Modular Reamer System

A rotary cutting tool having a longitudinal axis, the rotary cutting tool comprising:

• a monolithic cermet cutting member defining a cermet cutting head and a cylindrical cermet shaft;
• the shaft extending outwardly from the cutting head generally coaxially with the longitudinal axis;
• the shaft defining a shaft conduit generally coaxially with the longitudinal axis extending for substantially the length of the shaft;
• the cutting head defining a peripheral portion;
• the cutting head defining a plurality of cermet cutting edges and flutes alternating with the cutting edges in the peripheral portion;
• the cutting head defining at least one port in fluid communication with the shaft conduit;
• the cutting head, the shaft, and the cutting edges each being formed integrally with one another;
• a shank portion defining an elongated bore extending generally coaxially with the longitudinal axis;
• and
• the shaft of the cutting member being received in the bore in a shrink-fit relationship, wherein the shaft of the cutting member is substantially fixed against movement relative to the shank portion.

A method of making a rotary cutting tool, comprising:

• providing a monolithic carbide member having a carbide cutting head, a plurality of carbide cutting edges, and a carbide shaft of a first diameter defining a shaft conduit generally coaxial with the longitudinal axis extending for substantially the length of the shaft;
• the cutting head, the shaft, and the cutting edges each being formed integrally with one another;
• providing a shank portion defining an elongated bore of a second diameter extending generally coaxially with the longitudinal axis;
• the second diameter being approximately equal to the first diameter of the shaft at room temperature;
• heating the shank portion to a temperature sufficient to cause the second diameter to be greater than the first diameter;
• after the heating of the shank portion, inserting the shaft of the cutting head into the bore of the shank portion;
• and
• cooling the shank portion sufficiently to cause the bore of the shank portion to be in shrink-fit engagement with the shaft of the cutting member, wherein the shaft of the cutting member is generally fixed against movement with respect to the shank portion.

A method of making a rotary cutting tool, comprising:

• providing a monolithic cermet member having a cermet cutting head, a plurality of cermet cutting edges, and a cermet shaft of a first diameter defining a shaft conduit generally coaxial with the longitudinal axis extending for substantially the length of the shaft;
• the cutting head, the shaft, and the cutting edges each being formed integrally with one another;
• providing a shank portion defining an elongated bore of a second diameter extending generally coaxially with the longitudinal axis;
• the second diameter being approximately equal to the first diameter of the shaft at room temperature;
• heating the shank portion to a temperature sufficient to cause the second diameter to be greater than the first diameter;
• after the heating of the shank portion, inserting the shaft of the cutting head into the bore of the shank portion;
• and
• cooling the shank portion sufficiently to cause the bore of the shank portion to be in shrink-fit engagement with the shaft of the cutting member, wherein the shaft of the cutting member is generally fixed against movement with respect to the shank portion.

A method of making a rotary cutting tool, comprising:

• providing a monolithic carbide member received in a bore of a first shank portion;
• the carbide member having a carbide cutting head, a plurality of carbide cutting edges, and a carbide shaft having a shaft conduit generally coaxial with the longitudinal axis extending for substantially the length of the shaft, each being formed integrally with one another;
• the shaft being of a first diameter and the bore being of a second diameter, the second diameter being approximately equal to the first diameter of the shaft;
• heating the first shank portion to a temperature sufficient to cause the second diameter to be greater than the first diameter;
• removing the shaft from the bore;
• and
• reshaping the cutting head into a reshaped cutting head having a shaft of a third diameter.