Composite helical milling curved taper tool with sail-shaped micro-texture

Abstract

The application discloses a composite spiral hole milling curved surface conical cutter with sail-shaped micro-texture, and relates to the technical field of special cutter for spiral hole milling, which comprises a cutter bar, a neck and a cutter head; one end of the cutter bar is provided with the neck, and the other end of the neck is provided with the cutter head; the cutter head comprises a rear rake surface and a front rake surface, and the bottom of the front rake surface is connected with one side of the rear rake surface; a front rake surface base body is arranged on the front rake surface, and a plurality of sail-shaped micro-textures are arranged on the front rake surface base body. The cutter has micro-texture on the front rake surface, can reduce the actual contact area of the cutter and the chip, reduce the cutting force, increase the convection heat exchange area between the cutter and the air, and reduce the cutting temperature. The sail-shaped micro-texture is an overall concave micro-texture, the structure has good chip breaking capacity, and can reduce the size of the chip. The micro-texture is designed with a certain inclination angle, so that the chip is easily discharged from the chip discharge groove, the machined surface is prevented from being scratched by the chip, and the hole machining quality is improved.

Description

Technical Field

[0001] This invention relates to the field of special tools for spiral milling, and in particular to a composite material spiral milling curved surface tapered tool with a sail-shaped microtexture. Background Technology

[0002] Carbon fiber reinforced polymer (CFRP) possesses excellent properties such as lightweight, strong corrosion resistance, good fatigue resistance, high designability, and high specific strength and specific modulus, making it widely used in aerospace and other fields. However, due to its heterogeneity and anisotropy, CFRP is a typical difficult-to-process material, prone to damage such as burrs, tears, and delamination during processing, resulting in poor processing quality.

[0003] For CFRP, spiral milling offers the following advantages over traditional drilling: 1) Compared to the traditional "drill-ream-ream" process, spiral milling is a "milling-instead-drilling" process, resulting in a shorter process flow and higher processing efficiency. 2) The tool feed is helical, ensuring a smooth spiral milling process and high-quality holes. 3) Spiral milling involves intermittent eccentric machining, which facilitates tool heat dissipation and chip removal. 4) By adjusting the eccentricity, spiral milling can achieve "one-cut multi-hole" without changing the tool diameter, reducing processing costs.

[0004] The significant heat generated during helical milling raises the temperature of the cutting zone, exacerbating tool wear, reducing tool life, and consequently affecting hole quality. These problems can be mitigated by incorporating microtextures. Compared to tools without microtextures, microtextured tools offer the following advantages: 1) When the tool rake face has a concave microtexture, the actual tool-chip contact area is reduced, which helps lower cutting forces during helical milling. 2) The microtexture on the tool rake face increases the convective heat transfer area between the tool and air, contributing to lower cutting temperatures. 3) The microtexture on the tool rake face reduces chip size, facilitating chip removal. 4) Microtextures reduce the average shear strength on the rake face, while the concave microtexture can store chips, thereby reducing tool wear.

[0005] The core of a spiral milling tool with microtexture is the shape of the microtexture; therefore, different shapes of microtexture have different effects on the hole quality.

[0006] For example, patent document CN114160825A discloses a grooved micro-textured tool in the field of tool design, comprising several transverse parallel grooves on the rake face, with protruding keys formed between the parallel grooves. The protruding keys are clearance-fitted with the rake face, and there is a sandwich between the rake face and the flank face, containing several metal flaps. The positions of the metal flaps correspond one-to-one with the protruding keys, and the metal flaps are fixed within the sandwich. Compared with traditional cutting tools, the texture on the tool surface in this technical solution helps to reduce cutting force and cutting temperature by reducing the contact length between the tool and the chip and improving friction conditions. In addition, the texture can also store lubricant, which helps to achieve micro-lubrication, making the machining process more environmentally friendly. Therefore, micro-textured tools can effectively alleviate the problems of excessive cutting heat and serious pollution in existing machining processes and improve service life. However, this tool only reduces cutting force and cutting temperature through several transverse parallel grooves on the rake face, and the micro-textured structure is simple and cannot achieve good results.

[0007] For example, patent document CN115770888A discloses a wavy microtextured insert for machining difficult-to-machine materials. The insert body has a main cutting edge, a secondary cutting edge, a rounded tip, and a wavy microtexture. This invention is mainly applied to the finishing and semi-finishing of difficult-to-machine materials. Experiments show that the groove orientation of the wavy microtextured insert utilizes chip removal and heat dissipation, therefore, its cutting force and cutting temperature are lower, the tool's anti-adhesion performance and wear resistance are better, the surface roughness value of the machined surface is lower, and the chip curl radius is smaller. However, this invention patent only targets the insert design and is not applicable to helical milling tools.

[0008] For example, patent document CN114653954A discloses a method for laser cladding of nano-coated micro-textured cutters for tunnel boring machines. First, a mixture of blade and body powders is prepared using mechanical ball milling. This mixture is then integrated into the blade and body using 3D printing technology under ultrasonic impact assistance. Next, surface polishing removes surface contaminants, and laser micro-texturing is performed on the main cutting edge using a fiber laser marking machine. Following this, ultrasonic cleaning with alcohol and deionized water is conducted to ensure the cutter substrate surface is clean and free of impurities. Finally, nano-powder for the cladding coating is prepared using a stirring ball mill, and a high-wear-resistance and corrosion-resistant nanocrystalline coating is applied to the cutter surface using laser cladding technology. This invention improves the wear resistance, impact resistance, and high-temperature mechanical properties of tunnel boring machine cutters, thereby extending their service life. However, this method is only designed for coated micro-textured cutters and is not suitable for uncoated cutters. Summary of the Invention

[0009] To address the above technical problems, this invention provides a composite material spiral milling surface tapered tool with a sail-shaped microtexture. By using a complex microtexture structure, the cutting force and cutting temperature generated during spiral milling of CFRP are reduced, tool life is extended, and hole quality is improved.

[0010] To achieve the above objectives, the present invention provides the following solution:

[0011] This invention provides a composite material spiral milling surface tapered tool with sail-shaped microtexture, comprising a tool shank, a neck, and a tool head; one end of the tool shank is provided with the neck, and the other end of the neck is provided with the tool head; the tool head includes a flank face and a rake face, the bottom of the rake face being connected to one side of the flank face; a rake face substrate is provided on the rake face, and multiple sail-shaped microtextures are provided on the rake face substrate.

[0012] Optionally, the sail-shaped microtexture is a sail-shaped structure. The lowest point in the middle of the sail bottom of the sail-shaped microtexture is the first arc point of the sail bottom. The right side point of the sail bottom of the sail-shaped microtexture is the second arc point of the sail bottom. The highest point of the sail top of the sail-shaped microtexture is the second arc point of the sail top. A first region of the sail bottom, a second region of the sail top, and a fifth region of the sail side are provided on one side of the line connecting the first arc point of the sail bottom and the second arc point of the sail top. A second region of the sail bottom, a first region of the sail side, a second region of the sail side, a third region of the sail side, a fourth region of the sail side, and a first region of the sail top are provided on the other side of the line connecting the first region of the sail bottom and the fourth region of the sail side. The side of the connection between the first region of the sail top and the fourth region of the sail side away from the fifth region of the sail side is the first arc point of the sail top.

[0013] Optionally, the height and radius of the arc of the first, second, third, and fourth sail-side regions decrease sequentially.

[0014] Optionally, the height of the first region of the sail bottom is less than the height of the second region of the sail bottom.

[0015] Optionally, the radius of the arc of the first region of the sail bottom is the same as the radius of the arc of the second region of the sail bottom.

[0016] Optionally, the height and radius of the fifth region on the sail side are both greater than the height and radius of the first region on the sail side.

[0017] Optionally, the sail-shaped microtexture is inclined at an angle of ±30° to the central axis of the front blade surface substrate.

[0018] Optionally, multiple sail-shaped microtextures are arranged in a mirror image along the central axis of the rake face substrate.

[0019] Optionally, the area of ​​the rake face substrate accounts for 5% to 25% of the total area of ​​the rake face.

[0020] The present invention achieves the following technical effects compared to the prior art:

[0021] The composite material spiral milling tapered tool with a sail-shaped microtexture of this invention has a microtexture on the rake face, which reduces the actual contact area between the tool and the chip, lowers the cutting force, and increases the convective heat transfer area between the tool and the air, which helps to reduce the cutting temperature. The sail-shaped microtexture is concave in shape, which has good chip breaking ability and can reduce chip size. The microtexture is designed with a certain tilt angle, which facilitates the discharge of chips from the chip evacuation groove, avoids chip scratches on the machined surface, and improves the hole quality. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the first embodiment of the carbon fiber composite spiral milling curved surface conical tool with sail-shaped microtexture of the present invention;

[0024] Figure 2 This is a schematic diagram of the second embodiment of the carbon fiber composite spiral milling curved surface conical tool with sail-shaped microtexture of the present invention;

[0025] Figure 3 This is a schematic diagram of a sail-shaped microtexture.

[0026] Explanation of reference numerals in the attached diagram: 1. Blade shank; 2. Neck; 3. Blade tip; 4. Back face; 5. Front face; 6. Front face substrate; 7. First sail-shaped microtexture; 8. Line a1b1; 9. First arc point of the sail bottom; 10. Second arc point of the sail bottom; 11. First arc point of the sail top; 12. Second sail-shaped microtexture; 13. Line a2b2; 14. First region of the sail bottom; 15. Second region of the sail bottom; 16. First region of the sail side; 17. Second region of the sail side; 18. Third region of the sail side; 19. Fourth region of the sail side; 20. First region of the sail top; 21. Second arc point of the sail top; 22. Second region of the sail top; 23. Fifth region of the sail side. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Example 1:

[0029] like Figure 1 and 3 As shown, this embodiment provides a composite material spiral milling surface tapered tool with sail-shaped microtexture, including a tool holder 1, a neck 2, and a tool head 3; one end of the tool holder 1 is provided with a neck 2, and the other end of the neck 2 is provided with a tool head 3; the tool head 3 includes a flank face 4 and a rake face 5, the bottom of the rake face 5 is connected to one side of the flank face 4; a rake face substrate 6 is provided on the rake face 5, and multiple sail-shaped microtextures are provided on the rake face substrate 6.

[0030] In this specific embodiment, as Figure 1 As shown, the first sail-shaped microtexture 7 is arranged in two rows, totaling ten, accounting for 18% of the total area of ​​the front blade surface 5. The first arc point 9 of the sail bottom is 51.00 μm from the x-axis and 32.50 μm from the y-axis. The distance between the first arc point 11 of the sail top and the a1b1 line 8 is 29.67 μm. The distance between the second arc points 10 of the sail bottom of adjacent sail-shaped microtextures along the x-axis is 116.00 μm.

[0031] like Figure 3 As shown, the line connecting the second arc point 21 at the top of the sail and the first arc point 9 at the bottom of the sail makes an angle of 30° with the x-axis, which is the microtexture tilt angle. The height of the first region 14 at the bottom of the sail is 1.39 μm, and the arc radius is 350.00 μm; the height of the second region 15 at the bottom of the sail is 2.80 μm, and the arc radius is 350.00 μm; the height of the first region 16 on the side of the sail is 28.00 μm, and the arc radius is 2300.00 μm; the height of the second region 17 on the side of the sail is 18.00 μm, and the arc radius is 900.00 μm; the height of the third region 18 on the side of the sail is 10. The height of the fourth region 19 on the sail side is 4.00 μm, and the radius of the arc is 180.00 μm; the height of the first region 20 on the sail top is 1.00 μm, and the radius of the arc is 80.00 μm; the height of the second region 22 on the sail top is 0.60 μm, and the radius of the arc is 8.00 μm; the height of the fifth region 23 on the sail side is 64.40 μm, and the radius of the arc is 5760.00 μm.

[0032] Example 2:

[0033] This embodiment is an improved version based on Embodiment 1, such as... Figure 2 and3 As shown, in this embodiment, the second sail-shaped microtexture 12 is arranged in four rows, totaling forty, accounting for 18% of the total area of ​​the front blade surface 5. The first arc point 9 of the sail bottom is 25.50 μm from the x-axis and 16.25 μm from the y-axis. The distance between the first arc point 11 of the sail top and the a2b2 line 13 is 16.09 μm. The distance between the second arc points 10 of the sail bottom of adjacent sail-shaped microtextures arranged at the same angle is 47.50 μm along the y-axis and 58.00 μm along the x-axis.

[0034] The specific structure of a single sail-shaped microtexture is reduced by a factor of two based on the sail-shaped microtexture in Example 1.

[0035] The composite material spiral milling tapered tool with a sail-shaped microtexture of this invention has a sail-shaped microtexture on the rake face 5. This structure can reduce cutting force during spiral milling by reducing the actual tool-chip contact area; and reduce cutting temperature by reducing the tool-chip contact length and increasing the convective heat transfer area between the tool and the air. The sail-shaped microtexture is concave, which can accommodate CFRP chips, reduce tool wear, and improve tool life. At the same time, the concave design of the sail-shaped microtexture can reduce chip size and facilitate chip discharge; its inclined design can guide chips to the chip removal groove, avoid scratching the machined surface, and improve the hole quality.

[0036] It should be noted that, for those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0037] This specification uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A composite material spiral milling surface tapered tool with a sail-shaped microtexture, characterized in that, The tool includes a shank, a neck, and a cutting head; one end of the shank is provided with the neck, and the other end of the neck is provided with the cutting head; the cutting head includes a rear cutting face and a front cutting face, the bottom of the front cutting face being connected to one side of the rear cutting face; a front cutting face base is provided on the front cutting face base, and multiple sail-shaped microtextures are provided on the front cutting face base; the sail-shaped microtextures are sail-shaped structures, the lowest point in the middle of the sail bottom of the sail-shaped structure is the first arc point of the sail bottom, the right side point of the sail bottom of the sail-shaped microtextures is the second arc point of the sail bottom, and the highest point of the sail top of the sail-shaped structure is the second arc point of the sail top; On one side of the line connecting the first arc point of the sail bottom and the second arc point of the sail top, there are a first region of the sail bottom, a second region of the sail top, and a fifth region of the sail side; on the other side of the line connecting the first arc point of the sail bottom and the second arc point of the sail top, there are a second region of the sail bottom, a first region of the sail side, a second region of the sail side, a third region of the sail side, a fourth region of the sail side, and a first region of the sail top; the side of the connection between the first region of the sail top and the fourth region of the sail side away from the fifth region of the sail side is the first arc point of the sail top; the sail-shaped microtexture is inclined at an angle of ±30° to the central axis of the front blade surface substrate.

2. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, The height and radius of the arc of the first, second, third, and fourth sail-side regions decrease sequentially.

3. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, The height of the first region of the sail bottom is less than the height of the second region of the sail bottom.

4. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, The radius of the arc of the first region of the sail bottom is the same as the radius of the arc of the second region of the sail bottom.

5. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, The height and radius of the fifth region on the sail side are both greater than the height and radius of the first region on the sail side.

6. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, Multiple sail-shaped microtextures are arranged in a mirror image along the central axis of the front blade substrate.

7. The composite material spiral milling curved surface conical tool with sail-shaped microtexture according to claim 1, characterized in that, The area of ​​the rake face substrate accounts for 5% to 25% of the total area of ​​the rake face.

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