A face milling tool includes a tool body having a central rotation axis around which the tool is rotatable, and at least one insert seat formed in a transition between a front end and an envelope surface of the tool. The tool further includes at least one cutting insert mounted in the insert seat, the cutting insert having an upper side defining an upper extension plane, a cutting edge extending around the circumference of the upper side, and a lower side defining a lower extension plane directed towards the bottom support surface of the insert seat. A center axis extends perpendicularly through the upper and the lower extension planes. The tool is configured such that a main cutting edge portion is at an entering angle κ smaller than 80° and such that the upper extension plane is at a radial tipping-in angle −60°≦γ.sub.f≦−25° and at an axial tipping-in angle −20°≦γ.sub.m≦0°, such that an angle of inclination λ of the main cutting edge portion is within the range 15°≦λ≦50°.

A double-sided cutting insert for milling has a first cutting edge formed at a transition from a top side to a circumferential lateral surface and a second cutting edge formed at a transition from a bottom side to the circumferential lateral surface. A reference plane (R) runs normal to an axis of symmetry (S). The cutting edges have main cutting edge portions and face cutting edge portions arranged in alternation, which extend between raised cutting corners and lowered cutting corners. The circumferential lateral surface has face free surfaces, which extend along the face cutting edge portion and which approach the axis of symmetry (S) with increasing distance from the associated face cutting edge portion. The circumferential lateral surface has main free surfaces, which extend along the main cutting edge portion and which move farther away from the axis of symmetry with increasing distance from the associated main cutting edge portion.

Novel endmills are provided. Such endmills have 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 (α). 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. In various embodiments, one or more coolant passageways are provided, and in an embodiment, an exit port for coolant is provided at the center of rotation of the end face portion.

A double-sided cutting insert for milling has a first cutting edge formed at a transition from a top side to a circumferential lateral surface and a second cutting edge formed at a transition from a bottom side to the circumferential lateral surface. A reference plane (R) runs normal to an axis of symmetry (S). The cutting edges have main cutting edge portions and face cutting edge portions arranged in alternation, which extend between raised cutting corners and lowered cutting corners. The circumferential lateral surface has face free surfaces, which extend along the face cutting edge portion and which approach the axis of symmetry (S) with increasing distance from the associated face cutting edge portion. The circumferential lateral surface has main free surfaces, which extend along the main cutting edge portion and which move farther away from the axis of symmetry with increasing distance from the associated main cutting edge portion.

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 variable radius gash geometry may be provided on a variety of rotary cutting tools. The rotary cutting tools extend along a longitudinal axis, from a shank towards a cutting face that engages a material to be cut during a plunge or ramp operation, and a plurality of gashes may be provided in the cutting face of the rotary cutting tool. The gashes may each be a full radius gash, and the radius defining each of the gashes may be unique or different from one another and tangent to an axial rake face and clearance face surrounding the gash.

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 variable radius gash geometry may be provided on a variety of rotary cutting tools. The rotary cutting tools extend along a longitudinal axis, from a shank towards a cutting face that engages a material to be cut during a plunge or ramp operation, and a plurality of gashes may be provided in the cutting face of the rotary cutting tool. The gashes may each be a full radius gash, and the radius defining each of the gashes may be unique or different from one another and tangent to an axial rake face and clearance face surrounding the gash.

A rotary cutting tool may include a cylindrical body having a cutting portion that extends longitudinally along an axis of the cylindrical body towards an axial end of the cylindrical body. A cutting face may be provided at the axial end, the cutting face having a plurality of end cutting edges associated with a plurality of gash grinds in the cutting face, wherein each gash grind from the plurality of gash grinds is defined by a different constant radius such that of each end cutting edge from the plurality of end cutting edges is of equal length.