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 compression milling cutter includes a shank and a front cutting portion that terminates at a leading end of the milling cutter. The front cutting portion has a first circumferential row of one or more insert receiving pockets proximate a leading end of the milling cutter, and a second circumferential row of one or more insert receiving pockets, each insert receiving pocket configured to receive a respective indexable cutting insert. The cutting insert mounted in the first circumferential row has a positive axial rake angle, A, and the indexable cutting insert mounted in an insert pocket of the second circumferential row has a negative axial rake angle, B. Because of the different axial rake angles, chips generated during a machining operation flow in opposite directions, thereby creating a compression zone disposed between the first and second circumferential rows. This compression zone replicates the cutting action of a solid end mill, particularly when machining fiber reinforced plastic materials.

Abstract: A compression milling cutter includes a shank and a front cutting portion that terminates at a leading end of the milling cutter. The front cutting portion has a first circumferential row of one or more insert receiving pockets proximate a leading end of the milling cutter, and a second circumferential row of one or more insert receiving pockets, each insert receiving pocket configured to receive a respective indexable cutting insert. The cutting insert mounted in the first circumferential row has a positive axial rake angle, A, and the indexable cutting insert mounted in an insert pocket of the second circumferential row has a negative axial rake angle, B. Because of the different axial rake angles, chips generated during a machining operation flow in opposite directions, thereby creating a compression zone disposed between the first and second circumferential rows. This compression zone replicates the cutting action of a solid end mill, particularly when machining fiber reinforced plastic materials.

Abstract: A double-sided, indexable cutting insert for a milling cutter includes a first surface, a second surface, and side surfaces. Major cutting edges are defined at an intersection between the first and second surfaces and side surfaces. Minor cutting edges and ramping cutting edges are defined at the intersection between the first and second surfaces and side surfaces. The cutting insert is mounted in a milling cutter having a bottom seating surface formed at an angle with respect to a central, rotational axis of the milling cutter, which provides superior performance for both milling and ramping cutting operations.

Abstract: A rotary cutting tool includes a cutter body and a coolant cap removably secured to the cutter body. The coolant cap includes an outer surface, an inner surface and a generally cylindrical outer surface extending between the outer surface and the inner surface. The cylindrical outer surface has a second cylindrical outer surface portion with external threads formed thereon such that the coolant cap is capable of being threaded onto the cutter body.

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 rotary cutting tool includes a cutter body, a coolant cap, and a retaining ring for removably securing the coolant cap to the cutter body. The coolant cap includes an outer surface, an inner surface and a generally cylindrical outer surface extending between the outer surface and the inner surface. The retaining ring is disposed within a retaining ring notch of the cutter body such that the outer surface of the coolant cap contacts the retaining ring when high pressure coolant is introduced into the cutter body to removably secure the coolant cap to the cutter body.

Abstract: A cutting tool, such as a milling cutter, includes a tool body and a plurality of pockets for receiving cutting inserts. Each pocket includes a bottom support surface, an radial support surface, an axial support surface, a first corner relief between the bottom support surface and the radial support surface, and a first stress relief formed in the first corner relief at one end of the pocket. The first stress relief is formed at an angle with respect to a plane parallel to the radial support surface. The first stress relief reduces a tensile stress of the cutting tool during a machining operation. A second and third stress relief may be formed in the first corner relief and/or in a second corner relief.

Abstract: A rotary cutting tool includes a cutter body, a coolant cap, and a retaining ring for removably securing the coolant cap to the cutter body. The coolant cap includes an outer surface, an inner surface and a generally cylindrical outer surface extending between the outer surface and the inner surface. The retaining ring is disposed within a retaining ring notch of the cutter body such that the outer surface of the coolant cap contacts the retaining ring when high pressure coolant is introduced into the cutter body to removably secure the coolant cap to the cutter body.

Abstract: A rotary cutting tool includes a cutter body and a coolant cap removably secured to the cutter body. The coolant cap includes an outer surface, an inner surface and a generally cylindrical outer surface extending between the outer surface and the inner surface. The cylindrical outer surface has a second cylindrical outer surface portion with external threads formed thereon such that the coolant cap is capable of being threaded onto the cutter body.

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 cutting tool, such as a milling cutter, includes a tool body and a plurality of pockets for receiving cutting inserts. Each pocket includes a bottom support surface, an radial support surface, an axial support surface, a first corner relief between the bottom support surface and the radial support surface, and a first stress relief formed in the first corner relief at one end of the pocket. The first stress relief is formed at an angle with respect to a plane parallel to the radial support surface. The first stress relief reduces a tensile stress of the cutting tool during a machining operation. A second and third stress relief may be formed in the first corner relief and/or in a second corner relief.

Abstract: A fastener for attaching a milling cutter body to an adaptor includes a head portion, a body portion and an undercut disposed between the head portion and the body portion. The head portion has a diameter greater than a diameter of the undercut and a thread root diameter. The diameter of the undercut is equal to or less than the thread root diameter to allow the fastener to freely rotate when the fastener is threaded completely through the milling cutter body. Once threaded completely threaded the milling cutter body, the fastener is threaded into the adaptor to securely attached the milling cutter body to the adaptor.

Abstract: A toolholder assembly has a pocket adapted to receive a double-sided on-edge cutting insert with wiper facets. A pocket has at least two sides and supports pads extending from each of the at least two sides, wherein the support pads contact the wiper facets of the cutting insert when the cutting insert is mounted within the pocket.

Abstract: A double-sided, indexable cutting insert for a milling cutter includes a first surface, a second surface, and side surfaces. Major cutting edges are defined at an intersection between the first and second surfaces and side surfaces. Minor cutting edges and ramping cutting edges are defined at the intersection between the first and second surfaces and side surfaces. The cutting insert is mounted in a milling cutter having a bottom seating surface formed at an angle with respect to a central, rotational axis of the milling cutter, which provides superior performance for both milling and ramping cutting operations.

Abstract: A milling cutter includes a shank and upper portion with an insert pocket. The insert pocket includes a bottom surface, a radial support wall and an axial support wall. A cutting insert includes a hole extending from a bottom surface. A tapered pin includes a lower portion and a tapered upper portion. A spring engages the lower portion of the tapered pin and provides an upward biasing force on the tapered pin. A center axis of the tapered pin is closer to the radial support wall than a center axis of the hole of the cutting insert such that the tapered pin exerts pressure against the hole of the cutting insert to cause one of the side walls of the cutting insert to be forced against the radial support wall of the insert pocket when the cutting insert is mounted in the insert pocket.

Abstract: A fastener for attaching a milling cutter body to an adaptor includes a head portion, a body portion and an undercut disposed between the head portion and the body portion. The head portion has a diameter greater than a diameter of the undercut and a thread root diameter. The diameter of the undercut is equal to or less than the thread root diameter to allow the fastener to freely rotate when the fastener is threaded completely through the milling cutter body. Once threaded completely threaded the milling cutter body, the fastener is threaded into the adaptor to securely attached the milling cutter body to the adaptor.