Machining tool and method of manufacturing same

1. A machining tool insert holder, comprising:

a first surface;

a second surface opposite the first surface;

a first insert tip slot extending between the first surface and the second surface, the first insert tip slot being configured to support a first cutting insert tip; and

a first elevated projection extending from the first surface proximate the first insert tip slot;

wherein the first elevated projection is less than full density of the tool holder material and is deformed to increase its density to secure a cutting tip in the first insert tip slot.

2. The insert holder of claim 1 , wherein the first insert tip slot is defined by two side surfaces disposed on opposite sides of a backing surface, the first elevated projection being disposed proximate a first of the side surfaces, and further comprising:

a second elevated projection extending from the first surface proximate the backing surface; and

a third elevated projection extending from the first surface proximate a second of the side surfaces.

3. The insert holder of claim 2 , wherein the side surfaces are angled toward one another extending away from a center of the insert holder.

4. The insert holder of claim 1 , wherein the first elevated projection is one of a first plurality of elevated projections extending from the first surface proximate the first insert tip slot, and further comprising a second plurality of elevated projections extending from the second surface proximate the first insert tip slot.

5. The insert holder of claim 4 , further comprising:

a second insert tip slot extending between the first surface and the second surface, the second insert tip slot being configured to support a second cutting insert tip;

a third plurality of elevated projections extending from the first surface proximate the second insert tip slot; and

a fourth plurality of elevated projections extending from the second surface proximate the second insert tip slot.

6. The insert holder of claim 4 , wherein each of the first plurality of elevated projections has a height from the first surface in a range of 0.10 mm to 0.50 mm, and each of the second plurality of elevated projections has a height from the second surface in a range of 0.10 mm to 0.50 mm.

7. The insert holder of claim 1 , wherein the insert holder comprises a sintered powder metal.

8. A machining tool, comprising:

an insert holder having an insert holder hardness, and the insert holder including:

a first portion having a first density;

a second portion integrally connected to the first portion, the second portion defining a first insert tip slot, and the second portion having a second density, the second density being greater than the first density; and

a first cutting insert tip supported in the first insert tip slot by the second portion, and the first cutting insert tip having a first cutting insert tip hardness, the first cutting insert tip hardness being greater than the insert holder hardness;

wherein the first insert tip slot is defined by three sides, and the second portion includes:

a first feature proximate a first of the three sides, the first feature having the second density;

a second feature proximate a second of the three sides, the second feature having the second density; and

a third feature proximate a third of the three sides, the third feature having the second density.