A rotating machining device for machining a work piece includes a body having a support housing and a headstock rotatable relative to the support housing. A tool module is mounted to the headstock that includes a tool feed system and an actuating assembly is attached to the support housing. The actuating assembly is arranged to collide with and actuate the tool feed system at a collision point. The radial position of the collision point is adjustable relative to the tool module such that the collision point is repositionable independent of the tool module.

A rotating machining device for machining a work piece includes a support housing adapted for mounting on the work piece and a headstock rotatably mounted on the support housing about an axis. The headstock including an internal gear. A drive module is arranged to drive rotation of the headstock about the axis and at least one gear connection is formed between the internal gear and the drive module. The at least one gear connection is positioned radially inside of an outer diameter of the support housing to protect an operator from a pinch point associated with the at least one gear connection.

A rotating machining device for machining a work piece includes a support housing adapted for mounting on the work piece and a headstock rotatably mounted on the support housing about an axis. The headstock including an internal gear. A drive module is arranged to drive rotation of the headstock about the axis and at least one gear connection is formed between the internal gear and the drive module. The at least one gear connection is positioned radially inside of an outer diameter of the support housing to protect an operator from a pinch point associated with the at least one gear connection.

Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.