Method for machining a diamond tool with a helix angle and the tool

Abstract

A method for machining a diamond tool with a helix angle, comprising pre-forming a notch on a rod-shaped substrate material, the notch extending along the axial direction of the substrate material to form a first groove body, the first groove body at least including a first groove bottom surface; then, attaching a diamond composite sheet to the first groove bottom surface so that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material; finally, using laser or electro-etching to machine the first groove body with the attached diamond composite sheet as a whole to form a formed groove body and a rake face that meet the composite processing requirements, the formed rake face is spiral and has a helix angle of 10° to 55°. The diamond tool prepared by the method of the present invention can reduce the machining resistance by more than 30% compared with a common PCD tool.

Description

Technical Field

[0001] The present invention relates to a forming method of a material, and particularly to a method for processing a diamond material to form a helix angle, so as to be applied to the manufacture of tools for precision machining. Background Art

[0002] A diamond tool is a machining cutting tool made by installing a diamond blade or a diamond coating on a substrate material (such as cemented carbide). It has extremely high hardness and wear resistance, a low friction coefficient, a high elastic modulus, high thermal conductivity, a low coefficient of thermal expansion, and a small affinity with non-ferrous metals, and is used for the precision machining of non-metallic brittle materials such as graphite, highly wear-resistant materials, composite materials, high-silicon aluminum alloy, and other ductile non-ferrous metal materials.

[0003] Taking the machining of aluminum alloy materials as an example, improving the edge sharpness of diamond tools is beneficial to improving machining efficiency and tool life. The main technical means to improve sharpness is to increase the rake angle and clearance angle of the cutting edge, and to reduce the nose radius of the tool tip. Increasing the helix angle is a common technical method to achieve the purpose of increasing the rake angle.

[0004] The chip-mounted PCD tool is a currently most mainstream machining tool. It uses the edge inclination angle instead of the helix angle to obtain an angle with a helix degree of 5 to 7 degrees, and can only be used for short tools. The disadvantage is that it is difficult to manufacture diamond tools with a large helix angle (more than 10 degrees). The diamond-coated tool is another common machining tool, which is manufactured by first forming a helix angle on a cemented carbide substrate and then applying a diamond coating. Although the obtained helix angle is not limited, it will cause the nose radius of the edge to be too large, reducing the sharpness of the edge, and the manufacturing technology is not yet mature, and the yield is relatively low.

[0005] In order to solve the above technical problems, the third solution is to process the PCD material into a spiral shape as a whole. Although it overcomes the above technical defects, the manufacturing cost is too high and the price is too high, making it difficult to be widely used. Summary of the Invention

[0006] One object of the present invention is to provide a method for machining a diamond tool with a helix angle, so as to reduce the machining resistance of the diamond tool in metal machining cutting.

[0007] Another object of the present invention is to provide a method for machining a diamond tool with a helix angle, so that the rake angle of the entire edge remains consistent and partial edge damage occurs in advance.

[0008] Another object of the present invention is to provide a diamond tool with a large helix angle, which can effectively reduce the machining resistance of the diamond tool in metal machining cutting and improve machining efficiency.

[0009] Another object of the present invention is to provide a diamond tool with a large helix angle, which can perform precision machining on metal materials and improve the service life of the tool.

[0010] Lasers generally use pulsed or ultrafast lasers, with pulse widths ranging from 100 microseconds to 100 femtoseconds. During processing, energy is transferred to the lattice of the material in the form of heat or light energy within the pulse period, causing material vaporization or etching and achieving the purpose of removing the material.

[0011] Metals are composed of metallic elements. Most of them are excellent conductors of electricity and heat, have ductility, relatively high density, and high melting point. In Chinese characters, the names of these elements mostly have the radical "gold".

[0012] Non-ferrous alloys belong to metals, usually referring to all metals except iron, chromium, and manganese, such as: aluminum, magnesium, potassium, sodium, calcium, strontium, barium, copper, lead, zinc, tin, cobalt, nickel, antimony, mercury, cadmium, bismuth, gold, silver, platinum, ruthenium, rhodium, palladium, osmium, iridium, beryllium, lithium, rubidium, cesium, titanium, zirconium, hafnium, vanadium, niobium, tantalum, tungsten, molybdenum, gallium, indium, thallium, germanium, rhenium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, yttrium, thorium, and non-ferrous alloys, such as: but not limited to aluminum alloys, copper alloys, magnesium alloys, nickel alloys, tin alloys, tantalum alloys, titanium alloys, zinc alloys, molybdenum alloys, and zirconium alloys, etc. These substances are used alone or in combination in the present invention and are the direct objects of the technical solution of the present invention.

[0013] Diamond is a mineral composed of carbon elements, an allotrope of graphite, with the chemical formula C, and is also the original body of common diamonds. Graphite can form artificial diamonds under high temperature and high pressure. The hardness of diamond has directionality, the hardness of the octahedral crystal face is greater than that of the rhombic dodecahedral crystal face, and the hardness of the rhombic dodecahedral crystal face is greater than that of the hexahedral crystal face.

[0014] Diamond composite sheets, also known as polycrystalline diamond composite sheets, are sintered from diamond micropowders and cemented carbide substrates under ultra-high pressure and high temperature conditions, including a cemented carbide layer and a diamond layer. They have both the high hardness, high wear resistance, and thermal conductivity of diamond, and the strength and impact toughness of cemented carbide, and are ideal materials for manufacturing the cutting edges of cutting tools. Generally, they have a mirror-polished upper surface to facilitate the production of tools.

[0015] A method for machining a diamond tool with a helix angle includes:

[0016] A notch is pre-formed on a rod-shaped substrate material (such as cemented carbide). The notch extends along the axial direction of the substrate material to form a first groove body, and the first groove body at least includes a first groove bottom surface. Then, a diamond composite sheet is bonded to the first groove bottom surface, such that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material, forming an angle of 5° to 45° with the axis of the substrate material, preferably 5° to 10°. Finally, the first groove body with the diamond composite sheet bonded thereto as a whole is processed by laser etching or electro-etching to form a formed groove body and a rake face that meet the composite processing requirements. The formed rake face is spiral, with a spiral angle of 10° to 55°, preferably 15° to 25°, and the rake angle of the entire cutting edge is consistent.

[0017] To facilitate the bonding of the diamond composite sheet to the first groove bottom surface, a flat surface is preferably selected.

[0018] To manufacture a spiral rake face, the thickness of the diamond layer of the diamond composite sheet applicable to the method of the present invention is greater than 1.0 mm.

[0019] The present invention provides a diamond tool, the diamond cutting edge of which has a spiral angle of 15° to 25°, effectively reducing the machining resistance during the machining of metal by the diamond tool, improving the machining efficiency, performing precision machining on metal materials, and improving the machining efficiency.

[0020] The beneficial effects achieved by the technical solution of the present invention:

[0021] With the technical means provided by the present invention, that is, only by arranging the diamond composite sheet inclined to the axis of the substrate material, a tool without a formed spiral angle is used for the milling of aluminum alloy. After testing, it is shown that compared with a common PCD tool, the machining resistance can be reduced by about 15%.

[0022] The diamond tool manufactured by the solution provided by the present invention has a spiral rake face with a spiral angle of 10° to 55°. Using this tool for the milling of aluminum alloy, after testing, it is shown that compared with a common PCD tool (such as a straight groove tool), the machining resistance can be reduced by more than 30%.

[0023] Since the tool manufactured by the method provided by the present invention has a consistent rake angle throughout the entire cutting edge, it can effectively reduce the occurrence of premature damage of some cutting edges, improve the service life of the tool, and compared with a tool made of a three-dimensional sintered PCD material, the material cost is significantly reduced (more than 3 times). Description of the Drawings

[0024] Figure 1 Schematic diagram of an embodiment of the first groove body with a diamond composite sheet bonded to the substrate material;

[0025] Figure 2Schematic diagram of an embodiment of a formed cutting tool made by laser or electric etching. Detailed implementation manners

[0026] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings. The embodiments of the present invention are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solution of the invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solution of the present invention, and all of them should be covered by the scope of the claims of the present invention.

[0027] Figure 1 Schematic diagram of an embodiment of the first groove for bonding diamond composite sheets on the substrate material. As Figure 1 shown, a notch is pre-formed on the rod-shaped substrate material 100 (such as: cemented carbide), and the notch extends along the axial direction of the substrate material to form the first groove 110. The first groove 110 at least includes the first groove bottom surface. Then, the diamond composite sheet 200 is bonded to the first groove bottom surface, so that the upper surface of the diamond composite sheet 200 is inclined to the axis of the substrate material 100, forming an angle of 5° to 45° with the axis of the substrate material, preferably 5° to 10°. Finally, laser etching or electric etching is used to process the first groove 110 with the diamond composite sheet 200 bonded thereto as a whole to form a formed groove 300 and a rake face 400 that meet the composite processing requirements. The formed rake face 400 is spiral, with a spiral angle of 10° to 55°, preferably 15° to 25°, and the rake angle of the entire cutting edge is consistent.

[0028] To facilitate the bonding of the diamond composite sheet to the first groove bottom surface, a plane is preferably selected. The thickness of the diamond layer of the diamond composite sheet is greater than 1.0 mm.

[0029] Use a vertical machining center to perform side milling of a 7075 aluminum alloy with a milling cutter. The tool diameter is uniformly 10 mm, the cutting edge length is 20 mm × 2 edges. Except for the differences listed in Table 1 below, other design and manufacturing parameters are the same. Use external cooling for cutting, the tool speed is 3,500 / min, the feed is 1,200 mm / min, and the cutting depth is 0.1 mm, etc. to test the cutting noise (the cutting noise reflects the magnitude of the cutting resistance) and the service life. The results are shown in Table 1 below.

[0030] Table 1

[0031]

[0032]

[0033] The diamond tool prepared by the method provided in this embodiment is used for the milling of aluminum alloy. Tests show that, compared with ordinary PCD tools, the processing resistance can be reduced by more than 30%, effectively reducing the processing resistance of diamond tools in metal machining cutting and improving the processing efficiency.

Claims

1. A method for reducing the machining resistance of diamond tools in metal machining cutting, characterized in that The method for processing the diamond cutting tool includes: Pre-forming a notch on a rod-shaped substrate material, the notch extending along the axial direction of the substrate material to form a first groove body, the first groove body at least including a first groove bottom surface; then, attaching a diamond composite sheet to the first groove bottom surface such that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material; finally, using laser etching or electro-etching to process the first groove body with the diamond composite sheet attached as a whole to form a formed groove body and a rake face that meet the composite processing requirements, the formed rake face being helical, the helix angle being 15° to 25°, and the rake angle of the entire cutting edge being consistent; The diamond composite sheet is PCD, and the thickness of the diamond layer is greater than 1.0 mm; The diamond composite sheet forms an angle of 5° to 45° with the axis of the substrate material; The first groove bottom surface is a plane.

2. The method according to claim 1, characterized in that The diamond composite sheet forms an angle of 5° to 10° with the axis of the substrate material.

3. Application of a diamond tool manufactured by the method according to claim 1 in cutting aluminum alloy materials.

4. The application according to claim 3, characterized in that Compared with a straight groove cutting tool, the diamond cutting tool reduces the processing resistance by more than 30%.

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