and the front wall.

Abstract: A double-sided, trigon cutting insert has three three major cutting edges formed at an intersection between a first planar side surface portion and first and second surfaces, and three minor cutting edges formed at an intersection between a second planar side surface portion and first and second surfaces. A planar rake surface extends radially inward and downward from each major cutting edge, and a rounded rake surface extends radially inward and downward from each minor cutting edge. An insert-receiving pocket of a cutting tool includes a planar bottom support surface, a first planar side support surface, a second planar side support surface, and a third planar side support surface. Each rounded rake surface is formed with a radius, R, that causes only a high point of each minor cutting edge to contact a workpiece during a machining operation.

Abstract: A round cutting insert has a seating surface with a plurality of projections formed on the seating surface proximate a central opening. The projections do not extend to an outer perimeter of the seating surface such that the outer perimeter is continuous and uninterrupted a full 360 degrees. An insert-receiving pocket includes a seating surface with a plurality of dimples for receiving the plurality of projections to prevent rotation of the cutting insert when mounted in the insert-receiving pocket. The plurality of dimples do not extend to an outer perimeter of the seating surface such that the outer perimeter is continuous and uninterrupted a full 360 degrees, thereby maximizing contact between the cutting insert and the pocket.

Abstract: A cutting insert for heavy machining operations is described. The cutting insert has two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. The cutting insert further includes a major cutting edge formed at an intersection of each major edge and the end surface, and a minor cutting edge formed at an intersection of each minor edge and the end surface, and a corner cutting edge formed at an intersection of the major and minor cutting edges. The major cutting edge has a non-linear, variable slope with respect to a central axis A2 passing through the two minor side surfaces of the cutting insert.

Abstract: A combination of a cutting insert and a shim. The cutting insert and shim have two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. Each end surface of the insert has a shim abutment surface for contacting the shim. One end surface of the shim has an insert abutment surface for contacting the insert. The abutment surfaces contact each other along an entire length of the cutting insert and shim so as to help distribute the loads encountered in the cutting operation, as well as provide protection of the insert pocket in case of insert failure.

Abstract: A cutting insert for heavy machining operations is described. The cutting insert has two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. The cutting insert further includes a major cutting edge formed at an intersection of each major edge and the end surface, and a minor cutting edge formed at an intersection of each minor edge and the end surface, and a corner cutting edge formed at an intersection of the major and minor cutting edges. The major cutting edge has a non-linear, variable slope with respect to a central axis A2 passing through the two minor side surfaces of the cutting insert.

Abstract: A clamping tool holder includes a tool holder body and a clamp for clamping a cutting insert. The clamp causes the cutting insert to press against the bottom and the side walls of an insert-receiving pocket of the tool holder body. The tool holder body has an inclined surface sloping inward in a direction away from the insert-receiving pocket. The clamp has an inclined surface that acts as a ramp with the inclined surface of the tool holder body. When a clamp screw is tightened, a nub of the clamp engages only an inside rearward surface of a mounting bore of the insert along a line of contact and exerts a force downward and rearward on the insert. In addition, only a forward lower face of a head portion the clamp screw engages a top surface of the clamp.

Abstract: A clamping tool holder includes a tool holder body and a clamp for clamping a cutting insert. The clamp causes the cutting insert to press against the bottom and the side walls of an insert-receiving pocket of the tool holder body. The tool holder body has an inclined surface sloping inward in a direction away from the insert-receiving pocket. The clamp has an inclined surface that acts as a ramp with the inclined surface of the tool holder body. When a clamp screw is tightened, a nub of the clamp engages only an inside rearward surface of a mounting bore of the insert along a line of contact and exerts a force downward and rearward on the insert. In addition, only a forward lower face of a head portion the clamp screw engages a top surface of the clamp.