A rotary cutting tool. The tool has a body with outside diameter (OD), and outer surface, and a longitudinal axis, a plurality of flutes, helical in some embodiments. Flutes include a narrow leading edge land portion with circular segment profile and having flute cutting edge portions along a substantially uniform circumferential location, with an eccentric relief margin rotationally rearward of the narrow leading edge land portions. Face portions are provided with face cutting edge portions, and with a first dish portion adjacent each of the cutting edge portions sloping inwardly and downwardly generally toward a central longitudinal axis at a first dish angle alpha () Corner blend portions extend from flute cutting edge portions to the face cutting edge portions. Corner blend portions are provided in a variety of profiles, including an embodiment wherein the profile of the corner blend portions are truncated before the segment of curvature becomes tangential to the face cutting edge portions. Large core diameters of cutting tools are provided, which gives high strength when working with axial depths of cut of about three times outside tool diameter or less.

A rotatable cutting tool includes an elongate body and at least one helical flute extending over a length of the elongate body, the helical flute having a first end and a second end. The flute includes a cutting-edge with a first radius from a longitudinal center of the cutting tool, a trailing edge with a second radius from a longitudinal center of the cutting tool, wherein the second radius is smaller than the first radius, a flute surface between the cutting-edge and the trailing edge, the flute surface including a maximum radius at the cutting-edge and a plurality of foam chip shedding exclusions spaced along the cutting-edge of the helical flute, each of the foam chip shedding exclusions providing a gap in the cutting-edge where the radius within the gap is smaller than the first radius. The first radius defines a maximum tool cutting radius for the cutting tool. A gap distance between the foam chip shedding exclusions and the maximum tool cutting radius equals at least 15% of a radial height of the flute.

A rotary cutting tool. The tool has a body with outside diameter (OD), and outer surface, and a longitudinal axis, a plurality of flutes, helical in some embodiments. Flutes include a narrow leading edge land portion with circular segment profile and having flute cutting edge portions along a substantially uniform circumferential location, with an eccentric relief margin rotationally rearward of the narrow leading edge land portions. Face portions are provided with face cutting edge portions, and with a first dish portion adjacent each of the cutting edge portions sloping inwardly and downwardly generally toward a central longitudinal axis at a first dish angle alpha () Corner blend portions extend from flute cutting edge portions to the face cutting edge portions. Corner blend portions are provided in a variety of profiles, including an embodiment wherein the profile of the corner blend portions are truncated before the segment of curvature becomes tangential to the face cutting edge portions. Large core diameters of cutting tools are provided, which gives high strength at when working with axial depths of cut of about three times outside tool diameter or less.

A corner radius end mill includes a tooth adjacent a helically extending flute. The tooth includes axial and radial relief surfaces connected by a corner relief surface, as well as rake surface having a rake ridge. The rake ridge is continuously curved from a bisector line until at least an axial location rearward of the corner relief surface.

An end mill includes a plurality of teeth and flutes. The teeth and their associated flutes include one or more correlated physical parameters. One such correlated parameter is that, at an axial location in a front half of an effective cutting length, at least one tooth of the plurality of teeth has a rake angle smaller than an average rake angle value of the plurality of teeth, and, at the same axial location, a flute preceding each such tooth has a helix angle larger than an average helix angle value of the plurality of flutes.

An end mill includes a plurality of teeth and flutes. The teeth and their associated flutes include one or more correlated physical parameters. One such correlated parameter is that, at an axial location in a front half of an effective cutting length, at least one tooth of the plurality of teeth has a rake angle smaller than an average rake angle value of the plurality of teeth, and, at the same axial location, a flute preceding each such tooth has a helix angle larger than an average helix angle value of the plurality of flutes.

A rotatable cutting tool includes an elongate body having a longitudinal axis, a proximal end and a distal end and at least one helical flute extending over a length of the elongate body, the helical flute having a first end and a second end. The flute includes a cutting-edge with a first radius from a longitudinal center of the cutting tool, a trailing edge with a second radius from a longitudinal center of the cutting tool, wherein the second radius is smaller than the first radius, a flute surface between the cutting-edge and the trailing edge, the flute surface including a maximum radius at the cutting-edge and a plurality of foam chip shedding exclusions spaced along the cutting-edge of the helical flute, each of the foam chip shedding exclusions providing a gap in the cutting-edge where the radius within the gap is smaller than the first radius.

A corner radius end mill includes a tooth adjacent a helically extending flute. The tooth includes axial and radial relief surfaces connected by a corner relief surface, as well as rake surface having a rake ridge. The rake ridge is continuously curved from a bisector line until at least an axial location rearward of the corner relief surface.

An end mill includes a plurality of teeth and flutes. The teeth and their associated flutes include one or more correlated physical parameters. One such correlated parameter is that, at an axial location in a front half of an effective cutting length, at least one tooth of the plurality of teeth has a rake angle smaller than an average rake angle value of the plurality of teeth, and, at the same axial location, a flute preceding each such tooth has a helix angle larger than an average helix angle value of the plurality of flutes.

A rotatable cutting tool is disclosed and includes an elongate body having a longitudinal axis, a proximal end and a distal end. The cutting tool further includes at least one helical flute extending over a cutting length of the elongate body, the helical flute having a first end and a second end. The helical flute includes a leading cutting wall having an edge, a trailing cutting wall having an edge, and a flute surface between the leading cutting wall and the trailing cutting wall, the flute surface including a curved surface portion including a constant radius from the longitudinal axis of the elongate body. The cutting tool further includes a plurality of reliefs evenly spaced along the leading and trailing walls of the helical flute, each of the reliefs forming a semi-circular cutout on the flute surface, and wherein the reliefs in the trailing cutting wall are longitudinally offset from the reliefs in the leading cutting wall.