A near-net shape cutting tool has a main cooling passage along a longitudinal axis of the near-net shape cutting tool and at least one arcuate cooling channel having a first end and a second end, the first end in fluid communication with the main cooling passage, the second end spaced from the main cooling passage and providing a coolant exit in one or both of a radial surface and an axial surface of the near-net shape cutting tool.

A machining tool, in particular a drill carrier tool, includes a monolithic base body extending in the axial direction which, at least in one section, has a porous or grid-like core structure that is encased in a solid outer jacket. These measures allow less material to be used, while maintaining good mechanical properties. The porous or grid-like core structure is simultaneously used for transporting coolant. The base body is manufactured in particular by means of a 3D printing method.

A method of forming a shank comprises arranging first structures in a first set of the first structures and second structures in a second set of the second structures such that the first structures and the second structures extend away from a longitudinal central axis in a direction normal to the longitudinal central axis and such that ends of the first structures and the second structures, farthest away from the longitudinal central axis, form cylindrical surfaces, parallel to the longitudinal central axis and equidistant from the longitudinal central axis. The method further comprises indirectly bonding the first set of the first structures to the second set of the second structures, thereby forming the shank. At least one of the first structures consists of a first material. At least one of the second structures consists of a second material, such that the first material is different from the second material.

A method of forming a shank comprises arranging first structures in a first set of the first structures and second structures in a second set of the second structures such that the first structures and the second structures extend away from a longitudinal central axis in a direction normal to the longitudinal central axis and such that ends of the first structures and the second structures, farthest away from the longitudinal central axis, form cylindrical surfaces, parallel to the longitudinal central axis and equidistant from the longitudinal central axis. The method further comprises indirectly bonding the first set of the first structures to the second set of the second structures, thereby forming the shank. At least one of the first structures consists of a first material. At least one of the second structures consists of a second material, such that the first material is different from the second material.

A core pin used to create a cutting tool has at least one flute configured as an inverse shape of at least a portion of the cutting tool. Alternatively or in addition, a core pin has at least one step mold configured to form an axial surface with a stepped diameter having a diameter smaller than an overall diameter an outer axial surface of the core pin, and a radial surface between the axial surface and the outer axial surface. A core pin can include a main cooling passage mold and either a straight coolant channel mold or at least one arcuate cooling channel mold having a first end and a second end, the first end engaging the main cooling passage mold and the second end configured to create a coolant exit on a surface of the cutting tool. Carbide blanks are carbide material embedded with a core pin, and near-net shape cutting tools are created by pressing and heating the carbide blanks.

A tool holder has a tool body with at least one pocket for receiving at least one cutting insert. The at least one pocket has a support surface and an abutment surface transverse thereto, and a first stress relief surface located between the support surface and the abutment surface. The first stress relief surface extends along a first axis towards a first pocket peripheral surface. A second stress relief surface is formed between the first stress relief surface and the first pocket peripheral surface. The second stress relief surface has a convex shape in a cross-sectional view taken in a second plane containing the first axis. The convex shape may have a radius greater than 0.3 mm.

A tool holder has a tool body with at least one pocket for receiving at least one cutting insert. The at least one pocket has a support surface and an abutment surface transverse thereto, and a first stress relief surface located between the support surface and the abutment surface. The first stress relief surface extends along a first axis towards a first pocket peripheral surface. A second stress relief surface is formed between the first stress relief surface and the first pocket peripheral surface. The second stress relief surface has a convex shape in a cross-sectional view taken in a second plane containing the first axis. The convex shape may have a radius greater than 0.3 mm.

A cutting insert (100,100) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.

A cutting insert (100,100) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.

A method of manufacturing a machining tool in which an insert holder comprises a first surface, a second surface opposite the first surface, and a first insert tip slot extending between the first surface and the second surface. The first insert tip slot is configured so as to be compressed and densified to support a first insert tip. The insert holder further includes elevated projections extending from the first and second surfaces proximate the first insert tip slot.