Micro-textured cutting tool and method of machining thereof

Abstract

The present application relates to the technical field of metal cutting tools, and provides a micro-textured tool and a processing method thereof, which comprises a tool base body, a fan fin structure micro-texture, a raceway roller structure and a stepped structure are arranged on the tool base body rear face, a plurality of fan fin structure micro-textures are arranged close to the main cutting edge and the edge array of the tool base body, a plurality of stepped structures are equidistantly arranged on one side of the fan fin structure micro-texture, and two groups of raceway roller structures are communicated with the stepped structures and are arranged on the two sides of the stepped structures respectively. The fan fin structure micro-texture, the raceway roller structure and the stepped structure are matched with each other, which can not only promote the occurrence of derivative cutting and the quality of the processed surface, but also reduce the tool wear and prolong the service life of the tool.

Description

Technical Field

[0001] This invention belongs to the field of metal cutting tool technology, and particularly relates to a micro-textured tool and its processing method. Background Technology

[0002] Machining (including turning, milling, and drilling) plays an irreplaceable role in the manufacturing of key components for high-end equipment due to its advantages such as high efficiency, high surface quality, and high flexibility. Analysis of related accidents and failures in engineering projects shows that fatigue failure of components mostly originates from the surface or near-surface locations of parts with high working stress, complex shapes, and harsh working conditions. However, the issue of surface integrity was initially not recognized; designers simply chose high-strength materials or increased cross-sectional area to improve component strength, which not only increased costs but also failed to fundamentally prevent accidents. When the surface of a component is subjected to alternating loads and corrosive media erosion under long-term high temperature and high pressure conditions, the surface morphology, subsurface microstructure, and physical and mechanical properties all affect the reliability and service life of the component. Therefore, the surface integrity of key components has become an important basis for evaluating manufacturing quality.

[0003] Reducing tool wear during machining can effectively improve surface integrity. One option for reducing tool wear is the use of cutting fluids. Cutting fluids reduce friction between the chip and tool interface, thereby lowering the temperature and contributing to increased tool life. These fluids also act as coolants and lubricants, helping to remove debris generated during machining. However, the continued use of these cutting fluids has had adverse effects on the environment and human health. Most cutting fluids contain harmful chemicals that can cause various skin and lung diseases. Furthermore, disposing of these cutting fluids is very difficult, and recycling costs are extremely high. Due to these negative impacts and stringent environmental policies, current research focuses more on minimizing the use of cutting fluids.

[0004] Therefore, how to reduce the use of cutting fluid is a current research hotspot. However, reducing the use of cutting fluid will cause more friction and adhesion between the tool and workpiece material interface, which will increase the cutting temperature and ultimately lead to a shortened tool life. Adhesive wear, abrasive wear and plastic deformation of the tool are more likely to occur during the cutting process. Due to various wear mechanisms, the material removal rate and surface integrity of the finished part will be affected. Summary of the Invention

[0005] This invention provides a microtextured tool and its processing method, aiming to solve the above-mentioned technical problems.

[0006] The present invention is implemented as follows: a microtextured cutting tool includes a tool body. The back face of the tool body is provided with a fan-fin microtexture, a raceway roller structure and a stepped structure. A plurality of fan-fin microtextures are arranged in an array close to the main cutting edge and edge of the tool body. A plurality of stepped structures are arranged equidistantly on one side of the fan-fin microtexture. Two sets of raceway roller structures are connected to the stepped structures and are respectively arranged on both sides of the stepped structures.

[0007] Furthermore, the fan-shaped microtexture has a fan-shaped annular groove, a central groove is formed along the fan-shaped annular groove, and multiple parallel grooves are formed parallel to the central groove. The fan-shaped annular groove, the central groove, and the multiple parallel grooves are interconnected.

[0008] Furthermore, it also includes two staggered grooves, which are staggered and connected to the portion of the central groove that extends out of the fan-shaped annular groove.

[0009] Furthermore, the fan-fin structure microtexture is arranged in a 3*3 array, the central groove is parallel to the main cutting edge of the tool body, and the central groove extends into the fan-shaped annular groove toward the side away from the edge of the tool body.

[0010] Furthermore, the stepped structure has two stepped grooves in a herringbone pattern, with the two stepped grooves connected at their closest ends by a semi-circular groove.

[0011] Furthermore, the herringbone-shaped stepped grooves are positioned towards the edge of the tool base, and multiple stepped structures are arranged equidistantly along the main cutting edge.

[0012] Furthermore, the raceway roller structure has a straight groove, on which spherical grooves for accommodating spherical rollers are equidistantly arranged. The spherical rollers are rolled within the spherical grooves, and a portion of the spherical rollers protrudes from the spherical grooves. The diameter of the spherical grooves is greater than the width of the straight groove, and the stepped grooves connect to the straight groove.

[0013] Furthermore, the straight groove is parallel to the main cutting edge.

[0014] The above-mentioned microtextured tool processing method includes the following steps:

[0015] Select silicon carbide tool matrix and nickel-titanium alloy spherical rollers;

[0016] The tool substrate is polished, and then ultrasonically cleaned in a mixed solution of acetone and anhydrous ethanol.

[0017] The back face of the tool substrate is machined with femtosecond laser and wet etching to create straight grooves and spherical grooves with fan-fin microtexture, stepped structure and raceway roller structure.

[0018] A nickel-titanium alloy spherical roller is pressed into a spherical groove, and the spherical roller is heated to restore its shape to match the spherical groove, thus obtaining a microtextured tool.

[0019] The beneficial effects of this invention include: In the microtextured tool provided by this invention, the fan-fin microtexture, raceway roller structure, and stepped structure are applied to the flank face of the tool substrate. The elliptical coupled structure of the fan-shaped annular groove can temporarily store the cutting fluid flowing through the flank face, and supply it to the central groove through parallel grooves, accelerating the delivery rate of the cutting fluid stored in the central groove. The staggered grooves can increase the contact area between the tool and the cutting fluid, reduce the cutting temperature, reduce tool wear, and thus improve the tool's service life. The fan-fin microtexture reduces the negative rake angle of the tool substrate, which is conducive to promoting the occurrence of derivative cutting. Derivative cutting can smooth the machined surface and remove surface deposits caused by plastic flow, thereby improving the surface integrity of the workpiece and extending the tool's service life. It is suitable for cutting under high-precision machining conditions.

[0020] The raceway roller structure provides a smoother rolling contact, significantly reducing friction and wear between the tool and workpiece compared to direct frictional contact. It acts like a "warmer" on the machined surface, effectively improving its integrity. Through the coupling effect of the raceway roller structure, it better guides the flow of cutting fluid, improving cooling and lubrication, reducing heat buildup on the tool, and extending tool life. Installing a raceway roller structure increases tool stability, reduces vibration during machining, improves machining efficiency, and enhances the quality of the machined surface. The raceway roller structure also effectively disperses heat generated during machining, reducing deformation in the tool-workpiece contact area, thereby reducing tool wear.

[0021] The stepped structure extends the residence time of cutting fluid, thereby reducing the contact area between the tool and the workpiece, lowering cutting forces, accelerating airflow in the tool-workpiece contact area, speeding up heat transfer, improving heat conduction during the cutting process, lowering cutting temperatures, reducing adhesion to the machined surface, reducing tool wear, and improving workpiece surface quality. The stepped structure utilizes the corners and semi-circular grooves of each step to scrape and press the machined surface, promoting derivative cutting, thus improving the surface quality during the cutting process, reducing tool wear, extending tool life, optimizing cutting performance, and storing abrasive particles lost during cutting, thereby reducing the coefficient of friction and cutting forces. The stepped structure also promotes directional flow of cutting fluid, lowers cutting temperatures, reduces thermal deformation, thereby improving cutting quality. It also acts as a guide, interacting with the raceway roller structure to accelerate cutting fluid flow, increase the heat transfer surface area, and lower cutting temperatures.

[0022] The fan-fin microtexture, raceway roller structure, and stepped structure work together to promote derivative cutting, improve the quality of the machined surface, reduce tool wear, and extend tool life. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of a microtextured tool;

[0024] Figure 2 This is a schematic diagram of the microtexture of the fan-fin structure;

[0025] Figure 3 This is a schematic diagram of the raceway roller structure;

[0026] Figure 4 This is a schematic diagram of the fit between the spherical roller and the spherical groove;

[0027] Figure 5 This is a schematic diagram of a stepped structure;

[0028] Figure 6 This is a schematic diagram showing the connection between the stepped structure and the raceway roller structure.

[0029] The labels in the diagram represent: 1-tool body, 2-flank face, 3-fan-fin microtexture, 301-fan-shaped annular groove, 302-parallel groove, 303-center groove, 304-interlaced groove, 4-main cutting edge, 5-tool tip, 6-edge, 7-roller structure, 701-straight groove, 702-spherical groove, 703-spherical roller, 8-stepped structure, 801-stepped groove, 802-semi-circular groove. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0031] See Figures 1-6 This invention provides a microtextured cutting tool, including a tool body 1. The tool body 1 has a fan-fin microtexture 3, a raceway roller structure 7, and a stepped structure 8 formed on its flank face 2. Multiple fan-fin microtextures 3 are arrayed close to the main cutting edge 4 and the edge 6 of the tool body 1. Multiple stepped structures 8 are equidistantly arranged on one side of the fan-fin microtexture 3. Two sets of raceway roller structures 7 are connected to the stepped structures 8 and are respectively disposed on both sides of the stepped structures 8.

[0032] The fan-fin microtexture 3 has a fan-shaped annular groove 301, a central groove 303 is formed along the fan-shaped annular groove 301, and multiple parallel grooves 302 are formed parallel to the central groove 303. The fan-shaped annular groove 301, the central groove 303, and the multiple parallel grooves 302 are interconnected. This embodiment of the invention also includes two staggered grooves 304, which are staggered and connected to the portion of the fan-shaped annular groove 301 extending from the central groove 303. The fan-fin microtexture 3 is arranged in a 3*3 array. The central groove 303 is parallel to the main cutting edge 4 of the tool base 1, and the central groove 303 extends towards the side away from the edge 6 of the tool base 1, forming the fan-shaped annular groove 301.

[0033] A fan-fin microtexture 3 is formed on the flank face 2 of the tool body 1 to promote derivative cutting, reduce cutting temperature, and extend tool life. Multiple fan-fin microtextures 3 are formed on the flank face 2 of the tool body 1 near the main cutting edge 4. Each fan-fin microtexture 3 has a fan-shaped annular groove 301 with a concentric circle and an ellipse tangent to each other. Multiple parallel grooves 302 are symmetrically arranged on both sides along the length of the fan-shaped annular groove 301. A central groove 303 is arranged along the axis of symmetry of the multiple parallel grooves 302. One end of the central groove 303 extends outside the fan-shaped annular groove 301, and at least two staggered grooves 304 are staggered on both sides. The fan-shaped annular groove 301, parallel grooves 302, central groove 303, and staggered grooves 304 are interconnected.

[0034] The model of the tool substrate 1 can be selected according to the quality requirements of the parts, such as silicon carbide ceramic tools with model number SNGN1204 or CNGN090304.

[0035] The fan-shaped annular groove 301 reduces the contact area between the tool base 1 and the workpiece during cutting, thereby reducing friction and lowering the cutting temperature. Micro-debris adhering to the machined surface flows towards the fan-shaped annular groove 301 at the edge of the fan-fin microtexture 3 and is removed by the derivative cutting action of the groove. This derivative cutting action removes rough peaks from the machined surface, reducing surface roughness, improving workpiece surface quality, and effectively promoting derivative cutting. The fan-shaped annular groove 301 also stores and transports cutting fluid, reducing cutting fluid usage and lowering the cutting temperature.

[0036] The central groove 303 can perform derivative cutting during machining, improving the quality of the machined surface. It can also store and transport cutting fluid, ensuring that the cutting fluid is delivered to the contact area between the tool base 1 and the workpiece, reducing cutting temperature and increasing tool life. Connecting the fan-shaped annular grooves 301 through the central groove 303 accelerates the conduction of cutting temperature. During high-speed cutting, the concentric circle and ellipse tangent outer curve shape of the fan-fin microtexture 3, i.e., the circular-elliptical coupled structure, significantly increases the airflow intensity at the contact interface between the tool base 1 and the workpiece, increases the flow rate of cutting fluid, reduces tool wear, accelerates the delivery of cutting fluid stored in the central groove 303, parallel grooves 302, and staggered grooves 304, and extends tool life.

[0037] Parallel grooves 302 are symmetrically distributed within the inner ring of the fan-shaped annular groove 301. The straight groove structure of the symmetrical parallel grooves 302, combined with the curved groove structure of the fan-shaped annular groove 301, expands in multiple directions to form a micro-edge structure, promoting derivative cutting. The parallel grooves 302 and the fan-shaped annular groove 301 together form a curved-straight groove. The curved-straight groove acts as a micro-reservoir for cutting fluid. When relative movement occurs between the tool body 1 and the workpiece, the cutting fluid penetrates to the interface between the tool body 1 and the workpiece, reducing the cutting temperature and minimizing tool wear.

[0038] The staggered grooves 304 form micro-edges on the back face 2 through straight grooves that are staggered by 45 degrees, which effectively promotes derivative cutting. They can also increase the contact area between the tool body 1 and the cutting fluid, reduce the processing temperature in the contact area between the tool body 1 and the workpiece, and reduce tool wear.

[0039] By combining the fan-shaped annular groove 301, parallel groove 302, central groove 303, and staggered groove 304 on the tool base 1, it is possible to promote derivative cutting, improve the surface roughness of the machined surface and the cutting performance of the tool, and reduce machining energy consumption.

[0040] In this embodiment of the invention, fan-fin microtextures 3 are distributed on the back face 2 of the tool base 1 near the tip 5. Nine fan-fin microtextures 3 are formed, arranged in a 3*3 rectangular array with equal areas. The central groove 303 is parallel to the main cutting edge 4, and the fan-fin microtextures 3 are close to the tip 5 of the tool base 1. The fan-shaped annular groove 301 is an outer curve shape formed by a concentric circle and an ellipse tangent to each other. The radius of the circle is 50 μm, the major axis of the ellipse is 130 μm, the minor axis is 50 μm, the width of the fan-shaped annular groove 301 is 20 μm, and the depth is 35 μm. Parallel grooves 302 connect to the fan-shaped annular groove 301 and are straight groove structures. Six parallel grooves 302 are provided, and the six parallel grooves 302 have a 45-degree angle with the central groove 303. The distance between two adjacent fan-fin microtextures 3 is 10 μm along the direction of the main cutting edge 4 and 10 μm perpendicular to the main cutting edge 4. The distance between the 3×3 rectangular array of fan-fin microtextures 3 and the main cutting edge 4 is 50 μm, and the distance between the rectangular array and the edge 6 of the tool base 1 perpendicular to the main cutting edge 4 is 20 μm. The central groove 303 connects the fan-shaped annular groove 301 with each parallel groove 302, and extends 100 μm after the fan-fin microtexture 3 in a direction parallel to the main cutting edge 4. Its shape is a straight groove type, with a width of 20 μm, a depth of 35 μm, and a total length of 280 μm. The staggered groove 304 is a straight groove type structure, and there are two of them. One staggered groove 304 is connected to the end of the fan-shaped annular groove 301 extending from the central groove 303. The distance between the other staggered groove 304 and the previous staggered groove 304 is 50μm. The width of the staggered groove 304 is 20μm and the depth is 35μm.

[0041] The stepped structure 8 has two stepped grooves 801 that are shaped like a herringbone, and the two stepped grooves 801 are connected at their closest ends by a semi-circular groove 802. The herringbone stepped grooves 801 are positioned pointing towards the edge 6 of the tool base 1, and multiple stepped structures 8 are arranged at equal intervals along the main cutting edge 4.

[0042] The stepped structures 8 are spaced 35 μm apart in the direction perpendicular to the main cutting edge 4. The stepped structures 8 are arranged in a herringbone pattern, with each step being 20 μm long, 20 μm wide, and 10 μm deep. Each stepped groove 801 has 4 steps. The semi-circular groove 802 has a radius of 15 μm, a groove width of 5 μm, and a depth of 10 μm. The interval between two adjacent stepped structures 8 is 120 μm.

[0043] The stepped structure 8 can prolong the residence time of the cutting fluid, reduce the contact area between the tool body 1 and the workpiece, reduce cutting force, accelerate the airflow in the tool contact area, speed up heat transfer, improve heat conduction during the cutting process, lower the cutting temperature, reduce adhesion to the machined surface, reduce tool wear, and improve the surface quality of the workpiece. The stepped structure 8 utilizes each stepped corner structure and the semi-circular groove 802 to scrape and press the machined surface, promoting the occurrence of derivative cutting, thereby improving the surface quality of the machined surface during the cutting process, reducing tool wear, extending tool life, and optimizing the cutting effect. It also stores abrasive particles lost during the cutting process, thereby reducing the coefficient of friction and cutting force. The stepped structure 8 can also promote the directional flow of the coolant and lubricant, lower the cutting temperature, reduce thermal deformation, thereby improving cutting quality. It also acts as a guide, interacting with the raceway roller structure 7 to accelerate the flow of the cutting fluid, increase the heat conduction surface area, and lower the cutting temperature.

[0044] The raceway roller structure 7 has a straight groove 701. Spherical grooves 702, which accommodate spherical rollers 703, are equidistantly arranged on the straight groove 701. The spherical rollers 703 are rolled within the spherical grooves 702, with a portion of each roller protruding from the groove. The diameter of the spherical groove 702 is larger than the width of the straight groove 701. A stepped groove 801 connects to the straight groove 701. The straight groove 701 is parallel to the main cutting edge 4.

[0045] The distance between the center of the raceway roller structure 7 and the rectangular array of fan-fin microtexture 3 is 20 μm. The inner diameter of the spherical groove 702 is 20.5 μm, the width of the straight groove 701 is 10 μm, and the length is 820 μm. The spherical roller 703 has a diameter of 20 μm, and the interval between two adjacent spherical rollers 703 is 20 μm. The vertical distance between the two raceway roller structures 7 is 180 μm. The spherical roller 703 fits within the spherical groove 702, with an inner margin to facilitate multi-directional rolling of the spherical roller 703 under the action of the cutting fluid.

[0046] The spherical rollers 703 provide a smoother rolling contact, significantly reducing friction and wear between the tool body 1 and the workpiece compared to direct frictional contact. They act as a smoothing agent on the machined surface, effectively improving its integrity. Through the coupling effect of the raceway roller structure 7, the flow of cutting fluid is better guided, improving cooling and lubrication, reducing heat buildup in the tool, and extending tool life. The installation of the raceway roller structure 7 increases tool stability, reduces vibration during machining, improves machining efficiency, and enhances the quality of the machined surface. The raceway roller structure 7 also effectively disperses heat generated during machining, reducing deformation in the tool-workpiece contact area, thereby reducing tool wear.

[0047] This invention also provides a method for processing the above-mentioned microtextured cutting tool, the method comprising the following steps:

[0048] Silicon carbide tool substrate and nickel-titanium alloy spherical rollers are selected.

[0049] Polish the tool substrate 1, and then ultrasonically clean it in a mixed solution of acetone and anhydrous ethanol for 20-30 minutes.

[0050] On the back face 2 of the tool substrate 1, a fan-fin microtexture 3, a stepped structure 8, and a raceway roller structure 7 are machined by femtosecond laser and wet etching to form a straight groove 701 and a spherical groove 702.

[0051] The laser used in femtosecond laser processing has a wavelength of 800nm ​​and a pulse width of 120fs. Wet etching is carried out in a potassium hydroxide solution with a mass fraction of 30%. The wet etching is performed at 80°C under ultrasonic oscillation.

[0052] A nickel-titanium alloy spherical roller 703 is pressed into a spherical groove 702, and the spherical roller 703 is heated to restore its shape to match the spherical groove 702, thus obtaining a microtextured tool.

[0053] When the nickel-titanium alloy spherical roller 703 is pressed into the spherical groove 702, it will deform. Heating the spherical roller 703 can restore the original size of the nickel-titanium alloy spherical roller 703 with shape memory, so as to fit the spherical groove 702 for stable installation.

[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A microtextured cutting tool, comprising a tool substrate, characterized in that, The tool base has a fan-fin microtexture, a raceway roller structure and a stepped structure on its flank face. Multiple fan-fin microtextures are arranged close to the main cutting edge and edge array of the tool base. Multiple stepped structures are arranged equidistantly on one side of the fan-fin microtexture. Two sets of raceway roller structures are connected to the stepped structures and are respectively arranged on both sides of the stepped structures. The fan-shaped microtexture has a fan-shaped annular groove, a central groove is formed along the fan-shaped annular groove, and multiple parallel grooves are formed parallel to the central groove. The fan-shaped annular groove, the central groove and the multiple parallel grooves are interconnected. The stepped structure has two stepped grooves in a herringbone pattern, and the two stepped grooves are connected at their closest ends by a semi-circular groove.

2. The microtextured tool according to claim 1, characterized in that, It also includes two staggered grooves, which are staggered and connected to the portion of the central groove that extends out of the fan-shaped annular groove.

3. The microtextured tool according to claim 2, characterized in that, The fan-fin structure microtexture is arranged in a 3*3 array, the central groove is parallel to the main cutting edge of the tool body, and the central groove extends into the fan-shaped annular groove towards the side away from the edge of the tool body.

4. The microtextured tool according to claim 1, characterized in that, The herringbone-shaped stepped grooves are positioned towards the edge of the tool base, and multiple stepped structures are arranged equidistantly along the main cutting edge.

5. The microtextured tool according to claim 1, characterized in that, The raceway roller structure has a straight groove, and spherical grooves that can accommodate spherical rollers are equidistantly arranged on the straight groove. The spherical rollers are rolled in the spherical grooves, and a part of the spherical rollers protrudes from the spherical grooves. The diameter of the spherical grooves is greater than the width of the straight groove. The stepped grooves are connected to the straight groove.

6. The microtextured tool according to claim 5, characterized in that, The straight groove is parallel to the main cutting edge.

7. The processing method of the microtextured tool according to any one of claims 1 to 6, characterized in that, Includes the following steps: Select silicon carbide tool matrix and nickel-titanium alloy spherical rollers; The tool substrate is polished, and then ultrasonically cleaned in a mixed solution of acetone and anhydrous ethanol. The back face of the tool substrate is machined with femtosecond laser and wet etching to create straight grooves and spherical grooves with fan-fin microtexture, stepped structure and raceway roller structure; A nickel-titanium alloy spherical roller is pressed into a spherical groove, and the spherical roller is heated to restore its shape to match the spherical groove, thus obtaining a microtextured tool.

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