A high-speed precision interrupted ultrasonic vibration cutting method includes steps of: (1) installing an ultrasonic vibration apparatus on a machine tool, and stimulating a cutting tool to generate a transverse vibration, so as to realize varieties of machining processes; (2) realizing an interrupted cutting process by setting cutting parameters and vibration parameters to satisfy an interrupted cutting conditions; and (3) turning on the ultrasonic vibration apparatus and the machine tool, and starting a high-speed precision interrupted ultrasonic vibration cutting process. High-speed precision interrupted ultrasonic vibration cutting is able to be realized through the above steps during machining of difficult-to-machine materials in aviation and aerospace fields. A cutting speed is enhanced significantly, and exceeds a critical cutting speed of a conventional ultrasonic vibration cutting method and an elliptical ultrasonic vibration cutting method and even a high speed range of a traditional cutting method.

A cutting insert for a cutting tool is described. The cutting insert includes a front surface, a generally planar rear surface opposite the front surface, a generally planar first end surface, a generally planar second end surface opposite the first end surface, a generally planar first side surface, a generally planar second side surface opposite the first side surface. The front surface is continuously convex extending entirely between the first and second surfaces and entirely between the first and second side surfaces. At least one end surface is formed with a clearance angle (A1, A2, A3) to produce a cutting edge that is elliptical in shape having a relatively small depth-of-cut (DOC) to produce an extremely fine finish on a workpiece.

A milling tool includes a body which is rotatable about a first axis. At least one cutting tooth mounted on the body having a cutting edge for cutting about the first axis. A wiper tooth extends from the mill body. The wiper tooth includes at least at a portion having a peripheral surface about the second axis and the peripheral surface intersects a face surface defining a cutting edge that is round about the second axis for cutting about the first axis. In some embodiments, the peripheral surface, the face surface and the cutting edge are formed on an insert that is mounted the mill body.