Milling cutter for honeycomb core material

A milling tool for cutting honeycomb core material comprising:

• a shank having a first end for inserting into a chuck;
• a circular saw blade rigidly fixed to said shank at a second end, said saw blade having a top surface, a bottom surface and a cutting edge, said cutting edge being a sharp edge located around a periphery of said saw blade, said top surface being beveled adjacent said saw blade cutting edge, sloping downward toward said periphery to form said sharp cutting edge;
• and
• a plurality of circumferentially spaced cutter bodies positioned above and adjacent said saw blade top surface, each of said cutter bodies having a plurality of teeth extending generally parallel with respect to each other, each of said teeth having a piercing, cutting point and a sharp cutting edge extending from said piercing cutting point at a clearance angle, each of said cutter bodies including a flat surface extending vertically between said teeth of each cutter body.

A milling tool for cutting honeycomb core material comprising:

• a shank having a first end for inserting into a chuck;
• a circular saw blade rigidly fixed to said shank at a second end, said saw blade having a top surface, a bottom surface and a cutting edge, said cutting edge being a sharp edge located around a periphery of said saw blade, said top surface being beveled adjacent said saw blade cutting edge, sloping downward toward said periphery to form said sharp cutting edge;
• and
• a plurality of circumferentially spaced cutter bodied positioned above and adjacent said saw blade top surface, each of said cutter bodies having a plurality of teeth positioned vertically above each other and extending generally horizontal and parallel with respect to each other, each of said teeth having a piercing, cutting point and a sharp cutting edge extending from said piercing cutting point ar a clearance angle cutting point at a clearance angle between 12.degree. and 20.degree., said cutter body piercing points being aligned radially approximately at said saw blade cutting edge.

The method of cutting honeycomb core material comprising:

• cutting said honeycomb core material to create a final top surface free of burrs with a circular saw blade having a beveled, sharp peripheral cutting edge;
• piercing the honeycomb core material for a substantial distance vertically above said final top surface with a plurality of sharp piercing points, said piercing points being located on a plurality of cutter bodies, said cutter bodies being positioned vertically above said saw blade;
• and
• slicing said honeycomb core material positioned vertically above said final top surface after it has been cut and pierced with a plurality of sharp cutting edges positioned vertically with respect to each other and extending generally horizontal from said piercing point at a clearance angle.

The method of cutting honeycomb core material comprising:

• cutting said honeycomb core material to create a final top surface free of burrs with a circular saw blade having a beveled, sharp peripheral cutting edge;
• piercing the honeycomb core material for a substantial distance vertically above said final top surface with a plurality of sharp piercing points, said piercing points being located on a plurality of cutter bodies, said cutter bodies being positioned vertically above said saw blade;
• slicing said honeycomb core material positioned vertically above said final top surface after it has been cut and pierced with a plurality of sharp cutting edges positioned vertically with respect to each other and extending from said piercing point at a clearance angle;
• and
• slicing said honeycomb core material positioned vertically above said final top surface after it has been cut and pierced with a plurality of sharp cutting edges positioned vertically with respect to each other and extending from said piercing point at a clearance angle;
• and
• transporting honeycomb core material which has been cut and sliced in a depressed, flat surface extending vertically between and cutter body sharp cutting edges.