A cross-structured milling PCD composite tool

Abstract

A cross-structured milling PCD composite tool includes a tool body. A cutting part is provided at the front end of the tool body, and a clamping part is provided at the rear end. The cutting part includes two pairs of chip flutes arranged axially in a cross pattern. PCD blades are fixed in the chip flutes. A main coolant hole is provided in the tool body, and an internal cooling hole is provided in the chip flutes. The internal cooling hole is communicated with the main coolant hole. The product of the present invention can machine holes and both the front and back sides of the holes at one time, eliminating the need for special tools for machining holes, saving the number of tools and costs, and improving the machining efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of machining tools, and particularly to a cross-structured milling PCD composite tool. Background Art

[0002] High-speed cutting technology is a machining technology that is currently being vigorously promoted in the manufacturing industry. It is green, environmentally friendly, economical, has high machining efficiency, and stable quality. Traditional high-speed steel and cemented carbide tool materials have low hardness and poor wear resistance, and are unable to undertake high-speed cutting tasks. Therefore, PCD (Polycrystalline diamond) tools have emerged as the times require. PCD materials are increasingly used in the non-ferrous metal processing industry due to their high hardness, wear resistance, and low coefficient of thermal expansion, especially in the automotive manufacturing industry, aerospace manufacturing industry, and electronic product manufacturing industry. PCD materials are ideal tool materials for machining non-ferrous metals and their alloys. Importantly, PCD materials can undertake high-speed cutting tasks. The machining and forming of the stepped surface and holes inside the automotive engine gearbox housing have always been a difficult point in the machining and manufacturing process of the automotive production. The low efficiency and short tool life of ordinary tools and machining methods are real problems faced by the automotive manufacturing industry. Summary of the Invention

[0003] In view of this, the present invention aims to provide a cross-structured milling PCD composite tool with high machining efficiency, stable machining workpiece quality, and long tool life. To achieve the above object, the technical solution of the present invention is realized as follows:

[0004] A cross-structured milling PCD composite tool includes a tool body. A cutting part is provided at the front end of the tool body, and a clamping part is provided at the rear end. The cutting part includes two pairs of chip flutes arranged axially in a cross pattern. PCD inserts are fixed in the chip flutes. A main coolant hole is provided in the tool body, and an internal coolant hole is provided in the chip flutes. The internal coolant hole is communicated with the main coolant hole.

[0005] In some embodiments, the chip flutes include A-type chip flutes, B-type chip flutes, C-type chip flutes, and D-type chip flutes. The A-type chip flutes are located at the forefront of the cutting part and form an angle of 5° with the positive axis. The B-type chip flutes are closely adjacent to the A-type chip flutes and form an angle of 25° with the A-type chip flutes in the circumferential direction and an angle of -5° with the negative axis. The C-type chip flutes are arranged after the B-type chip flutes and are symmetric with the B-type chip flutes, forming an angle of 5° with the positive axis. The D-type chip flutes are located at the rear end of the cutting part and form an angle of 25° with the C-type chip flutes in the circumferential direction and an angle of -5° with the negative axis.

[0006] In some embodiments, there are four A-type chip flutes, B-type chip flutes, C-type chip flutes, and D-type chip flutes evenly arranged along the circumferential direction of the cutting part. PCD inserts are fixed in each of the A-type chip flutes, B-type chip flutes, C-type chip flutes, and D-type chip flutes.

[0007] In some embodiments, internal coolant holes are provided in each of the chip flutes of type A, type B, type C, and type D, with the openings facing the PCD cutting blade.

[0008] In some embodiments, the PCD cutting blade is welded and fixed in the chip flute.

[0009] In some embodiments, the material of the cutting part includes high-speed tool steel.

[0010] In some embodiments, the chip flute is arc-shaped.

[0011] In some embodiments, the clamping part and the cutting part are connected by an arc-shaped curved surface.

[0012] In some embodiments, a blade groove is provided in the chip flute, and the PCD cutting blade is welded in the blade groove.

[0013] In some embodiments, the shape of the blade groove is an arc-connected straight line type.

[0014] Compared with the prior art, the cross-structured milling PCD composite tool of the present invention has the following advantages:

[0015] This cross-arrangement design structure of the chip flutes of the tool body enables a large chip evacuation space for the tool. The chips can be discharged in time and smoothly, without scratching the workpiece and causing unqualified machining surface quality. Moreover, during the cutting process, the cutting edges do not affect each other. The blades for machining different positions are combined together without generating cutting resonance, having good shock resistance. This design structure also maximally ensures the machining rigidity of the tool, and the tool body provides sufficient cutting support for the blade. The product of the present invention can machine a hole and both the front and back sides of the hole at one time, eliminating the need for a dedicated tool for machining the hole, saving the number of tools and costs, and improving the machining efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0017] Figure 1 is a schematic structural diagram of a cross-structured milling PCD composite tool of the present invention.

[0018] Figure 2 is a front view of a cross-structured milling PCD composite tool of the present invention.

[0019] Figure 3 is a sectional view of the cutting part of a cross-structured milling PCD composite tool of the present invention.

[0020] Figure 4Schematic diagram of the axial angle of the chip flute of a cross-structured milling PCD composite tool according to the present invention Figure 1 。

[0021] Figure 5 Schematic diagram of the circumferential angle of the chip flute of a cross-structured milling PCD composite tool according to the present invention Figure 1 。

[0022] Figure 6 Schematic diagram of the circumferential angle of the chip flute of a cross-structured milling PCD composite tool according to the present invention Figure 2 。

[0023] Figure 7 Schematic diagram of the axial angle of the chip flute of a cross-structured milling PCD composite tool according to the present invention Figure 2 。

[0024] Figure 8 Schematic diagram of the part of the workpiece machined by a cross-structured milling PCD composite tool according to the present invention.

[0025] Figure 9 Schematic illustration of the part machining of a cross-structured milling PCD composite tool according to the present invention Figure 1 。

[0026] Figure 10 Schematic illustration of the part machining of a cross-structured milling PCD composite tool according to the present invention Figure 2 。

[0027] Description of reference numerals:

[0028] 1 - Cutting part, 2 - Clamping part, 10 - Chip flute, 101 - PCD blade, 102 - Internal coolant hole; 103 - Plug, 104 - Main coolant hole. Detailed implementation manners

[0029] It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments may be combined with each other.

[0030] Next, the technical solutions of the present invention will be clearly and completely described with reference to the accompanying drawings and in combination with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present invention without making creative efforts shall fall within the protection scope of the present invention.

[0031] Next, refer to Figures 1 to 10 and describe the cross-structured milling PCD composite tool of the embodiments of the present invention in combination with the embodiments.

[0032] A cross-structured milling PCD composite tool includes a tool body. A cutting part 1 is provided at the front end of the tool body, and a clamping part 2 is provided at the rear end. The cutting part 1 includes two pairs of chip flutes 10 arranged axially in a cross pattern. PCD inserts 101 are fixed in the chip flutes 10. A main coolant hole 104 is provided in the tool body, and an internal coolant hole 102 is provided in the chip flutes 10. The internal coolant hole 102 communicates with the main coolant hole 104.

[0033] The material of the cutting part 1 is high-speed tool steel, and the type of the clamping part 2 is selected according to the machine tool interface, such as types like HSK tool holder, BT tool holder, SK tool holder, etc.

[0034] In this embodiment, the HSK tool holder is taken as an example for elaboration, and its tool holder form can be flexibly designed into other forms such as the BT tool holder type or the SK tool holder, etc. Refer to Figure 1 , the present invention provides a cross-structured milling PCD composite tool, including a tool holder clamping part 2 and a cutting part 1. The cutting part 1 is located at the front end of the tool holder clamping part 2. In this example, the tool holder type is HSK-A63. The tool holder clamping part 2 is composed of a hollow conical surface at the clamping end and a tool change slot, and is connected to the cutting part 1 through an arc surface. The design of the arc surface enhances the rigidity of the tool during machining, avoids stress concentration, and improves the machining stability of the workpiece. A main coolant hole 104 communicating with the cutting part is provided along the core of the tool holder clamping part to convey coolant.

[0035] Combined with Figure 2 and Figure 3 , the cutting part includes structures such as PCD inserts 101, type A chip flutes, type B chip flutes, type C chip flutes, type D chip flutes, internal coolant holes 102, end plugs 103 for the coolant hole passage, and the main coolant hole 104, etc. Among them, the aperture of the main coolant hole 104 at the end connected to the tool holder is slightly larger than the aperture of the main coolant hole 104 at the end connected to the cutting edge. The sum of the cross-sectional areas of all the internal coolant holes 102 shall not be greater than the cross-sectional area of the main coolant hole 104, so as to ensure that the coolant does not relieve pressure and meet the water pressure value required by the machine tool.

[0036] Combined with Figure 4 , Figure 5 , Figure 6 and Figure 7, the A-type chip groove of the cutting part 1 is at the very front end of the tool. It has a positive axial angle of 5°, with 4 chip grooves evenly distributed along the circumference, spaced 90° apart from each other. Each chip groove is inlay-welded with a PCD blade in sequence; the B-type chip groove is right after the A-type chip groove and forms an angle of 25° with the A-type chip groove circumferentially. It has a negative axial angle of -5°, with 4 chip grooves evenly distributed along the circumference, spaced 90° apart from each other. Each chip groove is inlay-welded with a PCD blade in sequence; the C-type chip groove is next to the B-type chip groove and is symmetrically arranged with the B-type chip groove at an angle. It has a positive axial angle of 5°, with 4 chip grooves evenly distributed along the circumference, spaced 90° apart from each other. Each chip groove is inlay-welded with a PCD blade in sequence; the D-type chip groove is at the lower end of the cutting part and forms an angle of 25° with the C-type chip groove circumferentially. It has a negative axial angle of -5°, with 4 chip grooves evenly distributed along the circumference, spaced 90° apart from each other. Each chip groove is inlay-welded with a PCD blade in sequence. The cross structure of the chip grooves increases the chip-holding space, making the chip removal smooth during the machining process without residue; moreover, it ensures the support rigidity of the tool body. During the cutting process of the PCD blade, the back support of the tool body has high strength, stiffness, and stability. Such a design structure allows each cutting edge to exert its best machining advantage and is not easily prone to chatter due to resonance.

[0037] The PCD blade 101 of the cutting part is inlay-welded in the blade groove provided in each chip groove 10 by brazing technology. The blade groove is designed as an arc-connected straight line type, increasing the welding strength of the blade. The PCD blade 101 is firmly inlay-welded on the tool body along the axial direction of the chip groove 10, and the various types of chip grooves do not affect each other. Therefore, the PCD blade 101 can be designed with a high center or a low center and different axial angles according to its cutting working conditions. The PCD blades inlaid in the A-type chip groove, B-type chip groove, and C-type chip groove are designed with a low center, making the tool cutting sharp and improving the machining efficiency, fully meeting the machining requirements of modern high-speed cutting processes; the PCD blade inlaid in the D-type chip groove is designed with a high center, and a cylindrical edge band is designed on the cutting edge of the PCD blade to increase its wear resistance, improve the tool service life, and optimize the surface quality of the machined workpiece inner hole.

[0038] The internal coolant hole 102 of the cutting part is arranged in the chip groove 10 below each PCD blade 101. The mouth of the internal coolant hole 102 is aligned with the cutting edge of the PCD blade 101, allowing the coolant to flow through the rake face of the PCD blade 101, reducing the blade machining temperature, slowing down the machining wear of the blade, thereby extending the tool service life and greatly reducing the tool cost of component machining.

[0039] Combined Figure 8 、 Figure 9 and Figure 10 , describe the machining process of the invention product. The rotating tool positions and enters the machined hole with the hole center as the reference, quickly enters the machined hole, and stops at an appropriate position, such as Figure 9As shown. At this time, interpolation milling is used to machine the part to be machined (the planes on both sides of the hole), machining the planes on both sides of the hole simultaneously, as Figure 10 shown. Although the planes on both sides of the hole are machined simultaneously and the cutting area is large, the product of this invention patent adopts a special angle structure design, which can disperse the cutting resistance, avoid the concentration of resistance, and enables the product of this invention to easily complete the machining of the workpiece.

[0040] The shank clamping part 2 and the cutting part 1 are connected by a fillet curve transition to avoid possible stress concentration of the tool and also present the ergonomic beauty of the tool design.

[0041] Compared with the prior art, the cross-structured milling PCD composite tool of this invention has the following advantages:

[0042] This invention provides a special structural design scheme for machining the inner stepped surface and hole of an automotive engine gearbox housing, making the product of this patent have high machining efficiency, stable machining workpiece quality, and long tool life. The groove types of this composite formed PCD tool are arranged in a crosswise and opposite direction, with a unique structure, which can disperse the chips, prevent chip jamming and workpiece scratching, have excellent machining quality, high metal removal rate in high-speed cutting machining, greatly improve the machining efficiency, and save the manufacturing cost of enterprises.

[0043] The unique design structure of this invention enables each cutting edge of the tool to be independent of each other during the machining process, avoiding the phenomenon of tool chatter caused by resonance; at the same time, the chip flutes are arranged in a crosswise pattern, with a large chip evacuation space and no chip jamming; different positive and negative axial angles are adopted to enhance the machining rigidity and stability of the tool. The product of this invention can machine the hole and the front and back surfaces of the hole at one time, eliminating the need for a special tool for machining the hole, saving the number and cost of tools, and improving the efficiency.

[0044] The groove type design of this invention is streamlined, with a compact structure, large space, and good rigidity. The chip flutes are alternately staggered, reducing the stress intensity on the PCD blade during machining, eliminating the phenomenon of machining chatter caused by resonance, improving the machining quality and efficiency of the workpiece surface, prolonging the tool life, and meeting the requirements of high-speed cutting machining.

[0045] In the description of this invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing this invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation to the protected content of this invention.

[0046] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, the meaning of "a plurality" is at least two, such as two, three, etc., unless otherwise specifically defined.

[0047] In the present invention, unless otherwise clearly defined and limited, the terms such as "mounted", "connected", "coupled", "fixed", etc. shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection, an electrical connection or a connection capable of mutual communication; it may be directly connected, or indirectly connected through an intermediate medium, and it may be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0048] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A cross structure milling PCD composite tool, It is characterized in that The invention comprises a tool body, wherein the front end of the tool body is provided with a cutting portion (1), and the rear end is provided with a holding portion (2), the cutting portion (1) comprises two pairs of chip grooves (10) arranged crosswise in the axial direction, a PCD blade (101) is fixed in the chip groove (10), a main coolant hole (104) is provided in the tool body, an inner coolant hole (102) is provided in the chip groove (10), the inner coolant hole (102) is communicated with the main coolant hole (104), and the chip groove (10) comprises A-type chip grooves, B-type chip grooves, C-type chip grooves and D-type chip grooves, wherein the A-type chip groove is located at the front end of the cutting part (1) and is at an angle of 5° to the positive axis; the B-type chip groove is immediately behind the A-type chip groove and is at an angle of 25° to the A-type chip groove circumferentially and -5° to the negative axis; the C-type chip groove is arranged behind the B-type chip groove and is symmetrical with the B-type chip groove and is at an angle of 5° to the positive axis; the D-type chip groove is located at the rear end of the cutting part (1) and is at an angle of 25° to the C-type chip groove circumferentially and -5° to the negative axis.

2. The cross structure milling PCD composite tool according to claim 1, It is characterized in that The A-type chip groove, B-type chip groove, C-type chip groove and D-type chip groove are four evenly arranged along the circumference of the cutting part (1), and a PCD blade (101) is fixed in each of the A-type chip groove, B-type chip groove, C-type chip groove and D-type chip groove.

3. The cross structure milling PCD composite tool according to claim 2, It is characterized in that Each of the A-type chip groove, the B-type chip groove, the C-type chip groove and the D-type chip groove is provided with an internal cooling hole (102) opening toward the PCD cutting blade (101).

4. The cross structure milling PCD composite tool according to claim 3, It is characterized in that The PCD blade (101) is welded and fixed in the chip groove (10).

5. The cross structure milling PCD composite tool according to claim 4, It is characterized in that The material of the cutting part (1) includes high-speed tool steel.

6. The cross structure milling PCD composite tool according to claim 3, It is characterized in that The chip removal groove (10) is in an arc shape.

7. The cross structure milling PCD composite tool according to claim 3, It is characterized in that The supporting portion (2) is connected to the cutting portion (1) via an arc surface.

8. The cross structure milling PCD composite tool according to claim 4, It is characterized in that A blade groove is arranged in the chip removal groove (10), and the PCD blade is welded in the blade groove.

9. The cross structure milling PCD composite tool according to claim 8, It is characterized in that The blade groove is in the shape of a circular arc connected to a straight line.

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