Cutting inserts and cutting tool systems having sinusoidal and helical cutting edges

A cutting tool system comprising:

• a tool holder comprising two or more series of common insert pockets, each series of common insert pockets positioned in a helical orientation about a longitudinal axis of the tool holder;
• and
• a plurality of common cutting inserts removably attachable to the common insert pockets in the tool holder to form two or more cutting flutes on the tool holder, the two or more cutting flutes each comprising a helical grouping of the common cutting inserts positioned in the insert pockets;
• wherein the common cutting inserts each comprise at least one sinusoidal and helical cutting edge having a first portion and a second portion, the first portion being continuous with the second portion such that the first and second portions extend from one end of the at least one sinusoidal and helical cutting edge to another end of the at least one sinusoidal and helical cutting edge, wherein the first portion has a one-half sinusoidal wavelength shape and the second portion has a one-half sinusoidal wavelength shape;
• and
• wherein the two or more cutting flutes each comprise a sinusoidal and helical cutting edge positioned about the longitudinal axis of the tool holder and formed by alignment of the individual sinusoidal and helical cutting edges of the common cutting inserts that comprise the two or more cutting flutes.

A method for producing a cutting tool system comprising:

• a tool holder comprising a plurality of common insert pockets positioned in a helical orientation about a longitudinal axis of the tool holder;
• and
• a plurality of common cutting inserts removably attachable to the plurality of common insert pockets in the tool holder to form at least one cutting flute on the tool holder, the at least one cutting flute comprising a helical grouping of common cutting inserts positioned in the insert pockets;
• wherein the common cutting inserts each comprise at least one sinusoidal and helical cutting edge having a first portion and a second portion, the first portion being continuous with the second portion such that the first and second portions extend from one end of the at least one sinusoidal and helical cutting edge to another end of the at least one sinusoidal and helical cutting edge, wherein the first portion has a one-half sinusoidal wavelength shape and the second portion has a one-half sinusoidal wavelength shape;
• the method comprising:
• positioning a cutting insert having a sinusoidal-shaped cutting edge as if it were on the tool holder with a helix angle;
• and
• modifying the sinusoidal shape of the cutting edge of the cutting insert to coincide with a cylindrical surface defined by a cutting radius centered at a cutting axis of the cutting tool system.