A friction welding milling cutter manufacturing process

Abstract

The application discloses a friction welding milling cutter preparation process, which comprises the following steps: raw material processing, welding, pretreatment, first treatment, second treatment, head preparation and film plating. The raw materials are divided into batches according to shank diameters, the raw materials with similar shank diameters in the same batch are selected as shank materials and head materials, the friction welding mode is adopted to coaxially weld the head materials and the shank materials, the welding firmness and stability are improved, and the shank material side is polished to the requirements of products through automatic step difference, semi-finished product detection and multiple centerless polishing. Then, the head is prepared, and finally, film plating is carried out to improve the product performance. The milling cutter has good preparation effect, high strength, avoids welding separation in a vacuum film plating environment and has good stability.

Description

Technical Field

[0001] This invention relates to the field of milling cutter manufacturing technology, specifically to a friction welding milling cutter manufacturing process. Background Technology

[0002] Currently, there are generally two methods in the manufacturing process of milling cutters. One method uses an integrated shank and machines the shank and cutting head of the milling cutter on the shank by cutting or laser cutting. The other method is to weld the two steel parts of the head and shank together, remove the weld spatter, and then machine the head to make a complete milling cutter.

[0003] In the second method, there are two common welding techniques: resistance welding and arc welding using copper bars, silver bars, or brazing rods. Both methods have the following problems:

[0004] 1. After welding, resistance welding and arc welding result in uneven weld surfaces and uneven welding, which affects the overall strength and stability of the milling cutter. In the face of vacuum coating environment, the milling cutter is prone to detachment from the weld, and resistance welding and arc welding are costly.

[0005] 2. During the grinding process, the removal of weld scars is usually completed in one go. However, the weld scars after removal may not be the same diameter as the shank material, resulting in slight deficiencies in function and appearance. Summary of the Invention

[0006] The purpose of this invention is to provide a friction-welded end mill manufacturing process that strengthens the mounting through friction welding, and removes weld spatter through multiple processes and grinds the weld spatter and shank together to ensure consistent shank diameter and an integrated appearance, thus solving the problems of weak welding and imprecise grinding in the existing manufacturing processes mentioned above.

[0007] To overcome the above-mentioned shortcomings, this invention provides a process for manufacturing friction welding end mills, comprising the following steps:

[0008] S1: Raw material processing, including screening raw materials according to production control standards, dividing raw materials into handle material and head material, and cutting and cleaning the handle material and head material respectively.

[0009] S2: Welding, friction welding is used to coaxially weld the cleaned shank material and the head material end face in S1, with the shank material and the head material corresponding one-to-one;

[0010] S3: Pre-treatment, automatic stepping of the welded material in S2, and rough grinding of the weld scar protrusions;

[0011] S4: One-time processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2, and the bending strength of the material after centerless coarse grinding is tested.

[0012] S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire shank are centerlessly ground, and the shank diameter is controlled to D3. The material after centerless grinding is inspected as a semi-finished product.

[0013] S6: Head preparation, including grooving and tailing the head of the material that passed the semi-finished product inspection in S5;

[0014] S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is then coated using a vacuum coating process.

[0015] Preferably, the production control standard for screening in S1 is the handle diameter D1. The raw materials are divided into different batches according to the range of D1 values. Two raw materials with similar handle diameters in the same batch are selected as a set of head material and handle material. The material with smaller D1 is used as the head material, and the material with larger D2 is used as the handle material.

[0016] More preferably, D1 in S1 is divided into at least three batches.

[0017] Furthermore, in the cutting standard of S1, the shank is longer than the head, and the length of the shank is 1.60 to 1.81 times the length of the head.

[0018] Preferably, the value of D2 in S4 varies depending on the batch of D1 in S1, and the value of D2 corresponds one-to-one with the batch of D1.

[0019] More preferably, the flexural strength test standard in S4 is: flexural pressure of 3.0 MPa and breaking rate ≤0.6%.

[0020] Preferably, the value of D3 in S5 varies depending on the value of D2 in S4, and the value of D3 corresponds one-to-one with the value of D2.

[0021] Preferably, step S7 is followed by step S8: performing a second finished product inspection on the material coated in S7, and then putting the material into storage after the second finished product inspection.

[0022] The beneficial effects of this invention are:

[0023] 1. In this invention, friction welding is used in the welding step, and the weld spatter is cleaned and removed afterward to make the welded cross-section flat, the weld firm, improve the stability of the milling cutter, ensure that the weld does not detach during subsequent vacuum coating, and save costs.

[0024] 2. This invention involves multiple grinding processes, including coarse grinding, centerless coarse grinding, and centerless fine grinding. Quality is assessed between each grinding process. Coarse grinding reduces the size of weld scars, centerless coarse grinding brings the weld scars closer to the diameter of the shank material, and fine grinding grinds the weld scars and shank material together to the shank diameter that meets production requirements. The result is a shank-free appearance, as if it were formed as a single piece, and has high stability. Attached Figure Description

[0025] Figure 1 A schematic diagram of the welded cross-section of the shank and headstock after resistance welding of a milling cutter.

[0026] Figure 2 This is a schematic diagram of the welded cross-section of the shank and headstock after friction welding according to the present invention;

[0027] Figure 3 This is a schematic diagram of the welded cross-section of the shank and headstock after arc welding of a milling cutter. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0029] As a preferred embodiment 1, a friction welding end mill manufacturing process includes the following steps:

[0030] S1: Raw material processing, including screening raw materials according to production control standards, dividing raw materials into handle material and head material, and cutting and cleaning the handle material and head material respectively. During the process, the raw materials are screened and grouped according to the handle diameter to meet the matching of subsequent preparation. The handle material and head material are cut according to different length requirements.

[0031] S2: Welding. Friction welding is used to coaxially weld the cleaned shank and headstock end faces from S1. The shank and headstock correspond one-to-one, and the welding is performed using friction welding. Figure 2 The image shown is a schematic diagram of the welded cross-section of the shank and headstock after friction welding. Figure 1 This is a schematic diagram of the welded cross-section of the shank and headstock after resistance welding. Figure 3 This is a schematic diagram of the welded cross-section of the shank and headstock after arc welding, for comparison. Figure 1 , Figure 2 and Figure 3 It can be observed that when friction welding is used to prepare milling cutters, the welded cross-section is flat and almost invisible, approaching a single unit. In contrast, the welded cross-section of resistance welding is rough and the degree of welding is inconsistent, resulting in a less effective welding effect than friction welding. Furthermore, in the S7 vacuum coating environment, milling cutters prepared by friction welding are less prone to detachment than those prepared by resistance welding.

[0032] S3: Pre-processing, automatically stepping the welded material in S2, and rough grinding the weld scar protrusions. The purpose of stepping is to distinguish one side of the material, which is convenient for subsequent control in D2.

[0033] S4: First processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2. The material after centerless coarse grinding is tested for bending strength. Centerless coarse grinding is used to form a rough product. The rough product is tested for bending strength to check whether the poorly welded material is firm. If the test is qualified, it enters S5; otherwise, it is recycled.

[0034] S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire handle material are centerlessly fine-ground, and the handle diameter is controlled to D3. The material after centerless fine-grinding is inspected as a semi-finished product. Fine grinding is used to fine-tune the weld scars after grinding in S4 so that they meet the handle diameter requirements in the finished product inspection.

[0035] S6: Head preparation, including grooving and cutting the fish tail of the head of the material that passed the semi-finished product inspection in S5, and preparing the head into a cutting head as required;

[0036] S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is coated by vacuum coating process to improve the physical and chemical properties of the milling cutter and improve its performance.

[0037] Preferably, the production control standard for screening in S1 is the shank diameter D1. The raw materials are divided into different batches according to the range of D1 values. Two raw materials with similar shank diameters in the same batch are selected as a set of head material and shank material. The material with smaller D1 is used as the head material, and the material with larger D2 is used as the shank material, which is convenient to meet production requirements. After screening, the shanks with similar diameters are used for butt welding to reduce the amount of grinding work.

[0038] Alternatively, D1 in S1 is divided into at least three batches to meet production needs.

[0039] Furthermore, in the cutting standard of S1, the shank is longer than the head, and the length of the shank is 1.60 to 1.81 times the length of the head, which facilitates cutting to meet production needs.

[0040] Preferably, the value of D2 in S4 varies depending on the batch of D1 in S1, and the value of D2 corresponds one-to-one with the batch of D1. For the selected shank material in the same batch in S1, the shank material in that batch is processed in S4 to form the same shank diameter D2 within a certain error allowable range, which is convenient for subsequent processing requirements.

[0041] As a better alternative, the flexural strength test standard in S4 is: flexural pressure of 3.0MPa and fracture rate ≤0.6% to ensure the welding strength of the poorly welded material.

[0042] Preferably, the value of D3 in S5 varies depending on the value of D2 in S4, and the value of D3 corresponds one-to-one with the value of D2 and the value of D2 in S4. For the shank material in S4, the shank material with the same shank diameter D2 is finely ground to the corresponding shank diameter D3.

[0043] More preferably, D2 and D3 are mainly for controlling the shank diameter during shank grinding to ensure smoothness at higher steps. Therefore, before each centerless grinding, it is necessary to determine one side of the shank through automatic step difference. The shank diameter of the head material is controlled during head preparation in S6.

[0044] Preferably, step S8 is included after S7: a second finished product inspection is performed on the material after coating in S7, and the material after the second finished product inspection is put into storage.

[0045] As a preferred embodiment 2, a friction welding milling cutter manufacturing process includes the following steps:

[0046] S1: Raw material processing, including screening raw materials according to the handle diameter D1≥3.168mm, and dividing the batch of raw materials with similar handle diameters into handle materials and head materials, and cutting and cleaning the handle materials and head materials respectively.

[0047] S2: Welding, friction welding is used to coaxially weld the cleaned shank material and the head material end face in S1. The shank material and the head material correspond one-to-one, and the rotation of the shank material and the head material are opposite, and the cross-sections are friction welded relative to each other.

[0048] The welding production control standards are as follows:

[0049] Overall length 36.7±0.1mm;

[0050] Concentricity: ≤0.03mm;

[0051] The acceptable welding quality standards are as follows:

[0052] Overall length: 36.7 ± 0.15 mm;

[0053] Concentricity: ≤0.05mm;

[0054] S3: Pre-treatment, automatic stepping of the welded material in S2, and rough grinding of the weld scar protrusion. The purpose of the stepping is to distinguish one side of the material, which is convenient for subsequent control in D2. Weld scar diameter: 3.18mm~3.20mm.

[0055] S4: First processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2. The material after centerless coarse grinding is tested for bending strength. Centerless coarse grinding is used to form a rough product. The rough product is tested for bending strength to check whether the poorly welded material is firm. If the test is qualified, it enters S5; otherwise, it is recycled.

[0056] The D2 production control standard is as follows: D2 = 3.168 mm, 0 / -0.02 mm;

[0057] The acceptable standard for D2 quality is as follows: D2 ≥ 3.160 mm;

[0058] S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire handle material are centerlessly fine-ground, and the handle diameter is controlled to D3. The material after centerless fine-grinding is inspected as a semi-finished product. Fine grinding is used to fine-tune the weld scars after grinding in S4 so that they meet the handle diameter requirements in the finished product inspection.

[0059] The D3 production control standard is as follows: D3 = 3.166mm, 0 / -0.02mm;

[0060] The acceptable quality standard for D3 is as follows: D3 ≥ 3.158 mm;

[0061] S6: Head preparation, including grooving and cutting the fish tail of the head of the material that passed the semi-finished product inspection in S5, and preparing the head into a cutting head as required;

[0062] S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is coated by vacuum coating process to improve the physical and chemical properties of the milling cutter and improve its performance.

[0063] S8: Perform a second finished product inspection on the material coated in S7, and put the material into the warehouse after the second finished product inspection.

[0064] As a preferred embodiment 3, a friction welding milling cutter manufacturing process includes the following steps:

[0065] S1: Raw material processing, including screening raw materials according to the handle diameter 3.165mm≤D1≤3.167mm, and dividing the batch of raw materials with similar handle diameters into handle materials and head materials, and cutting and cleaning the handle materials and head materials respectively.

[0066] S2: Welding, friction welding is used to coaxially weld the cleaned shank material and the head material end face in S1. The shank material and the head material correspond one-to-one, and the rotation of the shank material and the head material are opposite, and the cross-sections are friction welded relative to each other.

[0067] The welding production control standards are as follows:

[0068] Overall length: 36.7±0.1mm;

[0069] Concentricity: ≤0.03mm;

[0070] The acceptable welding quality standards are as follows:

[0071] Overall length: 36.7 ± 0.15 mm;

[0072] Concentricity: ≤0.05mm;

[0073] S3: Pre-treatment, automatic stepping of the welded material in S2, and rough grinding of the weld scar protrusion. The purpose of the stepping is to distinguish one side of the material, which is convenient for subsequent control in D2. Weld scar diameter: 3.18mm~3.20mm.

[0074] S4: First processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2. The material after centerless coarse grinding is tested for bending strength. Centerless coarse grinding is used to form a rough product. The rough product is tested for bending strength to check whether the poorly welded material is firm. If the test is qualified, it enters S5; otherwise, it is recycled.

[0075] The D2 production control standard is as follows: D2 = 3.165mm, 0 / -0.02mm;

[0076] The acceptable standard for D2 quality is as follows: D2 ≥ 3.160 mm;

[0077] S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire handle material are centerlessly fine-ground, and the handle diameter is controlled to D3. The material after centerless fine-grinding is inspected as a semi-finished product. Fine grinding is used to fine-tune the weld scars after grinding in S4 so that they meet the handle diameter requirements in the finished product inspection.

[0078] The D3 production control standard is as follows: D3 = 3.163mm, 0 / -0.02mm;

[0079] The acceptable quality standard for D3 is as follows: D3 ≥ 3.158 mm;

[0080] S6: Head preparation, including grooving and cutting the fish tail of the head of the material that passed the semi-finished product inspection in S5, and preparing the head into a cutting head as required;

[0081] S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is coated by vacuum coating process to improve the physical and chemical properties of the milling cutter and improve its performance.

[0082] S8: Perform a second finished product inspection on the material coated in S7, and put the material into the warehouse after the second finished product inspection.

[0083] As a preferred embodiment 4, a friction welding milling cutter manufacturing process includes the following steps:

[0084] S1: Raw material processing, including screening raw materials according to the handle diameter 3.162mm≤D1≤3.164mm, and dividing the batch of raw materials with similar handle diameters into handle materials and head materials, and cutting and cleaning the handle materials and head materials respectively.

[0085] S2: Welding, friction welding is used to coaxially weld the cleaned shank material and the head material end face in S1. The shank material and the head material correspond one-to-one, and the rotation of the shank material and the head material are opposite, and the cross-sections are friction welded relative to each other.

[0086] The welding production control standards are as follows:

[0087] Overall length: 36.7 ± 0.1 mm;

[0088] Concentricity: ≤0.03mm;

[0089] The acceptable welding quality standards are as follows:

[0090] Overall length: 36.7 ± 0.15 mm;

[0091] Concentricity: ≤0.05mm;

[0092] S3: Pre-treatment, automatic stepping of the welded material in S2, and rough grinding of the weld scar protrusion. The purpose of the stepping is to distinguish one side of the material, which is convenient for subsequent control in D2. Weld scar diameter: 3.18mm~3.20mm.

[0093] S4: First processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2. The material after centerless coarse grinding is tested for bending strength. Centerless coarse grinding is used to form a rough product. The rough product is tested for bending strength to check whether the poorly welded material is firm. If the test is qualified, it enters S5; otherwise, it is recycled.

[0094] The D2 production control standard is as follows: D2 = 3.162mm, 0 / -0.02mm;

[0095] The acceptable standard for D2 quality is as follows: D2 ≥ 3.160 mm;

[0096] S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire handle material are centerlessly fine-ground, and the handle diameter is controlled to D3. The material after centerless fine-grinding is inspected as a semi-finished product. Fine grinding is used to fine-tune the weld scars after grinding in S4 so that they meet the handle diameter requirements in the finished product inspection.

[0097] The D3 production control standard is as follows: D3 = 3.160mm, 0 / -0.02mm;

[0098] The acceptable quality standard for D3 is as follows: D3 ≥ 3.158 mm;

[0099] S6: Head preparation, including grooving and cutting the fish tail of the head of the material that passed the semi-finished product inspection in S5, and preparing the head into a cutting head as required;

[0100] S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is coated by vacuum coating process to improve the physical and chemical properties of the milling cutter and improve its performance.

[0101] S8: Perform a second finished product inspection on the material coated in S7, and put the material into the warehouse after the second finished product inspection.

[0102] As a preferred embodiment 5, the cutting requirements in S1 are as follows:

[0103] Handle material: 23.0mm, Head material: 14.2mm;

[0104] The production control standards are as follows:

[0105] Head length: -0.00mm / +0.05mm;

[0106] Handle length: -0.00mm / +0.05mm;

[0107] Bevel: ≤0.04mm;

[0108] The quality acceptance criteria are as follows:

[0109] Head length: -0.09mm / +0.15mm;

[0110] Handle length: -0.09mm / +0.15mm;

[0111] Bevel: ≤0.06mm.

[0112] As a preferred embodiment 6, the cutting requirements in S1 are as follows:

[0113] Handle material: 24.5mm, Head material: 13.6mm;

[0114] The production control standards are as follows:

[0115] Head length: -0.00mm / +0.05mm;

[0116] Handle length: -0.00mm / +0.05mm;

[0117] Bevel: ≤0.04mm;

[0118] The quality acceptance criteria are as follows:

[0119] Head length: -0.09mm / +0.15mm;

[0120] Handle length: -0.09mm / +0.15mm;

[0121] Slope: ≤0.06mm.

Claims

1. A process for manufacturing friction welding end mills, characterized in that, Includes the following steps: S1: Raw material processing, including screening raw materials according to production control standards, dividing raw materials into handle material and head material, and cutting and cleaning the handle material and head material respectively. S2: Welding, friction welding is used to coaxially weld the cleaned shank material and the head material end face in S1, with the shank material and the head material corresponding one-to-one; S3: Pre-treatment, automatic stepping of the welded material in S2, and rough grinding of the weld scar protrusions; S4: One-time processing, the weld scars of the material after S3 coarse grinding are centerlessly coarsely ground, and the shank diameter is controlled at D2, and the bending strength of the material after centerless coarse grinding is tested. S5: Secondary processing. The material that passed the bending strength test in S4 is automatically stepped again. After cleaning, the weld scars and the entire shank are centerlessly ground, and the shank diameter is controlled to D3. The material after centerless grinding is inspected as a semi-finished product. S6: Head preparation, including grooving and tailing the head of the material that passed the semi-finished product inspection in S5; S7: Coating. The material prepared in S6 is cleaned and preliminarily inspected. The qualified material is then coated using a vacuum coating process.

2. The process for manufacturing a friction welding end mill according to claim 1, characterized in that, The production control standard for screening in S1 is the handle diameter D1. The raw materials are divided into different batches according to the range of D1 values. Two raw materials with similar handle diameters in the same batch are selected as a set of head material and handle material. The material with smaller D1 is used as head material, and the material with larger D2 is used as handle material.

3. The friction welding end mill manufacturing process according to claim 2, characterized in that, D1 in S1 is divided into at least three batches.

4. The friction welding end mill manufacturing process according to claim 3, characterized in that, In the cutting standard of S1, the shank is longer than the head, and the length of the shank is 1.60 to 1.81 times the length of the head.

5. The process for manufacturing a friction welding end mill according to claim 2, characterized in that, The value of D2 in S4 varies depending on the batch of D1 in S1, and the value of D2 corresponds one-to-one with the batch of D1.

6. The process for manufacturing a friction welding milling cutter according to claim 5, characterized in that, The flexural strength test standard in S4 is: flexural pressure of 3.0 MPa and breaking rate ≤0.6%.

7. The friction welding end mill manufacturing process according to claim 5, characterized in that, The value of D3 in S5 varies depending on the value of D2 in S4, and the value of D3 corresponds one-to-one with the value of D2.

8. A process for manufacturing a friction-welded end mill according to any one of claims 1 to 7, characterized in that, Step S8 follows S7: a second finished product inspection is performed on the material coated in S7, and the material after the second finished product inspection is put into storage.

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