Abstract: A system and method for monitoring and predicting wear of a cutting tool used for machining a workpiece is disclosed. The system includes a cutting tool having a shank and a cutting head. The system also includes a split, modular and wireless wear detection system including one or more sensors mounted to the cutting tool for providing a data signal representative of a physical condition of the system, and a data recording and data transmitting device for recording the data signal from the one or more sensors and for generating and transmitting a data signal to a processor. The processor applies a machine learning data processing technique in real time to monitor and/or predict a condition of various components and/or parameters of the system during a metal cutting operation.

Abstract: A rotary cutting tool includes a tool body including a shank portion and a cutting portion adjoining the shank portion. The cutting portion has a plurality of blades separated by helically twisted flutes. A tunable vibration absorber is disposed within an internal cavity formed in the cutting portion and has a shape that follows the helically twisted flutes. The tunable vibration absorber includes an absorber mass and a resilient material disposed between the absorber mass and an outer wall of the internal cavity. In one aspect, the tunable vibration absorber is tuned to a desired frequency by selecting the mechanical properties of the absorber mass and the resilient material. In another aspect, the tunable vibration absorber is tuned by controlling a pressure of fluid within a main internal fluid cavity disposed within the tunable vibration absorber.

Abstract: A rotary cutting tool includes a tool body including a chip flute portion having a plurality of helical chip flutes separated by lobes. In one aspect, a tunable vibration absorber assembly is disposed within a cavity formed in the chip flute portion. In another aspect, the tunable vibration absorber assembly is disposed within a cavity of a replaceable cutting head. In each aspect, the tunable vibration absorber assembly includes at least two tunable absorber masses, a resilient material between the one or more absorber masses and the cavity, and one or more connecting members for preventing relative angular displacement of the one or more tunable absorber masses. The at least two tunable absorber masses are suspended only by the resilient material, thereby enabling the tunable vibration absorber assembly to be tuned to a desired frequency for suppressing torsional vibration of the rotary cutting tool during a cutting operation.

Abstract: A hydraulic chuck assembly includes a tool support member having an axial bore. An expansion sleeve is received within the axial bore of the tool support member. The expansion sleeve comprises an inner surface, an outer surface and a front flange extending radially outward from the outer surface. A primary pressure chamber is formed between the axial bore of the tool support member and the outer surface of the expansion sleeve. A flexibility of the expansion sleeve is increased by removing material from the expansion sleeve in a vicinity of a front braze ring and a rear braze ring, thereby decreasing a maximum stress in the front braze ring and the rear braze ring. The material is removed by undercuts that form secondary pressure chambers in fluid communication with the primary pressure chamber.

Abstract: Hydraulic chuck assemblies for receiving tool shanks are disclosed. The hydraulic chuck assembly comprises a tool support member, a clamping tube, and an expansion sleeve. The clamping tube may be integral to or separate from and attached to the tool support member. The clamping tube comprises slots on the radial outer surface to provide torque transfer. The expansion sleeve comprises a generally cylindrical body, an integral flange, and a torque transfer projection. The torque transfer projection extends radially outward from the outer wall of the body below the integral flange. The expansion sleeve further comprises a pressure chamber in fluid communication with a pressurized fluid system in the tool support member. During operation, a pressure adjustment screw in the tool support member communicates with the pressurized fluid chamber of the expansion sleeve to clamp a tool shank.

Abstract: A hydraulic chuck may include an expansion sleeve, a plurality of pistons, and an actuator ring. The expansion sleeve may include a bore. The plurality of pistons may be axially mounted in at least one piston chamber of the expansion sleeve. The actuator ring may be rotatably mounted relative to the expansion sleeve. The actuator ring may be configured to actuate the plurality of pistons in the at least one piston chamber to hydraulically expand the expansion sleeve to provide a varying clamping force within the bore.

Abstract: A rotary cutting tool includes a main body, a shank portion having a rearward end, and a flute portion having a forward end with one or more flanks. One or more connecting fluid holes are in fluid communication with a central fluid hole and terminates at a flank at the forward end of the cutting tool. One or more twisted fluid holes extend through a lobe in the flute portion and terminates at a flank at the forward end of the cutting tool. A cross-sectional shape of the connecting fluid holes and the twisted fluid holes is selected to provide enhanced delivery of fluid to the cutting edge. In one aspect, the rotary cutting tool is a modular drill and the flute portion has a pocket for holding a replaceable cutting insert.

Abstract: A cutting tool includes a base body and a cutting head at least partially disposed within a modular pocket of the base body. The modular pocket is formed by at least one wall section removably attached to the base body. In one variation, a non-removable portion of the base body also forms part of the modular pocket. In another variation, the modular pocket is formed by two removable wall sections on opposite sides of the modular pocket. In yet another variation, the removable wall sections include a clamping portion to exert a downward force on the cutting head to enable mounting the cutting head in the modular pocket using an interference fit.

Abstract: A cutting tool includes a base body and a cutting head at least partially disposed within a modular pocket of the base body. The modular pocket is formed by at least one wall section removably attached to the base body. In one variation, a non-removable portion of the base body also forms part of the modular pocket. In another variation, the modular pocket is formed by two removable wall sections on opposite sides of the modular pocket. In yet another variation, the removable wall sections include a clamping portion to exert a downward force on the cutting head to enable mounting the cutting head in the modular pocket using an interference fit.

Abstract: Rotary cutting tools are disclosed comprising shanks and replaceable cutting inserts are provided. The shank comprises a pocket which receives an interchangeable cutting insert. The pocket includes a floor with a central pin-receiving hole, opposing pocket centering walls, and torque transmitting pocket drive walls. The cutting insert has a relatively long rear pin receivable in the central hole of the shank. A head of the cutting insert includes insert centering surfaces that contact the pocket centering walls of the shank, and insert drive surfaces that contact the torque transmitting pocket drive walls of the shank. The configurations and sizes of the shank and cutting insert features are controlled to provide improved torque transmission, rigidity and stability during operation of the rotary cutting tools.

Abstract: A modular boring head includes a tubular main body having an internal thread with a first pitch and a pair of axially extending cantilevered members. A movable rod engages the tubular main body such that the movable rod is movable with respect to the tubular main body in an axial direction, D. The movable rod has an internal thread with a second pitch different than the first pitch. A leadscrew is disposed within the tubular main body and has a plurality of gear teeth. Rotation of the leadscrew causes the pair of axially extending cantilevered members of the tubular main body to cooperatively engage with the plurality of gear teeth of the leadscrew in such a manner so as to produce an audible and tactile click, each click being indicative of a distance the movable rod is displaced with respect to the tubular main body.

Abstract: A hardware fastener with a movable threaded element suspended within a cavity formed in a body. The movable threaded element has an internal surface with threads for cooperating with a threaded fastener. The movable threaded element is suspended in the cavity by the one or more spring-like members such that an area, A, of reduced stiffness is created in the cavity proximate the movable threaded element, thereby allowing the movable threaded element to move a predetermined distance within the cavity when torque is applied to the threaded fastener. The one or more spring-like members store elastic potential energy to prevent the loss of pretension of the threaded fastener that can be caused by heat or vibration. The invention also eliminates the need for a torque wrench when tightening the threaded fastener to a specified torque value.

Abstract: A modular drill apparatus (100) includes: a shank (110) having a pocket (112); a cylindrical post (117) centrally secured within a bottom (114) of the pocket (112); a cutting tip (130) including a lower portion (131) including a central bore (136) which receives the cylindrical post (117), an upper portion (132) and a channel (134) therebetween; and an insert assembly (150) interfitted within and supported by the channel (134), the insert assembly (150) being expandable along a length thereof for securing the cutting tip (130) to the shank (110) within the pocket (112) by providing an interference fit and retractable along the length thereof for releasing the cutting tip (130) from the pocket (112) by overcoming the interference fit.

Abstract: A system and method for monitoring and predicting wear of a cutting tool used for machining a workpiece is disclosed. The system includes a cutting tool having a shank and a cutting head. The system also includes a split, modular and wireless wear detection system including one or more sensors mounted to the cutting tool for providing a data signal representative of a physical condition of the system, and a data recording and data transmitting device for recording the data signal from the one or more sensors and for generating and transmitting a data signal to a processor. The processor applies a machine learning data processing technique in real time to monitor and/or predict a condition of various components and/or parameters of the system during a metal cutting operation.

Abstract: A rotary cutting tool with enhanced bump-off capability is disclosed. The cutting tool includes a tool shank having a pocket. A replaceable cutting head is at least partially disposed within the pocket of the tool shank with an interference fit. A coupling pin assembly is at least partially received within a bore of the tool shank. The coupling pin assembly comprises a sleeve member and a coupling pin at least partially disposed within the sleeve member. The sleeve member includes an upper portion and a lower portion having a non-circular cross-sectional shape with a bump-off surface. An actuation screw contacts the coupling pin assembly and causes the replaceable cutting head to move relative to the tool shank. The bump-off surface of the lower portion of the sleeve member extends radially outward with respect to the coupling pin by a distance, D, thereby providing enhanced bump-off capability.

Abstract: A rotary cutting tool with enhanced bump-off capability is disclosed. The cutting tool includes a tool shank having a pocket. A replaceable cutting head is at least partially disposed within the pocket of the tool shank with an interference fit. A coupling pin assembly is at least partially received within a bore of the tool shank. The coupling pin assembly comprises a sleeve member and a coupling pin at least partially disposed within the sleeve member. The sleeve member includes an upper portion and a lower portion having a non-circular cross-sectional shape with a bump-off surface. An actuation screw contacts the coupling pin assembly and causes the replaceable cutting head to move relative to the tool shank. The bump-off surface of the lower portion of the sleeve member extends radially outward with respect to the coupling pin by a distance, D, thereby providing enhanced bump-off capability.

Abstract: A cutting tool includes a base body and a cutting head at least partially disposed within a modular pocket of the base body. The modular pocket is formed by at least one wall section removably attached to the base body. In one variation, a non-removable portion of the base body also forms part of the modular pocket. In another variation, the modular pocket is formed by two removable wall sections on opposite sides of the modular pocket. In yet another variation, the removable wall sections include a clamping portion to exert a downward force on the cutting head to enable mounting the cutting head in the modular pocket using an interference fit.

Abstract: Expansion sleeves are disclosed comprising a body and a flange. The body may be generally cylindrical and includes an inner wall, an outer wall integrally formed with the inner wall, and a pressurized fluid chamber located radially between and encapsulated in the inner wall and the outer wall. The front flange extends radially outward from the outer wall of the body. The front flange may comprise a tool support connection structured and arranged to fasten the front flange to a tool support member. The tool support member may include a pressurized fluid system that communicates with the pressurized fluid chamber of the expansion sleeve. The expansion sleeves may be secured to the tool support member by mechanical fasteners, threading, or combinations thereof. During operation, pressurized fluid in the tool support member communicates with the pressurized fluid chamber of the expansion sleeve to clamp a tool shank.

Abstract: A modular cutting tool includes a base body, an intermediate body removably attached to the base body, and a cutting head at least partially disposed within a pocket of the intermediate body. A tooling tree allows a user to select a different combination of the base body, the intermediate body and the cutting head of the cutting tool based on desired physical properties of each component.

Abstract: A cutting tool is provided having a hydrostatic bearing support to minimize bending of the tool when in use. More specifically, a tool is provided comprising a body, a cutting insert, at least one flow pressure supply channel, a hydrostatic bearing, and wherein the flow pressure supply channel is in communication with the hydrostatic bearing, and optionally at least one coolant channel in communication with the cutting insert, and wherein the flow pressure supply channel is in communication with a supply reservoir for containing a lubricant or coolant. The supply reservoir is ultimately in communication with a pump to supply pressure to the hydrostatic bearing when the tool is operational.