Round tooth cutters and method of design and use

A round cutting insert having:

• a. one or more rake surfaces that are outwardly facing relative to an insert axis for forming chips;
• b. a flank surface corresponding to each rake surface that is oriented relative to a cutting motion to provide clearance between the cutting insert and a surface created by removal of a layer that is converted into one or more chips;
• and
• c. a circular cutting edge at the intersection of each flank surface and its corresponding rake surface.

A method for designing a device for removing material from an object, thereby creating one or more chips of removed material while producing a new surface on the object, the device comprising:

• a. a body that is rotatable about an axis;
• b. at least one round cutting insert mounted on the body so that an orientation of the insert is characterized by a reference plane offset and an insert axis, the insert having:
• i. a rake surface that is outwardly facing relative to an insert axis, for forming a chip;
• ii. a flank surface that is oriented relative to a cutting motion so as to provide a means for clearance between the cutting insert and a surface created by removal of a layer that is converted into one or more chips;
• and
• iii. a circular cutting edge at the intersection of the flank and rake surfaces;
• the method comprising, not necessarily in the sequence described, the steps of:
• a. defining an axis of cutting motion rotation;
• b. defining a direction of relative feeding motion between the body and object;
• and
• c. setting an orientation of each round cutting insert so that the flank surface provides clearance between the cutting insert and the surface created by removal of a layer that is converted into one or more chips.