Abstract: A cutting tool includes a toolholder and a cutting insert. The toolholder includes a toolholder pocket having a pocket wall including a first anti-rotation engagement surface and a second anti-rotation engagement surface. The cutting insert is mounted in the toolholder pocket. The cutting insert includes: an upper surface, the upper surface having a plurality circular sinusoidal cutting edges; a lower surface opposite the upper surface; and an exterior sidewall between the upper surface and the lower surface. The first anti-rotation engagement surface and the second anti-rotation engagement surface of the pocket wall of the toolholder engage the exterior sidewall of the cutting insert to resist rotation of cutting insert.

Abstract: An indexable milling cutter includes a milling cutter body with a plurality of flutes and a plurality of seating surfaces adapted to mount a cutting insert thereon. The milling cutter body includes a plurality of coolant reservoirs in fluid communication with an adapter. In one aspect, each coolant reservoir lies along a circular intersection line of a coolant manifold. In another aspect, a longitudinal axis of each coolant reservoir is oriented at a non-zero angle, A, with respect to a central, longitudinal axis of the milling cutter. A plurality of coolant ducts in fluid communication with each coolant reservoir, each coolant duct having a smaller cross-sectional area than the coolant reservoir, provide multiple streams of coolant targeted at a plurality of specific critical cutting areas of the cutting insert.

Abstract: A cutting tool includes a toolholder and a cutting insert. The toolholder includes a toolholder pocket having a pocket wall including a first anti-rotation engagement surface and a second anti-rotation engagement surface. The cutting insert is mounted in the toolholder pocket. The cutting insert includes: an upper surface, the upper surface having a plurality circular sinusoidal cutting edges; a lower surface opposite the upper surface; and an exterior sidewall between the upper surface and the lower surface. The first anti-rotation engagement surface and the second anti-rotation engagement surface of the pocket wall of the toolholder engage the exterior sidewall of the cutting insert to resist rotation of cutting insert.

Abstract: In one aspect, rotary cutting tools are described herein comprising sets of coolant channels having exit aperture in the flutes of the tools for efficient coolant delivery to multiple cutting surfaces. Briefly, a rotary cutting tool comprises a shank portion, and a cutting portion extending from the shank portion along a longitudinal axis, the cutting portion comprising flutes helically extending along the longitudinal axis and internal coolant channels comprising exit apertures in the flutes. A projection of an exit aperture of a first set of internal coolant channels intersects a rake face extending below a corner edge of the rotary cutting tool, and a projection of an exit aperture of a second set of internal coolant channels intersects a rake face below a radial cutting edge of the rotary cutting tool.

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 rotary cutting tool includes a replaceable cutting insert, a pocket portion for holding the cutting insert, and a chip flute portion having a plurality of helical flutes. An internal coolant passage is formed in the chip flute portion and has both a twisted geometry and a “see-through” central portion. The internal coolant passage is polygonal in cross-sectional shape having a number of cusps equal to the number of flutes. The internal coolant passage greatly increases coolant flow area, while maintaining the stiffness and rigidity of the cutting tool. A method includes forming the internal coolant passage using additive manufacturing such that the internal coolant passage has a “see-through” central portion and a twisted geometry.

Abstract: An indexable milling cutter includes a milling cutter body with a plurality of flutes and a plurality of seating surfaces adapted to mount a cutting insert thereon. The milling cutter body includes a plurality of coolant reservoirs in fluid communication with an adapter. In one aspect, each coolant reservoir lies along a circular intersection line of a coolant manifold. In another aspect, a longitudinal axis of each coolant reservoir is oriented at a non-zero angle, A, with respect to a central, longitudinal axis of the milling cutter. A plurality of coolant ducts in fluid communication with each coolant reservoir, each coolant duct having a smaller cross-sectional area than the coolant reservoir, provide multiple streams of coolant targeted at a plurality of specific critical cutting areas of the cutting insert.

Abstract: In one aspect, rotary cutting tools are described herein comprising sets of coolant channels having exit aperture in the flutes of the tools for efficient coolant delivery to multiple cutting surfaces. Briefly, a rotary cutting tool comprises a shank portion, and a cutting portion extending from the shank portion along a longitudinal axis, the cutting portion comprising flutes helically extending along the longitudinal axis and internal coolant channels comprising exit apertures in the flutes. A projection of an exit aperture of a first set of internal coolant channels intersects a rake face extending below a corner edge of the rotary cutting tool, and a projection of an exit aperture of a second set of internal coolant channels intersects a rake face below a radial cutting edge of the rotary cutting tool.

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 rotary cutting tool includes a replaceable cutting insert, a pocket portion for holding the cutting insert, and a chip flute portion having a plurality of helical flutes. An internal coolant passage is formed in the chip flute portion and has both a twisted geometry and a “see-through” central portion. The internal coolant passage is polygonal in cross-sectional shape having a number of cusps equal to the number of flutes. The internal coolant passage greatly increases coolant flow area, while maintaining the stiffness and rigidity of the cutting tool. A method includes forming the internal coolant passage using additive manufacturing such that the internal coolant passage has a “see-through” central portion and a twisted geometry.

Abstract: Cutting tool systems including a tool holder and tangential cutting inserts are disclosed. The tangential cutting inserts have indexable cutting edges that may be sinusoidal-shaped and helical-shaped. The tangential cutting inserts have integrated fan and base portions. The tool holders comprise a plurality of insert pockets structured and arranged to receive the indexable tangential cutting inserts. The cutting tool systems provide cutting tools with effectively longer sinusoidal and helical cutting edges at their cutting rake faces and a strong support when seating in insert-receiving pockets on the tool holder.

Abstract: Cutting tool systems including a tool holder and tangential cutting inserts are disclosed. The tangential cutting inserts have indexable cutting edges that may be sinusoidal-shaped and helical-shaped. The tangential cutting inserts have integrated fan and base portions. The tool holders comprise a plurality of insert pockets structured and arranged to receive the indexable tangential cutting inserts. The cutting tool systems provide cutting tools with effectively longer sinusoidal and helical cutting edges at their cutting rake faces and a strong support when seating in insert-receiving pockets on the tool holder.

Abstract: A cutting insert with internal coolant passageways is disclosed. The cutting insert includes at least one internal coolant inlet passageway having a first cross-sectional area, and at least one internal coolant exit passageway having a second cross-sectional area. The at least one internal coolant exit passageway is in fluid communication with the at least one internal coolant inlet passageway. The coolant enters the at least one internal coolant inlet passageway at a first surface of the cutting insert and exits the at least one coolant exit passageway at a second, different surface of the cutting insert. The second cross-sectional area of the at least one internal coolant exit passageway are less than the first cross-sectional area of the at least one internal coolant inlet passageway, thereby producing an increased streaming effect of the coolant to an insert-chip interface.

Abstract: A method is provided for assessing tool-wear and predicting tool-life for a selected cutting tool performing a machining operation. The method is broadly defined as including the steps of determining a tool coating effect factor and a chip-groove effect factor for the coated, grooved cutting tool. Additionally, the method includes the calculation of a tool-life for the coated, grooved cutting tool. The method takes into account selected machining operation conditions such as the characteristics of the workpiece material to be cut, the depth of cut, the feed rate, the cutting speed and the cutting tool geometry.