Multi-tooth micro-blade milling cutter and manufacturing method and application thereof

Abstract

The invention relates to the technical field of milling cutters, in particular to a multi-tooth micro-blade milling cutter and a manufacturing method and application thereof. The multi-tooth micro-blade milling cutter comprises a cutter handle and a cutter head body, wherein the cutter head body is fixedly connected to one end of the cutter handle; the multiple cutter teeth are arranged on the outer side face of the cutter head body, and each cutter tooth extends to the tail end, close to the cutter handle, of the cutter head body from the top end, away from the cutter handle, of the cutter head body; each cutter tooth comprises a front cutter face, a rear cutter face and a cutting edge, the cutting edge is provided with a plurality of continuously-distributed micron-sized protruding micro-blades, the micro-blades form an arc-shaped sawtooth structure, the micro-blades extend to the front cutter faces and form micro grooves in the front cutter faces, the micro-blades extend to the front cutter faces and form micro grooves in the front cutter faces, and the micro-blades extend to the rear cutter faces and form micro grooves in the front cutter faces. The multi-tooth micro-blade milling cutter has the structure of the front angle of the front cutter face of the milling cutter tooth and the rear angle of the rear cutter face of the milling cutter tooth, the linear cutting blade of the traditional cutter tooth is dispersed into micro blades, the stress concentration of the cutter is reduced, a plurality of convex micro blades are in grinding motion on the machining face in the milling process, and the milling and grinding combined machining effect is formed. Unification of machining efficiency and machining precision is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of milling cutters, and in particular to a multi-tooth micro-edge milling cutter and a manufacturing method and application thereof. Background Art

[0002] Typical hard-to-machine hard and brittle materials, such as high-precision glass, advanced ceramics, and sapphire; hard-to-machine metal materials, such as high-temperature alloys and amorphous alloys; and hard-to-machine composite materials, such as carbon fiber composites and honeycomb materials, are widely used in the manufacture of high-performance parts in aerospace, semiconductors, precision electronics, and new energy vehicles. With the development of the manufacturing industry, high-performance parts face unconventional operating environments, increasingly complex and sophisticated part shapes and structures, and ever-increasing machining precision. The ability to achieve high-precision, high-efficiency, and low-damage machining of difficult-to-machine materials is a serious constraint on the application of high-performance parts and the development of high-end equipment.

[0003] Grinding is one of the most commonly used methods for precision machining of difficult-to-machine materials. It achieves precise removal by repeatedly removing a large number of abrasive particles on the same plane. However, in order to obtain a high-quality machined surface with low roughness and low damage, the machining depth and feed rate usually need to be maintained at a few microns or even nanometers. The machining efficiency corresponding to the extremely low material removal rate is self-evident. In addition, grinding three-dimensional parts with complex structural features is particularly difficult.

[0004] Milling offers a more flexible and efficient alternative to grinding for producing high-quality parts with complex shapes. The cutting performance of milling cutters plays a crucial role. Traditional milling cutter designs assume that a highly straight cutting edge is essential for achieving high-precision machining. However, during tool sharpening, a perfectly straight cutting edge cannot be achieved due to the uneven grain size and distribution of the tool material. Uneven grain shedding and micro-chipping of the material create microscopic jagged defects on the cutting edge, leading to localized stress during cutting and increased tool wear. To achieve highly sharp and straight cutting edges, multiple grinding cycles are required, using different grinding wheel grit sizes to optimize machining efficiency and accuracy. Finally, ultra-precision grinding techniques are used to achieve high-quality cutting edges. However, many straight-edge cutters still exhibit small microscopic chips or grinding marks even after sharpening. This process is complex and places extremely high demands on the grinding equipment, tools, and process. To meet the demands for high-precision, high-efficiency, and low-damage machining of high-performance parts made of difficult-to-machine materials, a new tool design is needed to mitigate the impact of microscopic cutting edge defects on tool performance.

[0005] In addition to tool design, tool manufacturing technology is the key to ensuring its high cutting performance. In order to combine the different processing advantages of milling and grinding, it is necessary to create a complex surface structure with similar grinding wheel characteristics on the traditional milling cutter; however, tools suitable for processing difficult-to-machine materials, such as diamond tools, carbide tools, coated tools, and ceramic tools, all have high hardness and high stability, which are difficult to process. It is particularly difficult to manufacture complex surface polycrystalline diamond milling cutters using traditional processing methods such as diamond grinding wheels and electric sparks. The manufacturing cost is high, the processing efficiency is low, and the processing technology is extremely complex.

[0006] Although the prior art discloses relevant milling cutter structures, it still has shortcomings:

[0007] Patent 202410800394.2 discloses a multi-micro-blade hole-making tool, a composite tool, and a hole-making method. The cutting edge at the front of the tool is designed as a fish-scale micro-tooth structure, while the rear end is a grinding structure. It is primarily used for deep hole machining. The machining process is equivalent to milling first, followed by grinding. However, this milling-first approach can cause cracks in the material.

[0008] Patent 202311165349.6 discloses a combined electrolytic and micro-blade machining tool. The micro-blades in this patent surround a central cutting edge, lacking defined rake and relief angles. The machining method primarily removes material through grinding and polishing of multiple cutting edges, rather than milling. Based on the diameter and number of blades, the micro-blades have a width of approximately 0.2 mm.

[0009] Patent 201821568808.X discloses a polycrystalline diamond head machining tool. The tool has multiple cutting edges, which are evenly distributed in a ring shape on the cutting body, and the number is 32 to 36. The main advantage of this patent is that it uses polycrystalline diamond material for machining, and the tool is a whole, thereby increasing the strength for cutting. However, the patent does not define the front and rear angles of the cutting edge (defined as the tooth in this patent), and proposes that the surface roughness Ra of the cutting edge is 0.1 to 0.4 μm. This indicates that the cutting edge is a traditional straight edge rather than a micro-edge. Therefore, the main structural feature and removal form of the tool is to achieve removal by scraping the material surface with multiple cutting edges.

[0010] Patent 202020574721.4 discloses a microstructured tool head. The tool head has a microstructure on its rake face, which consists of multiple spaced and parallel microgrooves. However, the tool described in this patent is a blade structure, and the microgrooves are evenly distributed on the rake face and do not directly contact the workpiece surface. The cutting edge is still a straight cutting edge, and the main function of the grooves is to dissipate heat. Summary of the Invention

[0011] The purpose of the present invention is to avoid the shortcomings of the prior art and provide a multi-tooth micro-blade milling tool. The multi-tooth micro-blade milling tool has a structure of a front angle of the front cutting edge of the milling cutter tooth and a back angle of the back cutting edge, and can make the sharp cutting edge of the tooth with high straightness discrete into irregularly distributed micron-scale cutting edges. The micro-blade structure of the present invention forms continuous micron-scale micro-blades with orderly and controllable sizes on the cutting edge, overcoming the randomly distributed microscopic defects on the traditional macro-cutting edge, so that the obtained micro-blades and the macro-cutting edge work together during processing to form a milling and grinding composite processing effect, thereby achieving the unity of processing efficiency and processing accuracy.

[0012] To achieve one of the above objectives, the present invention provides the following technical solutions:

[0013] Provide multi-tooth micro-edge milling tools, including

[0014] Handle,

[0015] A cutter head body, the cutter head body being fixedly connected to one end of the handle;

[0016] A plurality of blade teeth are provided on the outer side of the blade head body, and each blade tooth extends from the top end of the blade head body away from the blade handle to the rear end of the blade head body close to the blade handle;

[0017] Each tooth includes a rake face, a flank face and a cutting edge. The cutting edge is provided with a number of continuously distributed micro-blades with micron-sized protrusions. Several of the micro-blades form an arc-shaped serrated structure. These serrated structures act as micro-cutting edges during cutting. The micro-blades extend to the rake face and form micro-grooves on the rake face.

[0018] In some embodiments, a tooth pitch is formed between adjacent teeth, a ratio of the tooth width of the teeth to the tooth pitch is 1:1.5 to 1:2, and a height of the teeth is ≤2 mm.

[0019] In some embodiments, the plurality of micro-edges are distributed on the cutting edge in a continuous manner, the micro-edge height of the micro-edges is 3 μm to 10 μm, and the micro-edge width of the micro-edges is 5 μm to 20 μm.

[0020] In some embodiments, the rake angle of the front cutting edge is 0° to 15°, and the clearance angle of the flank cutting edge is 1° to 10°.

[0021] In some embodiments, the length direction of each micro groove is perpendicular to the edge line of the corresponding cutting edge.

[0022] The beneficial effects of the multi-tooth micro-edge milling tool of the present invention are as follows:

[0023] (1) The multi-tooth micro-blade milling tool of the present invention retains the positive rake angle and clearance angle structure of the traditional milling cutter, ensuring that the tool can achieve the high-efficiency cutting performance of the traditional milling cutter in terms of cutting depth and cutting speed, meeting the needs of high-efficiency processing; the cutting edge of each milling cutter tooth is designed to be a continuous micron-level arc serration with orderly and controllable shape and size. These serrations change the action surface of the tool and the workpiece from the traditional line contact to point contact during the cutting process. The point contact method can better disperse the stress of the cutting force on the workpiece, effectively avoiding the processing difficulties of difficult-to-process materials caused by stress concentration when the traditional cutting edge contacts the workpiece, playing a micro-cutting role, and is therefore defined as a micro-blade. When traditional milling cutters process brittle materials, stress concentration easily causes the workpiece to crack or break, while the tool of the present invention can significantly reduce the stress concentration phenomenon through the point contact method of the micro-blade structure, making the precision milling of difficult-to-process materials more feasible.

[0024] (2) The multi-tooth micro-blade milling tool of the present invention also has the function of milling and grinding during the cutting process, which can not only remove materials efficiently, but also perform fine processing on the machined surface, so that the tool can process materials with higher hardness, and significantly improve the processing effect of materials with higher hardness. When traditional milling cutters process materials with higher hardness, problems such as rapid tool wear and poor machined surface quality will occur. The multi-tooth micro-blade milling tool of the present invention can effectively solve these problems through the combination of milling and grinding, and achieve high-precision, high-efficiency, and low-damage processing of difficult-to-process materials, which is conducive to improving the processing effect of complex materials in the field of high-end manufacturing.

[0025] (3) The multi-tooth micro-blade milling tool of the present invention determines the number of teeth as much as possible according to the tool diameter and the characteristics of the material being processed. During the processing, more micro-blades can repeatedly remove material from the same plane, which can ensure the flatness and precision of the processed surface. Compared with traditional milling cutters, the tool of the present invention can better control the roughness and dimensional accuracy of the processed surface, and ultimately obtain a flat and smooth processed surface. The tool of the present invention can not only improve processing efficiency, but also ensure processing quality and meet the needs of high-precision processing.

[0026] (4) The multi-tooth micro-blade milling tool of the present invention can not only achieve the processing efficiency of the milling cutter but also give the milling cutter a grinding effect, effectively allowing the processing efficiency and processing accuracy to coexist.

[0027] (5) The multi-tooth micro-edge milling tool of the present invention can effectively overcome the problem of small chipping or grinding marks on the traditional cutting edge by only setting micro-edges on the linear cutting edge, effectively improving production efficiency and reducing tool preparation costs.

[0028] To achieve the second of the above objectives, the present invention provides the following technical solutions:

[0029] A method for manufacturing the multi-tooth micro-edge milling tool is provided, comprising the following steps:

[0030] Step 1: Processing the outer contour: Grinding, EDM, and laser processing are used to process the bar blank to obtain the outer contour of the bar. In the laser processing method, the laser beam is made tangent to the bar blank so that the local energy of one side of the Gaussian beam acts on the surface of the bar blank.

[0031] Step 2: Processing the teeth: Import the tooth model into the machine tool and use the laser beam to process the teeth. The tooth processing parameters are: single pulse energy density is 10J / cm 2 ~50J / cm 2 , pulse overlap rate 90%~98%, scan overlap rate 90%~96%, scan times 1%~50%.

[0032] Step 3: Processing the flank: Import the flank model into the machine tool and use the laser beam to process the flank of each tooth. The flank processing parameters are: single pulse energy density of 10J / cm 2 ~30J / cm 2 , pulse overlap rate 90% to 98%, scan overlap rate 90% to 96%, scan times 1 to 10 times;

[0033] Step 4: Processing micro-edges: Import the micro-edge model into the machine tool and use the laser beam to process the rake face of each tooth to obtain a micro-edge. The micro-edge processing parameters are: single pulse energy density of 2J / cm 2 ~20J / cm 2 , pulse overlap rate 20% to 60%, scan overlap rate 90% to 96%, and scan times 1 to 20 times.

[0034] In some embodiments, after step one, the chip breaker is machined before step two. The step of machining the chip breaker includes: determining a tool model, importing a chip breaker model into a machine tool, and machining the chip breaker using a laser beam.

[0035] In some embodiments, in step 4, the micro-blade morphology is adjusted by controlling the single pulse energy density and the pulse overlap ratio.

[0036] In some embodiments, the tool is applied to precision milling, and the rotation speed N of the tool is adjusted. r , feed speed f v , axial cutting depth a p and radial cutting depth a e . BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a schematic diagram of the working states of a traditional cutting knife and the micro-edge cutting knife of this embodiment.

[0038] Figure 2 It is a simulation diagram of the damage to the material caused by the traditional cutting knife and the micro-edge cutting knife of this embodiment.

[0039] Figure 3 This is a simulation diagram showing the effect of the tooth pitch of the cutter teeth on the machining effect in this embodiment.

[0040] Figure 4 This is a diagram showing the effect of the number of cuts on the processing effect of a traditional cutting knife and the micro-edge cutting knife of this embodiment.

[0041] Figure 5 3 is a comparison diagram of the morphology of a traditional cutting knife and the micro-edge cutting knife of this embodiment.

[0042] Figure 6 Schematic diagram of the multi-tooth structure micro-edge milling tool of this embodiment.

[0043] Figure 7 It is a schematic diagram of a multi-tooth structure micro-edge milling tool with various structures.

[0044] Figure 8 This is a processing flow chart of the multi-tooth structure micro-edge milling tool of this embodiment.

[0045] Figure 9 It is a morphology diagram of the micro-blade effect processed with different pulse overlap rates.

[0046] Figure 10 It is a partially enlarged schematic diagram of the micro-blade structure.

[0047] Figure 11 This is a partially enlarged schematic diagram of the ceramic micro-blade.

[0048] Figure 12 The machining process of PCD micro-edge end mills: (a) machining process diagram; (b) bar turning; (c) chip breaker and cutter tooth milling;

[0049] Figure 13 PCD micro-edge end mills manufactured by laser turning and milling: (a) Profile of PCD bar after turning; (b) SEM image of the tool; (c) Measured profile of the macro-tooth; (d) Measured profile of the micro-edge;

[0050] Figure 14 Aluminosilicate glass processing test system: (a) Aluminosilicate glass workpiece; (b) experimental tool; (c) experimental equipment

[0051] Figure 15 There are three types of chip shapes processed by tools (processing parameters:

[0052] V c =376m / min,f v=1300mm / min,a p =0.05mm,a e =0.21mm): (a) 4-edge PCD milling cutter; (b) PCD micro-edge milling cutter; (c) diamond grinding head

[0053] Figure 16 The variation of specific cutting energy of three tools for cutting glass materials with material removal rate

[0054] Figure 17 The surface roughness of three different cutting tools varies with material removal rate.

[0055] Figure 18 The subsurface micromorphology of glass workpieces with three tools (processing parameters:

[0056] V c =376m / min,f v =1300mm / min,a p =0.05mm,a e =0.21mm): (a) 4-edge PCD milling cutter; (b) diamond grinding head; (c) PCD micro-edge milling cutter

[0057] Figure 19 It is the application of PCD micro-edge milling cutter in SiC material (processing conditions: UHB-400CC precision machining center,

[0058] V c =470m / min, f v =2000mm / min, a p =0.03mm, a e =0.1mm, MRR=6mm 3 / min): (a) Comparison between PCD micro-blade tools and other brands of diamond grinding heads; (b) Mirror-finishing SiC samples with PCD micro-blade tools

[0059] Figure 20 The application of PCD micro-edge milling cutter in sapphire material (processing conditions: UHB-400CC precision machining center, V c =414m / min, f v =1000mm / min, a p =0.003mm, a e =0.21mm, MRR=0.63mm 3 / min): (a) Comparison between PCD micro-blade tools and other brands of diamond grinding heads; (b) Surface processing of sapphire samples using PCD micro-blade tools. DETAILED DESCRIPTION

[0060] The preferred embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although preferred embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments described herein. Rather, these embodiments are provided to make the present invention more thorough and complete and to fully convey the scope of the present invention to those skilled in the art.

[0061] The terms used in this invention are intended solely for the purpose of describing specific implementations and are not intended to limit the invention. The singular forms "a," "an," and "the" used in this invention and the appended claims are intended to include plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0062] It should be understood that although the terms "first", "second", "third", etc. may be used to describe various information in the present invention, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of the present invention, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "plurality" means two or more, unless otherwise clearly and specifically defined.

[0063] Example 1

[0064] The multi-tooth micro-edge milling tool disclosed in this embodiment includes

[0065] Handle,

[0066] A cutter head body, the cutter head body being fixedly connected to one end of the handle;

[0067] The cutter head body is used as a support body to set the cutter teeth.

[0068] A plurality of blade teeth are provided on the outer side of the blade head body, and each blade tooth extends from the top end of the blade head body away from the blade handle to the rear end of the blade head body close to the blade handle;

[0069] A plurality of teeth are arranged on the side of the cutter head body, and a certain cutting surface is formed by each tooth extending from the top end of the cutter head body away from the handle to the tail end of the cutter head body close to the handle.

[0070] Each tooth includes a rake face, a flank face, and a cutting edge. The cutting edge has a number of continuously distributed, micron-sized raised arc-shaped serration structures. These serration structures act as micro-cutting edges during cutting and are therefore defined as micro-edges. The micro-edges extend to the rake face and form micro-grooves on the rake face.

[0071] The cutting edge of the tooth is the part that comes into direct contact with the processed material and produces cutting. The micro-edge completely changes the contact form between the cutting edge and the material, transforming the linear contact of the traditional tool into a discrete release, reducing stress concentration. This release form is similar to the contact of grinding abrasives. The tool cutting edge also has the front and rear angle characteristics of the milling cutter, so the entire cutting process presents a cutting method that combines milling and grinding.

[0072] To compare and illustrate the effects of the multi-tooth micro-edge milling cutter of this embodiment and the traditional milling cutter on stress, the following tests were conducted:

[0073] The size and distribution of the micro-blades were simulated, and the two-dimensional finite element method was used to simulate the surface formation process of repeated cutting of aluminosilicate glass, a typical hard and brittle material, and the crack propagation during the multi-micro-blade indentation process. Figure 1 、 2 It can be seen that the material crushing situation when the straight edge tool and the micro edge tool are pressed in. The simulation results show that the material crushing depth when the micro edge is pressed in is much smaller than the straight edge crushing depth.

[0074] Figure 4 As shown in the figure, the simulation compares the effect of repeated cutting times on the machined surface. The simulation results show that for micro-edge teeth with a constant tooth pitch, the higher the number of micro-edge cutting times, the smoother the machined surface and the less sub-surface damage. Therefore, in micro-edge design, the more micro-edges, the better.

[0075] Figure 5 As shown, by comparing the morphology of the traditional cutting knife and the micro-blade cutting knife of this embodiment, it can be seen that the multi-tooth structure micro-blade milling tool of this embodiment forms a micro-blade on the cutting edge, and forms micro-grooves on the front cutting edge, so that grinding can be performed during the deep cutting process, ensuring that grinding can be performed throughout the entire process.

[0076] Figure 6 This is a schematic diagram of a multi-tooth structure micro-edge milling tool of this embodiment. It can be seen that many micro grooves are formed on the rake face and micro edges are formed on the cutting edge. In addition, the multi-tooth structure micro-edge milling tool can also be used as Figure 7 Various structures shown.

[0077] To further illustrate, the micro blade can also be Figures 10-11 As shown, it can be seen that this embodiment can produce a micro-blade that meets the requirements.

[0078] In this embodiment, a tooth pitch is formed between adjacent teeth, the ratio of the tooth width of the teeth to the tooth pitch is 1:1.5 to 1:2, and the height of the teeth is ≤2 mm.

[0079] By controlling the ratio of the tooth width to the tooth pitch, it is possible to ensure that the number of teeth is maintained as much as possible while ensuring the milling effect, so that repeated grinding is possible and the processing effect is improved.

[0080] In this embodiment, the plurality of micro-edges are evenly distributed on the cutting edge, the micro-edge height of the micro-edges is 3 μm to 10 μm, and the micro-edge width of the micro-edges is 5 μm to 20 μm.

[0081] The smaller the micro blade size, the better the grinding effect.

[0082] In this embodiment, the rake angle of the front cutting edge is 0-15°, and the clearance angle of the flank cutting edge is 1-10°.

[0083] The tooth rake angle and tool back angle are the dimensions of traditional milling cutters and can be adjusted according to actual conditions.

[0084] In this embodiment, the length direction of each micro groove is perpendicular to the edge line of the corresponding cutting edge.

[0085] The length direction of each micro groove is perpendicular to the edge line of the corresponding cutting edge, so that cutting and grinding can be carried out smoothly during the cutting process.

[0086] This embodiment introduces the grinding head processing characteristics into the positive rake angle milling tool structure on the front cutting edge, increases the number of teeth, and uses laser processing technology to process irregular micro-protrusions on each tooth, which play a role in grinding abrasive particles. The tool has the processing characteristics of combined milling and grinding, achieving high-precision, high-efficiency, and low-damage processing of difficult-to-machine materials. The tool retains the structure of the positive rake angle and clearance angle of the traditional milling cutter teeth, discretizing the sharp cutting edges with high straightness into irregularly distributed micron-scale cutting edges. These tiny cutting edges can play a grinding role during milling. To achieve repeated removal of the same surface, the number of teeth is increased, which can reduce the amount of removal per tooth and increase the number of micro-edges on the tool to play a grinding role. The micro-edges of this tool are small in size and highly random in structure. It is proposed to use laser processing to form micro-edges by optimizing the laser processing parameters and the interaction of the material. Ultimately, high-efficiency, precision, and low-damage processing of high-performance parts made of difficult-to-machine materials is achieved.

[0087] Example 2

[0088] This embodiment discloses a method for manufacturing a multi-tooth micro-edge milling tool according to Example 1. The tool material is typically a high-hardness material, including but not limited to polycrystalline diamond, single crystal diamond, cemented carbide, coated tools, ceramic tools, and cubic boron nitride tools. The machinable materials include hard and brittle metal materials and composite materials.

[0089] Manufacturing method of multi-tooth micro-edge milling tool, such as Figure 8 As shown, the following steps are included:

[0090] Step 1: Processing the outer contour: Grinding, EDM, and laser processing are used to process the bar blank to obtain the outer contour of the bar. In the laser processing method, the laser beam is made tangent to the bar blank so that the local energy of one side of the Gaussian beam acts on the surface of the bar blank.

[0091] Specifically, the outer contour of the bar can be processed by grinding, EDM, laser processing, or a combination thereof. Grinding and EDM are conventional processing methods, while laser processing requires the use of laser turning. The bar is clamped in the laser turning station, and the probe program is called to position the tool. The tool's position coordinates will be directly imported into the machine tool. Subsequently, the nanosecond laser focusing program is called to perform focus positioning. In the laser turning station, the rotating C-axis drives the tool blank to rotate. The focused laser beam is tangent to the tool blank, so that the local energy on one side of the Gaussian beam acts on the tool surface, thereby avoiding excessive material removal due to the concentration of laser energy. This step usually uses a high-energy-density nanosecond laser to achieve efficient contour processing. Depending on the tool material and contour requirements, multiple processing can be performed using different laser processing parameters.

[0092] Step 2: Processing the teeth: Import the tooth model into the machine tool and use the laser beam to process the teeth. The tooth processing parameters are: single pulse energy density is 10J / cm 2 ~50J / cm 2 , pulse overlap rate 90%~98%, scan overlap rate 90%~96%, scan times 1%~50%.

[0093] Specifically, the tooth model is selected and imported into the machine tool, and the highest point and yaw angle of the model are set. To ensure higher processing efficiency, the laser is controlled by a 3D galvanometer to move the path. The light spot is focused on the highest point of the model and the light beam moves to the lower left (end tooth) and lower right (side tooth) respectively. After processing one tooth, the C-axis of the machine tool rotates and continues to process the next tooth until all teeth are processed.

[0094] Step 3: Processing the flank: Import the flank model into the machine tool and use the laser beam to process the flank of each tooth. The flank processing parameters are: single pulse energy density of 10J / cm 2 ~30J / cm 2 , pulse overlap rate 90% to 98%, scan overlap rate 90% to 96%, scan times 1 to 10 times;

[0095] Specifically, the back face model is selected and imported into the machine tool. The highest point and the swing angle of the model are the same as those for the tooth processing. The laser is controlled by the 3D galvanometer to move the path. After processing one tooth, the C axis of the machine tool rotates and continues to process the next tooth until all teeth are processed.

[0096] Step 4: Processing micro-edges: Import the micro-edge model into the machine tool and use the laser beam to process the rake face of each tooth to obtain a micro-edge. The micro-edge processing parameters are: single pulse energy density of 2J / cm 2 ~20J / cm 2 , pulse overlap rate 20% to 60%, scan overlap rate 90% to 96%, and scan times 1 to 20 times.

[0097] Specifically, the micro-edge needs to be perpendicular to the tooth. Therefore, micro-edge machining requires maintaining the beam perpendicular to the tooth. A micro-edge model is imported and positioned on the rake face of the tooth, machining in a direction perpendicular to the tooth. The machine's A-axis deflects, while the galvanometer mirror and focus follow the movement to ensure a constant focal length. Micro-edge machining involves a coordinated mechanical and laser process. After machining one tooth, the machine's C-axis rotates to continue machining the next tooth until all teeth are machined.

[0098] In this embodiment, after step one, the chip breaker is machined first and then step two is performed. The steps of machining the chip breaker include: determining the tool model, importing the chip breaker model into the machine tool, and machining the chip breaker using a laser beam.

[0099] The tool model is used to draw the tool, and the model is imported into the machine tool. The laser processing path is set. The laser machine tool is equipped with a 3D galvanometer. During the processing, the mechanical axis does not move, and the galvanometer controls the movement of the laser path.

[0100] In this embodiment, the morphology of the micro-blade is controlled by adjusting the pulse overlap rate so that the required plane can be obtained according to production needs. When processing the micro-blade,

[0101] The formula for calculating laser energy density is:

[0102] The calculation formula of pulse overlap ratio is:

[0103] In practical applications, different process parameters are usually used for cutting teeth and micro-edge processing. Laser processing mainly depends on the combination of laser energy density and pulse overlap rate. The energy density of a single pulse is determined by the laser power, pulse overlap rate and spot size, while the pulse overlap rate is affected by factors such as spot diameter, scanning speed and repetition frequency. Figure 9 As shown in the figure, different micro-blade morphologies can be processed by adjusting the pulse overlap ratio.

[0104] Laser energy is selected according to different tool materials. The corresponding relationship between tool material and laser energy density is that high hardness material corresponds to high energy density processing, among which single crystal diamond > polycrystalline diamond > ceramic tool > superhard coating > cemented carbide > cubic boron nitride.

[0105] Laser processing is the only choice for the processing of cutter teeth and micro-edges. The processing of micro-edges is achieved by adjusting the laser energy and pulse overlap rate. Compared with traditional milling cutter processing, the use of laser processing to produce this cutting edge greatly reduces cutting forces, reduces sub-surface damage to materials, improves surface quality, and achieves the unity of processing quality and efficiency.

[0106] Experimental example

[0107] To further illustrate the performance of the multi-tooth micro-edge milling tool of the present invention, the following experiments were conducted. The tool is mainly used for precision milling of difficult-to-machine metal materials, hard and brittle materials, and composite materials. The machining parameters include the rotation speed N r , feed speed f v , axial cutting depth a p , radial cutting depth a e , clamp the workpiece on the machine tool, select the tool size according to the workpiece material and processing requirements, taking D6 size tool processing as an example:

[0108] Experimental Example 1

[0109] Tool material / number of teeth: carbide, coated tool / 40 blades;

[0110] Processed materials: amorphous alloy / high temperature alloy (metal material),

[0111] Processing parameters: rotation speed Nr: 10000-20000r / min, feed speed fv: 800~1500mm / min, axial cutting depth ap: 0.05~0.3mm, radial cutting depth ae: 0.003~0.12mm.

[0112] Processing effect: The minimum surface roughness of the final processed amorphous alloy is 0.1μm, which can achieve a mirror effect.

[0113] Experimental Example 2

[0114] Tool material / number of teeth: single crystal diamond, polycrystalline diamond / 30 blades;

[0115] Processed material: graphite (hard and brittle material),

[0116] Processing parameters: speed N r : 15000-26000r / min, feed speed f v:1000~12000mm / min, axial cutting depth a p : 0.05~0.3mm, radial cutting depth a e :0.002~0.1mm.

[0117] Processing effect: The minimum surface roughness of graphite is 15nm.

[0118] Experimental Example 3

[0119] Tool material / number of teeth: single crystal diamond, polycrystalline diamond / 40 blades;

[0120] Processed materials: sapphire / glass (hard and brittle materials),

[0121] Processing parameters: speed N r : 15000-26000r / min, feed speed f v :1000~12000mm / min, axial cutting depth a p : 0.05~0.3mm, radial cutting depth a e :0.002~0.1mm.

[0122] Processing effect: The minimum surface roughness of glass is 80nm, and the minimum surface roughness of sapphire is 43nm.

[0123] Experimental Example 4

[0124] Tool material / number of teeth: polycrystalline diamond / 30 blades;

[0125] Processed materials: Silicon carbide ceramics (hard and brittle materials),

[0126] Processing parameters: speed N r : 15000-26000r / min, feed speed f v :1000~12000mm / min, axial cutting depth a p : 0.05~0.3mm, radial cutting depth a e :0.002~0.1mm.

[0127] Processing effect: The minimum surface roughness of silicon carbide is 18nm.

[0128] Experimental Example 5

[0129] Tool material / number of teeth: polycrystalline diamond, ceramic / 30 blades;

[0130] Processed materials: carbon fiber composite materials (composite materials),

[0131] Processing parameters: speed N r: 15000-26000r / min, feed speed f v :1500~2000mm / min, axial cutting depth a p : 0.05~0.3mm, radial cutting depth a e :0.003~0.08mm.

[0132] Processing effect: The minimum surface roughness of silicon carbide is 18nm.

[0133] Experimental Example 6

[0134] Tool material / number of teeth: polycrystalline diamond / 40 blades;

[0135] Processed materials: honeycomb composite materials (composite materials),

[0136] Processing parameters: speed N r : 15000-26000r / min, feed speed f v :1500~2000mm / min, axial cutting depth a p : 0.05~0.3mm, radial cutting depth a e :0.003~0.08mm.

[0137] Processing effect: The minimum surface roughness of silicon carbide is 18nm.

[0138] In order to further illustrate the effect of the processing method of the present invention, the following experiments were conducted:

[0139] Laser processing PCD micro-blade tool experiment

[0140] Experiment 1: Laser processing PCD micro-blade tool experiment

[0141] Tool processing process such as Figure 12 As shown in Table 1,

[0142] Table 1 Optimal process parameters for laser processing of PCD micro-edge end mills

[0143]

[0144] The profile of the PCD bar after laser turning is shown in Figure 13(a). The surface roughness after roughing is Sa = 6.42 μm. After finishing, the bar diameter is 6 mm, with controllable dimensional accuracy and surface roughness, and a surface roughness of Sa = 1.01 μm. The PCD micro-edge end mill after laser milling has 40 teeth (Figure 13(b)) on a macro scale, with micro-edges distributed across the teeth.

[0145] The geometric characteristics of the teeth and micro-teeth of the manufactured PCD micro-edge end mill were scanned and measured using a 3D measurement system. The results are shown in Figures 13(c) and (d). The parameters are: tool rake angle γ = 6.2°, back angle α = 12.3°, width W = 0.21mm, pitch P = 0.24mm, and ratio of P to W r = 1.14, all of which meet the requirements. Figure 18 The tool design requirements in the tool design. The measured irregular micro-edge feature dimensions, namely arc height h and width w, are also within the control range of laser processing parameters (13(c))

[0146] Experiment 2: Comparison of micro-blade cutting performance with traditional cutting tools and grinding heads

[0147] The cutting performance of PCD micro-edge tools was evaluated by comparing the chip formation, cutting force, cutting specific energy, surface roughness, and subsurface damage of three 6mm diameter PCD micro-edge end mills, a traditional 4-edge solder-type PCD milling cutter, and a 1000# diamond grinding head (Sanwakema Co., Ltd., Japan). The tool life and wear failure modes of micro-edge tools and their correlation with cutting parameters were analyzed.

[0148] Figure 14 (a) and (b) show the workpiece material and tool used in the experiment, respectively. Figure 14 (c) shows the aluminosilicate glass processing test equipment. All tests were carried out on the UHB-400CC precision machining center. Based on the optimal cutting parameters of the micro-edge tool obtained by MATLAB simulation in Chapter 2, this study selected the tool speed N r =8000, 14000, 20000 and 26000r / min (corresponding to cutting speed V c 150, 263, 376 and 489m / min), feed speed f v =800, 1300, 1800 and 2300 mm / min (it should be noted that since the grinding head cannot convert the feed per tooth, the feed speed is used as the cutting parameter in this study), the axial cutting depth a p =0.003, 0.005, 0.007 and 0.009 mm, radial cutting depth a e = 0.05, 0.13, 0.21 and 0.29 mm. All machining processes were carried out in the ROOB COOL cutting fluid environment. Cutting tests were performed at least three times under each parameter.

[0149] There are three different chip forms. The PCD micro-edge milling cutter forms powder and strip chips, such as Figure 15 (b) is consistent with the simulation results ( Figure 13-17 The powdered chips are similar to the chips produced by diamond grinding ( Figure 15 (c)) shows that the micro-blade and the grinding head have similar glass removal mechanisms. By promoting the intersection of transverse cracks, the workpiece material is removed in the form of tiny pits, squeezed and crushed; the stacked strip-shaped chips have a smooth shear surface and plastic flow marks, indicating that under the repeated cutting action of the irregular micro-blade, the thickness of the undeformed chips of each subsequent micro-blade cutting is reduced, resulting in micro-plastic shear removal of the workpiece material; therefore, the glass material exhibits the typical milling (forming strip-shaped chips) and grinding (forming powder debris) composite deformation removal characteristics during PCD micro-blade milling.

[0150] Figure 16 The variation of specific cutting force energy with material removal rate when PCD micro-edge milling cutter, traditional 4-edge PCD milling cutter and diamond grinding head are given. s Both decrease with increasing material removal rate (MRR). In addition, due to the unique stress state of the micro-blade arc teeth, the cutting forces in the XY horizontal direction are partially offset. It can be seen that at any given material removal rate (MRR), the specific cutting energy of the PCD micro-blade milling cutter is significantly lower than that of the 4-blade PCD tool and is basically the same as that of the diamond grinding head, which further demonstrates that the PCD micro-blade milling cutter has the characteristics of grinding removal.

[0151] Figure 17 The surface roughness (Ra) achieved by machining glass using a PCD micro-edge milling cutter, a conventional four-flute PCD milling cutter, and a diamond grinding head at the same material removal rate (MRR) was compared. Generally, as the material removal rate increases, the degree of surface deformation increases, resulting in an upward trend in surface roughness (Ra) achieved by the three tools with increasing MRR. For any given MRR, the PCD micro-edge milling cutter achieved the lowest surface roughness (Ra = 0.08–0.42 μm), significantly superior to the diamond grinding head (Ra = 0.42–0.89 μm) and the conventional four-flute PCD milling cutter (Ra = 1.78–1.99 μm).

[0152] Figure 18 The cross-sectional micromorphology of the machined surface obtained by machining glass with three tools is shown. It can be seen that when machining glass with a conventional 4-edge PCD milling cutter, large chips separated from the workpiece in the form of cleavage fracture lead to the dual long-distance extension of subsurface transverse and longitudinal cracks, as shown in Figure (a). The extension and interlacing of transverse cracks form large-scale chipping, and further longitudinal crack extension leads to the maximum damage depth H inside the workpiece. d As high as 22.93μm. In contrast, the subsurface damage produced by diamond grinding heads and micro-blade tools is mainly manifested as tiny pits formed by surface material fragmentation caused by transverse crack propagation, such as Figure 18 (b) and (c); where the maximum pit depth h in the workpiece r9.41μm and 4.13μm respectively.

[0153] Experiment 3: Processing Silicon Carbide and Sapphire

[0154] Figure 19 Figure (a) shows the surface roughness achieved by machining SiC using three different tools. As shown in Figure (b), at the same material removal rate, the PCD micro-edge milling cutter designed and manufactured in this work achieves a surface roughness of only 18 nm when machining SiC. This represents an improvement of over 80% compared to the machining quality of renowned diamond grinding heads, achieving a mirror finish.

[0155] Figure 20 (a) Comparison of the surface roughness obtained by three tools under the same conditions when machining sapphire surfaces. PCD micro-edge milling cutters are also suitable for machining sapphire surfaces. Their surface roughness is only 43nm, which is more than 70% higher than the machining quality of well-known diamond grinding heads at home and abroad. Figure 20 (b) shown.

[0156] As shown in the comparative experiments conducted on glass processing using PCD micro-edge milling tools, conventional milling cutters, and diamond grinding heads, the PCD micro-edge milling cutter achieved a specific cutting energy comparable to that of a 1000# diamond grinding head and over 1.5 times lower than that of a conventional straight-edge PCD milling cutter. Due to the unique stress-bearing state of the micro-edge arc teeth of the micro-edge milling cutter, which partially offsets the horizontal cutting forces, the PCD micro-edge milling cutter's specific cutting energy is significantly lower than that of a straight-edge PCD milling cutter and is essentially equivalent to that of a diamond grinding head at any given material removal rate. The milling-grinding hybrid processing characteristics of the PCD micro-edge milling cutter result in surface roughness and subsurface damage levels that are 2–5 times and 2 times lower than those of a 1000# diamond grinding head, and 4–11 times and 5.5 times lower than those of a conventional four-edge PCD milling cutter, respectively, at the same cutting depth. It shows that polycrystalline diamond micro-blade milling cutters have lower processing damage and higher surface quality; the PCD micro-blade milling tools are also compared with diamond grinding heads to process silicon carbide and sapphire. The surface roughness obtained by polycrystalline diamond micro-blade tools in processing silicon carbide and sapphire is 80% and 70% lower respectively than that of diamond grinding head products of well-known domestic and foreign companies, and mirror processing of silicon carbide materials can be achieved.

[0157] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of this application.

[0158] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A multi-tooth micro-edge milling tool, characterized in that: include Handle, A cutter head body, the cutter head body being fixedly connected to one end of the handle; A plurality of blade teeth are provided on the outer side of the blade head body, and each blade tooth extends from the top end of the blade head body away from the blade handle to the rear end of the blade head body close to the blade handle; Each tooth includes a rake face, a flank face and a cutting edge. The cutting edge is provided with a number of continuously distributed micro-sized raised micro-edges. The micro-edges form an arc-shaped serrated structure, and the micro-edges extend to the rake face and form micro grooves on the rake face.

2. The multi-tooth micro-edge milling tool according to claim 1, characterized in that: A tooth pitch is formed between adjacent teeth, the ratio of the tooth width of the teeth to the tooth pitch is 1:1.5 to 1:2, and the height of the teeth is ≤2mm.

3. The multi-tooth micro-edge milling tool according to claim 1, characterized in that: A plurality of micro blades are distributed on the cutting edge in a continuous manner, the micro blade height of the micro blade is 3 μm to 10 μm, and the micro blade width of the micro blade is 5 μm to 20 μm.

4. The multi-tooth micro-edge milling tool according to claim 1, characterized in that: The rake angle of the front cutting edge is 0° to 15°, and the clearance angle of the flank cutting edge is 1° to 10°.

5. The multi-tooth micro-edge milling tool according to claim 1, characterized in that: The length direction of each micro groove is perpendicular to the edge line of the corresponding cutting edge.

6. The method for manufacturing a multi-tooth micro-edge milling tool according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1: Processing the outer contour: Grinding, EDM, and laser processing are used to process the bar blank to obtain the outer contour of the bar. In the laser processing method, the laser beam is made tangent to the bar blank so that the local energy of one side of the Gaussian beam acts on the surface of the bar blank. Step 2: Processing the teeth: Import the tooth model into the machine tool and use the laser beam to process the teeth. The tooth processing parameters are: single pulse energy density is 10J / cm 2 ~50J / cm 2 , pulse overlap rate 90% to 98%, scan overlap rate 90% to 96%, scan times 1 to 50 times; Step 3: Processing the flank: Import the flank model into the machine tool and use the laser beam to process the flank of each tooth. The flank processing parameters are: single pulse energy density of 10J / cm 2 ~30J / cm 2 , pulse overlap rate 90% to 98%, scan overlap rate 90% to 96%, scan times 1 to 10 times; Step 4: Processing micro-edges: Import the micro-edge model into the machine tool and use the laser beam to process the rake face of each tooth to obtain a micro-edge. The micro-edge processing parameters are: single pulse energy density of 2J / cm 2 ~20J / cm 2 , pulse overlap rate 20% to 60%, scan overlap rate 90% to 96%, and scan times 1 to 20 times.

7. The method for manufacturing a multi-tooth micro-edge milling tool according to claim 6, characterized in that: After step one, the chip breaker is machined before step two. The steps of machining the chip breaker include: determining the tool model, importing the chip breaker model into the machine tool, and machining the chip breaker using a laser beam.

8. The method for manufacturing a multi-tooth micro-edge milling tool according to claim 6, characterized in that: In step 4, the micro-blade morphology is adjusted by controlling the single pulse energy density and pulse overlap rate.

9. Use of the multi-tooth micro-edge milling tool according to any one of claims 1 to 5, characterized in that: The tool is applied to precision milling, and the speed N of the tool is adjusted. r , feed speed f v , axial cutting depth a p and radial cutting depth a e .

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