Abstract: In one aspect, cutting tools are provided comprising radiation ablation regions defining at least one of refractory surface microstructures and/or nanostructures. For example, a cutting tool described herein comprises at least one cutting edge formed by intersection of a flank face and a rake face, the flank face formed of a refractory material comprising radiation ablation regions defining at least one of surface microstructures and surface nanostructures, wherein surface pore structure of the refractory material is not occluded by the surface microstructures and surface nanostructures.

Abstract: In one aspect, cutting tools are provided comprising radiation ablation regions defining at least one of refractory surface microstructures and/or nanostructures. For example, a cutting tool described herein comprises at least one cutting edge formed by intersection of a flank face and a rake face, the flank face formed of a refractory material comprising radiation ablation regions defining at least one of surface microstructures and surface nanostructures, wherein surface pore structure of the refractory material is not occluded by the surface microstructures and surface nanostructures.

Abstract: A method and apparatus for removing material from a cutting insert is disclosed. A source of electromagnetic radiation produces a laser beam that passes through a aperture for truncating a dimension of the laser beam and a homogenizer for providing a cross section of the laser beam with a uniform energy density. A mask having a predetermined shape reduces the dimension of the laser beam, and an imaging lens projects the laser beam onto a surface of the cutting insert. The predetermined shape of the mask provides for selective adjustment of an amount of material removed from the surface of the cutting insert. In one embodiment, the mask has a shape of an isosceles trapezoid for producing a T-land surface at the intersection between a top rake face and the flank face of the cutting insert.

Abstract: A cutting insert (100,100?) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.

Abstract: A cutting insert (100, 100?) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.

Abstract: A cutting insert includes a body having an upper face, a lower face, a plurality of planar flank faces joining the upper and lower faces, and a plurality of curved flank faces joining the plurality of flank faces. A T-land is formed at a downward sloping angle with respect to the upper face. A cutting edge is formed at an intersection of a respective flank face and the T-land. A curved cutting edge is formed at an intersection of a respective curved flank face and the T-land. A micro-channel is formed in one of the flank faces, the curved flank faces and the T-land and proximate one of the cutting edge and the curved cutting edge.

Abstract: A micro end mill includes a shank made of a first material and a cutting tip made of a second, different material that is bonded to the shank. The first material can be, for example, carbide or high speed steel (HSS), and the second material can be, for example, cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), ceramic or polycrystalline diamond (PCD). The micro end mill is manufactured by producing a billet made of Superhard material using laser radiation, bonding the billet to a shank of the end mill, and removing material from the billet using laser radiation to produce a cutting tip made of the Superhard material. The laser radiation may comprise a laser beam encased in a water jet or a laser beam with a non-Gaussian intensity profile.

Abstract: In one aspect, cutting tools are provided comprising radiation ablation regions defining at least one of refractory surface microstructures and/or nanostructures. For example, a cutting tool described herein comprises at least one cutting edge formed by intersection of a flank face and a rake face, the flank face formed of a refractory material comprising radiation ablation regions defining at least one of surface microstructures and surface nanostructures, wherein surface pore structure of the refractory material is not occluded by the surface microstructures and surface nanostructures.

Abstract: A cutting insert (100, 100?) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.

Abstract: A micro end mill includes a shank made of a first material and a cutting tip made of a second, different material that is bonded to the shank. The first material can be, for example, carbide or high speed steel (HSS), and the second material can be, for example, cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), ceramic or polycrystalline diamond (PCD). The micro end mill is manufactured by producing a billet made of Superhard material using laser radiation, bonding the billet to a shank of the end mill, and removing material from the billet using laser radiation to produce a cutting tip made of the Superhard material. The laser radiation may comprise a laser beam encased in a water jet or a laser beam with a non-Gaussian intensity profile.

Abstract: A cutting insert includes a body having an upper face, a lower face, a plurality of planar flank faces joining the upper and lower faces, and a plurality of curved flank faces joining the plurality of flank faces. A T-land is formed at a downward sloping angle with respect to the upper face. A cutting edge is formed at an intersection of a respective flank face and the T-land. A curved cutting edge is formed at an intersection of a respective curved flank face and the T-land. A micro-channel is formed in one of the flank faces, the curved flank faces and the T-land and proximate one of the cutting edge and the curved cutting edge.

Abstract: A method and apparatus for removing material from a cutting insert is disclosed. A source of electromagnetic radiation produces a laser beam that passes through a aperture for truncating a dimension of the laser beam and a homogenizer for providing a cross section of the laser beam with a uniform energy density. A mask having a predetermined shape reduces the dimension of the laser beam, and an imaging lens projects the laser beam onto a surface of the cutting insert. The predetermined shape of the mask provides for selective adjustment of an amount of material removed from the surface of the cutting insert. In one embodiment, the mask has a shape of an isosceles trapezoid for producing a T-land surface at the intersection between a top rake face and the flank face of the cutting insert.