Abstract: An indexable threading and turning insert with integral press-in chip breakers, having a threading insert portion and a turning insert portion. Each of the threading insert portion and the turning insert portion has, respectively, an integral pressed-in chip breaker having ideal chip management characteristics. The indexable threading and turning insert has a substantially diamond shape having a first planar face, an opposite second planar face, and four insert faces extending between the first and second planar faces. The threading insert portion is characterized by a first cutting edge formed at the intersection of the first insert face and a first land and a second cutting edge formed at the intersection of the second insert face and a second land. The first and second cutting edges have a plurality of noses separated by gullets.

Abstract: A method of designing a cutting tool uses finite element numerical models to predict a response of the tool during a simulated cutting operation on a workpiece, and to simulate a chip-flow phenomenon occurring during the cutting operation. The chip-flow model incorporates representations of a fracture mechanism describing a chip separation phenomenon, a heat-generating mechanism describing a thermal coupling phenomenon, and a shear localization mechanism describing a shearing phenomenon wherein these phenomena occur during the cutting operation. The predicted tool response and the chip-flow simulation are evaluated by an artificial intelligence system to render rule-based judgments which are embodied in recommendations for continuously modifying the models and input design variables until the simulation and response converge to an optimal result.

Abstract: A dense cermet article including about 44-93% of a granular first hard phase, about 4-44% of a granular second hard phase, and about 2-20% of a metal phase, all expressed in % by volume. The first hard phase consists essentially of alumina and from 0% to less than 5% of one or more oxides selected from magnesia, zirconia, yttria, hafnia, and silica. The second hard phase consists essentially of a hard refractory carbide, nitride, or boride, or mixture or solid solution thereof. Preferred materials for inclusion in the second hard phase are titanium carbide, hafnium carbide, tantalum carbide, tantalum nitride, tungsten carbide, titanium diboride, and boron carbide. The metal phase consists essentially of a combination of nickel and aluminum having a ratio of nickel to aluminum of from about 85:15 to about 88:12, and 0-5% of an additive selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, cobalt, boron, and/or carbon.

Abstract: A method for machining a high temperature nickel based alloy workpiece or other difficult-to-work material. The method involves machining the workpiece at an effective cutting speed of up to about 1500 sfm per minute, moving a ceramic-metal cutting tool across the face of the workpiece at a rate of up to about 0.04 in/rev, and cutting the workpiece with the ceramic-metal cutting tool to effect a depth of cut of up to about 0.15 inches per pass. The ceramic-metal cutting tool has a density of at least about 95% of theoretical, and includes about 80-98%, preferably 88-96%, by volume of granular hard phases and about 2-20%, preferably 4-12%, by volume of a metal phase. The granular hard phases are (a) a major hard phase portion of alumina and (b) a minor hard phase portion of hard refractory metal carbides, nitrides, carbonitrides, and borides.

Abstract: A dense cermet article including about 80-95% by volume of a granular hard phase and about 5-20% by volume of a metal phase. The granular hard phase consists essentially of a ceramic material selected from the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, carboxynitrides, and borides of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, boron, and mixtures thereof. The metal phase consists essentially of a combination of nickel and aluminum having a weight ratio of nickel to aluminum of from about 90:10 to about 70:30 and 0-5% by weight of an additive selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, cobalt, boron, or carbon, or combinations thereof. In the preferred metal phase, an amount of about 15-80% by volume of the metal phase component exhibits a Ni.sub.3 Al ordered crystal structure.

Abstract: A dense cermet article including about 80-90% by volume of a granular hard phase and about 5-20% by volume of a metal phase. The hard phase is a carbide, nitride, carbonitride, oxycarbide, oxynitride, or carboxynitride of a cubic solid solution selected from W-Ti, W-Hf, W-Nb, W-Ta, Zr-Ti, Hf-Ti, Hf-Zr, V-Ti, Nb-Ti, Ta-Ti, or Mo-Ti. The metal phase consists essentially of a combination of nickel and aluminum having a ratio of nickel to aluminum of from about 90:10 to about 70:30 by weight, and 0-5% by weight of an additive selected from titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, cobalt, boron, and/or carbon. The preferred hard phase is a cubic solid solution of tungsten and titanium. In the preferred metal phase, an amount of about 15-80% by volume of the metal phase component exhibits a Ni.sub.3 Al ordered crystal structure. The article may be produced by presintering the hard phase - metal phase component mixture in a vacuum or inert atmosphere at about 1475.

Abstract: A method for manufacturing a dense cermet article including about 80-95% by volume of a granular hard phase and about 5-20% by volume of a metal binder phase. The hard phase is (a) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, carboxynitrides, borides, and mixtures thereof of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and B, or (b) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, and carboxynitrides, and mixtures thereof of a cubic solid solution of Zr--Ti, Hf--Ti, Hf--Zr, V--Ti, Nb--Ti, Ta--Ti, Mo--Ti, W--Ti, W--Hf, W--Nb, or W--Ta. The binder phase is a combination of Ni and Al having a Ni:Al weight ratio of from about 85:15 to about 88:12, and 0-5% by weight of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Co, B, and/or C. The method involves presintering the hard phase/binder phase mixture in a vacuum or inert atmosphere at about 1475.degree.-1675.degree. C., then HIPing at about 1575.degree.-1675.degree. C.