Method for manufacturing a rotatable tool body to minimize cutting insert runout, a tool body produced therefrom, and a method of using such a tool body

A method for manufacturing a rotatable tool body with pockets positioned circumferentially between flutes about a cylindrical body to accept removable cutting inserts, wherein the method is comprised of the steps of:

• beginning with a cylindrical blank having a longitudinal axis, identifying a plurality of concentric circles along the cylindrical blank, wherein the concentric circles are spaced along the longitudinal axis and define rows and wherein a plurality of insert pocket locations are spaced circumferentially about the cylindrical blank in each row and each insert pocket location is defined by a radial line perpendicular to the longitudinal axis;
• and
• machining a plurality of pockets at the insert pocket locations of each row, wherein all of the pockets associated with one row are machined before proceeding to machine all of the pockets associated with another row and wherein the machining of each pocket comprises the steps of machining a radial side wall surface and a back wall surface upon which a cutting insert contacts when secured within the pocket, wherein the plurality of insert pocket locations includes primary pocket locations, secondary pocket locations, tertiary pocket locations, and remaining pocket locations and wherein the machining of the plurality of insert pocket locations is performed in the following sequence at each row:
• first machining the blank at one insert pocket location which is the primary pocket location to form a primary pocket;
• then machining the blank at a pair of other pocket locations which are the secondary pocket locations adjacent to the primary pocket location and away from the primary pocket location to form a pair of secondary pockets;
• then machining the blank at a pair of still other pocket locations which are tertiary pocket locations, wherein each tertiary pocket location is adjacent to one of the secondary pocket locations and away from the primary pocket location to form a pair of tertiary pockets;
• and
• then continuing to machine the blank at remaining pocket locations which are a pair of next pocket locations, wherein each next pocket location is adjacent to one of the tertiary pocket locations and away from the primary pocket location to form another pair of pockets;
• and continuing this progression on the remaining pairs of pocket locations.