Alloy milling cutter for fiber material processing and processing technology of alloy milling cutter

Abstract

The invention relates to the technical field of alloy milling cutters, and particularly discloses an alloy milling cutter for fiber material processing and a processing technology of the alloy milling cutter. According to the scheme, the alloy milling cutter for fiber material machining is provided with the first leftward-rotating crushing teeth and the second rightward-rotating crushing teeth which are centrosymmetric, the two-way spiral blades synchronously act on a fiber layer during high-speed cutting, the leftward-rotating teeth generate inward cutting force in the radial direction, the rightward-rotating teeth generate outward cutting force in the radial direction, and the two forces offset each other, so that the overall stress of the cutter is balanced, and the service life of the cutter is prolonged. And the burr height caused by fiber interlayer stripping is effectively inhibited. Two sides of the first crushing teeth and two sides of the second crushing teeth are respectively provided with first fine trimming teeth and second fine trimming teeth which are distributed at opposite angles of 60 degrees and 35 degrees, so that a'coarse crushing-fine trimming 'collaborative cutting mechanism is formed: the crushing teeth rapidly cut off a fiber layer at a high helical angle and a large cutting amount, and the fine trimming teeth carry out secondary trimming on residual fiber fractures after rough machining through small-included-angle cutting edges; and cutting edge breakage caused by single cutting overload is avoided.

Description

Technical Field

[0001] The present application relates to the technical field of alloy milling cutters, and in particular to an alloy milling cutter for processing fiber materials and a processing technology of the alloy milling cutter. Background Art

[0002] As the core tool for precision machining of composite materials, alloy milling cutters are widely used in the cutting, trimming and fine milling of high-performance composite materials such as carbon fiber and glass fiber in the fields of aerospace, automobile manufacturing, etc. This type of material has become a key material for lightweight upgrades in modern industry due to its light weight, high strength and corrosion resistance. However, its anisotropy and weak interlayer bonding force have put forward extremely high requirements on machining tools: burr-free edges, high surface finish and long life stable machining are required under high-speed cutting. However, the limitations of existing alloy milling cutters in blade design, coating process and matrix performance have led to frequent problems such as delamination and tearing, resin sticking to the tool, and blade chipping in the processing of fiber materials, which seriously restricts machining accuracy and efficiency.

[0003] Specifically, conventional alloy milling cutters mostly use a unidirectional spiral blade structure. Although the chip removal capacity is improved by increasing the spiral angle, the unidirectional cutting force causes fiber interlayer peeling, and the burr height reaches 15-30μm. At the same time, the cutting edge is not graded, and the roughing and finishing functions are mixed. The fiber fractures remaining after roughing need to be cut again with a fine blade, which aggravates the cutting edge wear and the tool life is generally less than 200 hours. In addition, although the traditional chemical vapor deposition coating process improves the surface hardness, high-temperature deposition causes the substrate to become brittle, and stress accumulates in the coating to form microcracks, which are prone to peeling under the high-frequency impact of the fiber material, further shortening the effective life of the tool.

[0004] Although the industry has tried to improve it through composite coatings (AlTiN / TiSiN) or local blade optimization (such as increasing the rake angle), the improvement effect is limited due to the lack of systematic adaptation to the cutting mechanism of composite materials: the one-way chip removal design cannot balance the axial and radial cutting forces, resulting in processing vibration and edge collapse; the homogeneous coating is difficult to balance high hardness and low friction coefficient, and the edge adheres to resin particles to form a hot melt nodule, which worsens the chip removal conditions. At its root, the processing of fiber composite materials requires tools with multi-level collaborative cutting capabilities, a high-toughness matrix and a systematic design of gradient wear-resistant coatings, and the existing technology has not yet formed an effective solution for this. Summary of the invention

[0005] In order to improve the above-mentioned problems existing in alloy milling cutters, the present application provides an alloy milling cutter for processing fiber materials and a processing technology of the alloy milling cutter.

[0006] The first aspect of the present application provides an alloy milling cutter for fiber material processing, which adopts the following technical solution: An alloy milling cutter for processing fiber materials, comprising a cutter body and a cutter head, wherein a first crushing tooth and a second crushing tooth are arranged on a side wall of the cutter head in a circumferential direction, wherein the first crushing tooth and the second crushing tooth are centrally symmetrical about any point on an axis of the cutter head, and the first crushing tooth has a left-handed rotation, and the second crushing tooth has a right-handed rotation, and the helix angles of the first crushing tooth and the second crushing tooth are both 85° and are diagonally distributed; A first finishing tooth and a second finishing tooth are provided on both sides of the first crushing tooth or the second crushing tooth, the included angle of the two first finishing teeth is 60° and they are diagonally distributed, and the included angle of the two second finishing teeth is 35° and they are diagonally distributed; A chip groove is provided between the first crushing tooth and the first finishing tooth and the second finishing tooth, respectively; a chip groove is provided between the first finishing tooth and the second finishing tooth, respectively; and a chip groove is provided between the second crushing tooth and the first finishing tooth and the second finishing tooth, respectively.

[0007] By adopting the above technical scheme, the alloy milling cutter for processing fiber materials in this scheme is provided with a centrally symmetrical left-handed first crushing tooth and a right-handed second crushing tooth. During high-speed cutting, the bidirectional spiral blade acts on the fiber layer synchronously. The left-handed teeth generate a radially inward cutting force, and the right-handed teeth generate a radially outward cutting force. The two forces offset each other, so that the overall force of the tool is balanced, and the burr height caused by peeling between fiber layers is effectively suppressed.

[0008] The first and second finishing teeth are arranged at diagonal angles of 60° and 35° on both sides of the first crushing tooth and the second crushing tooth respectively, forming a "rough crushing-fine finishing" collaborative cutting mechanism: the crushing teeth quickly cut off the fiber layer with a high helix angle and a large cutting amount, and the finishing teeth perform secondary finishing on the fiber fractures remaining from rough machining through a small-angle cutting edge, avoiding cutting edge chipping caused by a single cutting overload.

[0009] The continuous distribution of chip grooves between adjacent teeth (between crushing teeth and finishing teeth, between finishing teeth and finishing teeth) combined with the 4° helix angle design allows the chips to be evenly discharged along the spiral direction of the groove body, avoiding scratches on the machined surface caused by chip accumulation, ensuring the surface finish Ra≤0.8μm. This multi-stage cutting structure greatly increases the tool life, reduces the frequency of tool changes, and greatly improves processing efficiency.

[0010] Optionally, the first crushing teeth and the second crushing teeth of the cutter body are alternately arranged at 62° and 70° respectively, the helix angles of the chip groove between the first finishing tooth and the first crushing tooth and the chip groove between the second finishing tooth and the second crushing tooth are both 4°, and the helix angle of the chip groove between the first finishing tooth and the second finishing tooth is 4°.

[0011] By adopting the above technical solution, through the alternating arrangement of teeth with different helix angles, a periodic cutting load change is formed during axial feed, which disperses the cutting heat accumulation, reduces the local temperature rise of the cutting edge, and slows down the expansion of microcracks caused by thermal stress of the titanium metal coating. The 4° helix angle design of the chip groove between the first finishing tooth and the crushing tooth, and between the second finishing tooth and the crushing tooth, allows the long fiber debris generated by rough machining to be guided by the groove wall during discharge, and flow in layers with the fine debris generated by the finishing teeth, avoiding the blockage of the groove body caused by chip removal interference, and improving the chip removal efficiency by 30%. The same-angle spiral structure of the chip groove between the finishing teeth ensures the rapid export of the finishing debris, further reducing the wear of the chip adhesion on the cutting edge. The synergistic effect of this interactive configuration and the chip removal structure greatly reduces the vibration amplitude of the tool in the processing of carbon fiber laminates and the edge chipping rate.

[0012] Optionally, the surface of the blade body is coated with a titanium physical vapor deposition coating, the titanium physical vapor deposition coating has a thickness of 2-3 μm and a friction coefficient of ≤0.15.

[0013] By adopting the above technical solution, the 2-3μm titanium metal physical vapor deposition coating coated on the surface of the blade is deposited at a low temperature of 400-450℃ through an unbalanced magnetron sputtering process, avoiding the coarsening of the cemented carbide matrix grains caused by high temperature, and increasing the bonding strength between the coating and the matrix. The TiAlN / TiSiN multi-layer alternating structure forms a gradient hardness distribution, the high hardness of the surface layer resists the impact of the fiber, and the high toughness of the inner layer inhibits the initiation of cracks.

[0014] The coating surface with a friction coefficient of ≤0.15 significantly reduces the tendency of resin adhesion and greatly improves the fluency of chip removal.

[0015] Optionally, the tooth root arc radius R of the first crushing tooth and the second crushing tooth is 0.1-0.15 mm, and the tooth top arc radius R is 0.05-0.08 mm.

[0016] By adopting the above technical solution, the cutting force is concentrated on the tooth top arc area by optimizing the tooth profile curvature to match the shear strength of the fiber layer, avoiding tooth root fracture caused by stress concentration. At the same time, the small arc radius design of the tooth top enhances the cutting edge cutting ability, reduces the cutting resistance at the same feed speed, and realizes chatter-free cutting with an 85° helix angle, and the machined surface waviness Wz≤2μm.

[0017] Optionally, the edge passivation radius of the first finishing tooth is 0.01-0.02 mm, and the edge passivation radius of the second finishing tooth is 0.005-0.01 mm.

[0018] By adopting the above technical solution, the first finishing tooth and the second finishing tooth are subjected to graded passivation treatment, so that the roughing edge has a moderate micro-edge strength to withstand the fiber impact, and the finishing edge achieves a "mirror-like" cutting effect through an ultra-small passivation radius. Actual measurements show that this design can adjust the surface residual stress of the finishing area from -200MPa (compressive stress) to -50MPa, effectively suppressing the warping deformation of the laminate after fiber composite material processing, while reducing the edge chipping rate to 0.1 times / 10,000 revolutions.

[0019] Optionally, a nano-hydrophobic coating is provided at the bottom of each chip groove, and the contact angle is ≥150°.

[0020] By adopting the above technical solution, the nano-hydrophobic coating at the bottom of the chip groove forms a fluorosilane molecular layer through a chemical vapor deposition process, reducing the adhesion between the chips and the groove body to less than 0.1N / mm². The hydrophobic properties combined with the 4° helical angle chip groove allow the chips to be discharged in a rolling form rather than sliding friction, reducing the groove wear rate by 60%, especially in glass fiber processing, it can avoid abrasive wear between SiO2 chips and metal groove bodies, and the chip removal efficiency remains stable throughout the life cycle of the tool.

[0021] Optionally, the titanium metal physical vapor deposition coating is a TiAlN / TiSiN multi-layer alternating structure, with a single layer thickness of 0.2-0.3 μm and a total number of layers of 10-15 layers.

[0022] By adopting the above technical solution, the TiAlN / TiSiN multilayer coating is deposited alternately through 10-15 layers, and the thickness of each layer is strictly controlled at 0.2-0.3μm, and the interlayer interface effect is used to prevent the cross-layer extension of cracks. The TiAlN layer provides high-temperature stability, and the TiSiN layer fills the columnar crystal gaps through the amorphous phase, so that the coating porosity is ≤0.5%.

[0023] This structure exhibits excellent thermal shock resistance in intermittent cutting of fiber composite materials. There is no peeling after 1,000 hot and cold cycles (ΔT=800°C), and the coating life is 2 times longer than that of a single-layer structure.

[0024] A second aspect of the present application provides a processing technology of an alloy milling cutter for processing fiber materials, based on any one of the alloy milling cutters for processing fiber materials described in the first aspect, comprising the following steps: S1: Ultrafine-grained cemented carbide powder is used to make a blade blank through low-pressure sintering, the sintering temperature is 1420-1450℃, the insulation pressure is 6-8MPa, and the grain size is ≤0.5μm; S2: The front angle of the cutter teeth is mirror polished, with a roughness of Ra ≤ 0.05 μm. After polishing, liquid nitrogen cryogenic treatment is used at a temperature of -196°C for 2 hours. S3: The first crushing tooth and the second crushing tooth are processed synchronously by a five-axis linkage grinder, with a helix angle tolerance of ±0.5° and a cutting edge passivation radius of 0.01-0.02mm; S4: The titanium metal coating is deposited on the surface of the blade using an unbalanced magnetron sputtering process. The target material purity is ≥99.99%, the deposition temperature is 400-450°C, the bias voltage is -80V to -120V, and the coating deposition rate is 0.3μm / h.

[0025] By adopting the above processing technology, the ultra-fine-grained carbide blade blank is sintered at 1420-1450℃ low pressure (grain size ≤0.5μm), and the bending strength of the matrix reaches more than 4500MPa, which is 30% higher than the conventional sintering process. The mirror polishing of the front angle of the blade teeth (Ra≤0.05μm) combined with liquid nitrogen cryogenic treatment (-196℃ for 2 hours, 3 cycles) reduces the dislocation density of the cutting edge to the order of 10^8 / cm², the residual austenite content is less than 1%, and the micro-chip size of the cutting edge is controlled within 0.5μm. The five-axis linkage grinder simultaneously processes the crushing teeth and finishing teeth, with a helix angle tolerance of ±0.5°, ensuring that the phase synchronization accuracy of the bidirectional cutting edge is ≤0.01mm, achieving high consistency processing without repeated cutting marks.

[0026] Furthermore, the liquid nitrogen cryogenic treatment in step S2 includes: placing the polished blade blank in a liquid nitrogen environment, cooling it to -196°C at a rate of 5°C / min, and then warming it to room temperature at a rate of 2°C / min after keeping it for 2 hours, and the number of cycles is ≥3 times; The unbalanced magnetron sputtering process in step S2 includes: alternately introducing argon and nitrogen during the deposition process, with an argon-nitrogen flow ratio of 5:1, a pressure in the deposition chamber of 0.3-0.5 Pa, and a distance between the target and the blade of 80-100 mm.

[0027] By adopting the above technical solutions, liquid nitrogen cryogenic treatment uses a gradient cooling of 5℃ / min to avoid thermal stress cracking of the substrate, and the temperature recovery rate is 2℃ / min to fully transform the martensite, and the substrate hardness is increased from HRC62 to HRC65, while the toughness is increased by 20%. In the unbalanced magnetron sputtering process, the argon-nitrogen flow ratio is 5:1, and the coating density is increased to more than 98% through high-energy argon ion bombardment. The low-pressure environment of 0.3-0.5Pa in the deposition chamber reduces the incorporation of gas impurities, and the oxygen content of the coating is ≤0.5at%, which significantly improves the high-temperature oxidation resistance (oxidation weight gain at 1000℃ <1mg / cm²).

[0028] A processing technology of an alloy milling cutter for processing fiber materials, further comprising the following steps: S5: Place the coated tool in a vacuum furnace, heat it to 600°C at 10°C / min, keep it at that temperature for 1 hour, and then quench it to below 200°C with inert gas; S6: The coating surface is micro-sandblasted, the blasting pressure is 0.2-0.3MPa, the abrasive is aluminum oxide particles (particle size 20-30μm), and the blasting time is 30-60 seconds.

[0029] By adopting the above processing technology, vacuum annealing at 600℃ after coating relaxes the internal stress of the multilayer coating from -2.5GPa (compressive stress) to -1.0GPa, avoiding interlayer peeling under cutting impact. Micro-sandblasting (aluminum oxide particles 20-30μm, 0.2-0.3MPa) forms a uniform roughness of Ra=0.1-0.2μm on the coating surface, increases the mechanical bite resistance between resin debris and the coating surface, and increases the critical peeling force of the adhesive from 0.5N / mm² to 2.0N / mm², and cooperates with the hydrophobic coating to achieve a "self-cleaning" cutting effect.

[0030] In summary, the present application includes at least one of the following beneficial technical effects: 1. In this scheme, the alloy milling cutter for fiber material processing is provided with a centrally symmetrical left-handed first crushing tooth and a right-handed second crushing tooth. During high-speed cutting, the bidirectional spiral blade acts on the fiber layer synchronously, so that the left-handed tooth generates a radially inward cutting force, and the right-handed tooth generates a radially outward cutting force. The two forces offset each other, so that the overall force of the tool is balanced, and the burr height caused by peeling between fiber layers is effectively suppressed; 2. The first and second finishing teeth are set at 60° and 35° diagonally on both sides of the first crushing tooth and the second crushing tooth, respectively, to form a "rough crushing-fine finishing" collaborative cutting mechanism: the crushing teeth quickly cut off the fiber layer with a high helix angle and a large cutting amount, and the finishing teeth perform secondary finishing on the fiber fractures remaining from the rough machining through a small angle cutting edge to avoid edge chipping caused by a single cutting overload. The continuous distribution of chip grooves between adjacent teeth (between crushing teeth and fine finishing teeth, and between fine finishing teeth) combined with a 4° helix angle design allows the debris to be evenly discharged along the spiral direction of the groove body, avoiding scratches on the machined surface caused by debris accumulation, and ensuring a surface finish of Ra ≤ 0.8μm. This multi-stage cutting structure increases the tool life to more than 500 hours, while reducing the frequency of tool changes and increasing machining efficiency by 40%; 3. The first crushing teeth and the second crushing teeth are alternately arranged at 62° and 70°. Through the alternating arrangement of teeth with different helix angles, a periodic cutting load change is formed during axial feeding, which disperses the cutting heat accumulation, reduces the local temperature rise of the cutting edge, and slows down the expansion of micro cracks caused by thermal stress of the titanium metal coating; 4. The 4° helix angle design of the chip removal groove between the first finishing tooth and the crushing tooth, and between the second finishing tooth and the crushing tooth, allows the long fiber debris generated by rough machining to be guided by the groove wall during discharge, and flow in layers with the fine debris generated by the finishing teeth, avoiding the blockage of the groove body caused by chip removal interference, and improving the chip removal efficiency by 30%; 5. The spiral structure of the chip removal grooves between the fine teeth ensures the rapid removal of fine machining debris, further reducing the wear of the cutting edge caused by debris adhesion. The synergistic effect of this interactive configuration and the chip removal structure reduces the vibration amplitude of the tool in the processing of carbon fiber laminates from 0.1mm to below 0.03mm, and the edge chipping rate is reduced by 70%; 6. Ultrafine-grained carbide blade blanks are sintered at 1420-1450℃ low pressure (grain size ≤0.5μm), and the matrix bending strength reaches more than 4500MPa, which is 30% higher than the conventional sintering process. The mirror polishing of the front angle of the blade teeth (Ra≤0.05μm) and the deep cryogenic treatment of liquid nitrogen (-196℃ for 2 hours, 3 cycles) reduce the dislocation density of the cutting edge to the order of 10^8 / cm², the residual austenite content is less than 1%, and the micro-chip size of the cutting edge is controlled within 0.5μm. The five-axis linkage grinder synchronously processes the crushing teeth and finishing teeth, and the helix angle tolerance is ±0.5°, ensuring that the phase synchronization accuracy of the bidirectional cutting edge is ≤0.01mm, achieving high consistency processing without repeated cutting marks. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0032] Figure 1 It is a schematic diagram of the overall structure of the alloy milling cutter in the embodiment of the present application; Figure 2 yes Figure 1 A schematic diagram of the structure of the cutter head of the alloy milling cutter; Figure 3 yes Figure 2 A plan view of the end of the cutter head; Figure 4 yes Figure 1 Parameter diagram of the alloy milling cutter from the first perspective; Figure 5 yes Figure 1 Parameter diagram of the alloy milling cutter from the second perspective.

[0033] Figure numerals: 1, cutter body; 2, cutter head; 3, first crushing tooth; 4, second crushing tooth; 5, first finishing tooth; 6, second finishing tooth; 7, chip removal groove. DETAILED DESCRIPTION

[0034] The following is combined with Figure 1-5 This application is described in further detail.

[0035] The present application embodiment discloses an alloy milling cutter for processing fiber materials. Figure 1 , Figure 2 and Figure 3 , including a cutter body 1 and a cutter head 2, the side wall of the cutter head 2 is circumferentially provided with a first crushing tooth 3 and a second crushing tooth 4, the first crushing tooth 3 and the second crushing tooth 4 are symmetrical about any point on the axis of the cutter head 2, and the hand direction of the first crushing tooth 3 is left-handed, and the hand direction of the second crushing tooth 4 is right-handed, and the helix angles of the first crushing tooth 3 and the second crushing tooth 4 are both 85° and are diagonally distributed.

[0036] The first crushing tooth 3 or the second crushing tooth 4 is provided with a first finishing tooth 5 and a second finishing tooth 6 on both sides. The included angle of the two first finishing teeth 5 is 60° and they are diagonally distributed. The included angle of the two second finishing teeth 6 is 35° and they are diagonally distributed.

[0037] Reference Figure 1 and Figure 2 A chip groove 7 is provided between the first crushing tooth 3 and the first finishing tooth 5 and the second finishing tooth 6, a chip groove 7 is provided between the first finishing tooth 5 and the second finishing tooth 6, and a chip groove 7 is provided between the second crushing tooth 4 and the first finishing tooth 5 and the second finishing tooth 6.

[0038] In the present scheme, the alloy milling cutter for processing fiber materials is provided with a centrally symmetrical left-handed first crushing tooth 3 and a right-handed second crushing tooth 4. During high-speed cutting, the bidirectional spiral blade acts on the fiber layer synchronously. The left-handed teeth generate a radially inward cutting force, and the right-handed teeth generate a radially outward cutting force. The two forces offset each other, so that the overall force of the tool is balanced, and the burr height caused by peeling between fiber layers is effectively suppressed, and the height is reduced from the conventional 15-30μm to below 5μm.

[0039] The first and second finishing teeth 6 are respectively arranged at 60° and 35° diagonally on both sides of the first crushing tooth 3 and the second crushing tooth 4, forming a "rough crushing-fine finishing" collaborative cutting mechanism.

[0040] Although some existing technologies combine rough milling teeth with fine milling teeth, such as the patent publication CN119304971A, in this solution, the rough milling teeth and fine milling teeth are simply arranged in the axial direction to achieve functional superposition, with the rough milling teeth in front and the fine milling teeth in the back. The cutting paths of the two are independent and no mechanical connection is formed. The effect is only the sequential execution of rough machining and fine machining, and the following problems are not solved: The vibration of rough milling is directly transmitted to the fine milling teeth through the cutter body, resulting in residual chatter marks on the finished surface. The large chips produced by rough milling are mixed with the fine chips from fine milling, blocking the chip groove. The cutting parameters such as speed and feed rate need to be adjusted step by step for rough milling and fine milling, which reduces efficiency.

[0041] Moreover, the unidirectional spiral design of the rough milling teeth causes the cutting force to be concentrated in a single direction, which cannot offset the lateral shear stress between fiber layers, and the risk of interlayer delamination still exists (burr height > 10μm). Although the fine milling teeth improve the surface quality through the small rake angle design, the fine finishing effect is limited due to the vibration transmission of the rough milling teeth (Ra≈1.2μm).

[0042] For example, the rough milling teeth and the fine milling teeth disclosed in the publication number TWM643904U share the same-direction chip groove 7. The large chips produced by rough machining and the fine chips produced by fine finishing are mixed and accumulated, resulting in partial blockage of the chip groove 7 (blockage rate > 30%). The cutting heat cannot be discharged in time, and the edge temperature rises to more than 600°C, which accelerates the peeling of the coating.

[0043] The technical solution in this application has mechanically balanced the left-handed and right-handed first crushing teeth 3 and second crushing teeth 4. Not only does it form independent channels for the chip grooves 7 of the first crushing teeth 3 and second crushing teeth 4 and the chip grooves 7 of the first finishing teeth 5 and second finishing teeth 6, but it also physically isolates the discharge paths, greatly reducing the possibility of residual chatter marks on the finishing surface. The left-handed chips are discharged to the left side of the tool along the left-hand spiral groove, and the right-handed chips are discharged to the right side of the tool along the right-hand spiral groove. The finishing chips are axially guided out through the middle groove. This design realizes the physical diversion of chips by size / type, reduces the blockage rate of the chip groove 7 from 30% to 5%, and reduces the cutting temperature from 600℃ to below 400℃.

[0044] The first finishing teeth 5, the second finishing teeth 6 and the chip removal groove 7 are coordinated and optimized, so that the first crushing teeth 3 generate a radially inward force F1 when cutting, and the second crushing teeth 4 generate a radially outward force F2, and the combined forces of the two tend to be balanced, that is, F1+F2 is approximately equal to 0, thereby eliminating the transverse shear stress of the fiber layer and reducing the burr height to below 3μm. The left-handed and right-handed helical teeth form a bidirectional helical tooth, which forms a "shear-stretch" composite effect. The fiber layer is cut into a uniform fracture in the rough milling stage, avoiding the fiber drawing phenomenon caused by unidirectional cutting in the prior art.

[0045] The first crushing tooth 3 and the second crushing tooth 4 quickly cut the fiber layer with a high helix angle and a large cutting amount, and the first finishing tooth 5 and the second finishing tooth 6 perform secondary trimming on the fiber fracture remaining from rough machining through a small angle cutting edge to avoid cutting edge chipping caused by a single cutting overload.

[0046] The synergistic optimization between the first finishing tooth 5, the second finishing tooth 6 and the chip removal groove 7 is reflected in the graded cutting and directional chip removal: The first finishing tooth 5 removes the fiber burrs remaining from rough milling at an angle of 60°, and the second finishing tooth 6 performs mirror finishing on the surface at an angle of 35°, realizing the three-level coordination of "rough crushing-semi-finishing-fine polishing", and the surface finish Ra≤0.4μm (existing technology Ra≈1.2μm).

[0047] The helix angle of the chip removal groove 7 matches the rotation direction of the bidirectional helical tooth. The chips of the first crushing tooth 3 (left-handed tooth) are discharged along the left-handed spiral groove, and the chips of the second crushing tooth 4 (right-handed tooth) are discharged along the right-handed spiral groove. The refined chips are discharged through the middle groove to avoid mixing and blockage, and the chip removal efficiency is improved by 50%.

[0048] Compared with the related technology (TWM643904U), the clogging rate of chip groove 7 is 30%, which is reduced to 5% in this solution, and the finishing efficiency is improved by 80% (the finishing time is shortened to 1 / 3 under the same processing volume).

[0049] Furthermore, the continuous distribution of the chip removal grooves 7 between adjacent teeth (between the crushing teeth and the finishing teeth, and between the finishing teeth) combined with the 4° helix angle design allows the chips to be evenly discharged along the spiral direction of the groove body, avoiding scratches on the machined surface caused by chip accumulation, ensuring the surface finish Ra≤0.8μm. This multi-stage cutting structure increases the tool life to more than 500 hours, while reducing the frequency of tool changes and increasing processing efficiency by 40%.

[0050] Reference Figure 4 and Figure 5 The first crushing teeth 3 and the second crushing teeth 4 of the cutter body 1 are alternately arranged at 62° and 70° respectively, the helix angles of the chip groove 7 between the first finishing tooth 5 and the first crushing tooth 3 and the chip groove 7 between the second finishing tooth 6 and the second crushing tooth 4 are both 4°, and the helix angle of the chip groove 7 between the first finishing tooth 5 and the second finishing tooth 6 is 4°.

[0051] Through the alternating arrangement of teeth with different helix angles, a periodic cutting load change is formed during axial feed, which disperses the cutting heat accumulation and reduces the local temperature rise of the cutting edge. The measured cutting zone temperature drops from the conventional 600°C to below 450°C, slowing down the propagation of microcracks caused by thermal stress in the titanium metal coating.

[0052] The 4° helix angle design of the chip groove 7 between the first finishing tooth 5 and the crushing tooth, and between the second finishing tooth 6 and the crushing tooth, allows the long-fiber debris generated by rough machining to be guided by the groove wall during discharge, and flow in layers with the fine debris generated by the finishing teeth, avoiding blockage of the groove body caused by chip interference, and improving chip removal efficiency by 30%.

[0053] The spiral structure of the chip removal groove 7 between the fine teeth ensures the rapid removal of fine machining chips, further reducing the wear of the cutting edge caused by chip adhesion. The synergistic effect of this interactive configuration and the chip removal structure reduces the vibration amplitude of the tool from 0.1mm to below 0.03mm in the processing of carbon fiber laminates, and reduces the edge chipping rate by 70%.

[0054] The surface of the cutter body 1 is coated with a titanium physical vapor deposition coating, the thickness of the titanium physical vapor deposition coating is 2-3μm, and the friction coefficient is ≤0.15. The 2-3μm titanium physical vapor deposition coating coated on the surface of the cutter body 1 is deposited at a low temperature of 400-450℃ by an unbalanced magnetron sputtering process to avoid the coarsening of the cemented carbide substrate grains caused by high temperature (the substrate grain size is maintained at ≤0.5μm), and the bonding strength between the coating and the substrate is more than 80N.

[0055] The TiAlN / TiSiN multilayer alternating structure (single layer 0.2-0.3μm, total number of layers 10-15 layers) forms a gradient hardness distribution. The high hardness of the surface layer (HV3200) resists fiber impact, and the high toughness of the inner layer (fracture toughness KIC≥6MPa・m^1 / 2) inhibits crack initiation. The coating surface with a friction coefficient of ≤0.15 significantly reduces the tendency of resin adhesion. The actual measurement shows that the weight of the adhesive on the cutting edge is only 0.5mg after 500 hours of cutting (conventional coating is 3mg), the chip removal fluency is improved by 50%, and the tool durability is more than 1.5 times the industry standard.

[0056] The tooth root arc radius R of the first crushing tooth 3 and the second crushing tooth 4 is 0.1-0.15mm, and the tooth top arc radius R is 0.05-0.08mm. By optimizing the tooth curvature to match the shear strength of the fiber layer (the shear strength between carbon fiber layers is about 80MPa), the cutting force is concentrated in the tooth top arc area to avoid tooth root fracture caused by stress concentration, and the tooth root fracture probability is reduced from 10% to less than 0.5%.

[0057] At the same time, the small arc radius design on the tooth top enhances the cutting edge capability, reducing the cutting resistance by 20% at the same feed speed, and achieving chatter-free cutting with an 85° helix angle, with the machined surface waviness Wz ≤ 2μm.

[0058] The edge passivation radius of the first finishing tooth 5 is 0.01-0.02mm, and the edge passivation radius of the second finishing tooth 6 is 0.005-0.01mm. The graded passivation treatment of the edges of the first finishing tooth 5 and the second finishing tooth 6 makes the rough cutting edge have moderate micro-edge strength to withstand fiber impact, and the finishing edge achieves a "mirror-like" cutting effect through an ultra-small passivation radius. Actual measurements show that this design can adjust the surface residual stress of the finishing area from -200MPa (compressive stress) to -50MPa, effectively suppressing the warping deformation of the laminate after processing of the fiber composite material, with a deformation of ≤0.1mm / m, and the edge chipping rate is reduced to 0.1 times / 10,000 revolutions.

[0059] A nano-hydrophobic coating is provided at the bottom of each chip groove 7, and the contact angle is ≥150°. The nano-hydrophobic coating at the bottom of the chip groove 7 (contact angle ≥150°) forms a fluorosilane molecular layer through a chemical vapor deposition process, so that the adhesion between the debris and the groove body is reduced to below 0.1N / mm².

[0060] The hydrophobic property combined with the 4° helix angle chip groove 7 allows the chips to be discharged in a rolling manner rather than sliding friction, reducing the groove wear rate by 60%. Especially in glass fiber processing, it can avoid abrasive wear between SiO2 chips and the metal groove body, and the chip removal efficiency remains stable throughout the life cycle of the tool.

[0061] The titanium metal physical vapor deposition coating is a multi-layer alternating structure of TiAlN / TiSiN, with a single layer thickness of 0.2-0.3μm and a total of 10-15 layers. The TiAlN / TiSiN multi-layer coating is deposited alternately through 10-15 layers, and the thickness of each layer is strictly controlled at 0.2-0.3μm. The interlayer interface effect is used to prevent the cross-layer extension of cracks, and the crack extension rate is reduced from 10^-6m / cycle to 10^-8m / cycle. The TiAlN layer (Al content 30at%) provides high temperature stability, and the TiSiN layer (Si content 10at%) fills the columnar crystal gaps through the amorphous phase, so that the coating porosity is ≤0.5%.

[0062] This structure exhibits excellent thermal shock resistance in intermittent cutting of fiber composite materials. There is no peeling after 1,000 hot and cold cycles (ΔT=800°C), and the coating life is 2 times longer than that of a single-layer structure.

[0063] The implementation principle of an alloy milling cutter for processing fiber materials in an embodiment of the present application is as follows: by setting a centrally symmetrical left-handed first crushing tooth 3 and a right-handed second crushing tooth 4, the bidirectional spiral blade acts on the fiber layer synchronously during high-speed cutting, the left-handed teeth generate a radially inward cutting force, and the right-handed teeth generate a radially outward cutting force, the two forces offset each other, so that the overall force of the tool is balanced, and the burr height caused by peeling between fiber layers is effectively suppressed.

[0064] The first and second finishing teeth 6 are respectively arranged at 60° and 35° diagonally distributed on both sides of the first crushing tooth 3 and the second crushing tooth 4, forming a "rough crushing-fine finishing" collaborative cutting mechanism: the crushing teeth quickly cut off the fiber layer with a high helix angle and a large cutting amount, and the finishing teeth perform secondary finishing on the fiber fractures remaining from rough machining through a small angle cutting edge, avoiding edge chipping caused by a single cutting overload.

[0065] The continuous distribution of the chip removal grooves 7 between adjacent teeth (between the crushing teeth and the finishing teeth, and between the finishing teeth) combined with the 4° helix angle design allows the chips to be evenly discharged along the spiral direction of the groove body, avoiding scratches on the machined surface caused by chip accumulation, ensuring the surface finish Ra≤0.8μm. This multi-stage cutting structure increases the tool life to more than 500 hours, while reducing the frequency of tool changes and increasing processing efficiency by 40%.

[0066] The synergy of this application is derived from the system coupling of mechanical balance design, physical field directional control and cross-scale material-structure optimization, rather than the simple functional superposition of existing technologies. Through innovative designs such as bidirectional helical teeth to offset radial forces, graded fine-tuning teeth to cut sequentially, and independent chip grooves to physically divert, it solves the core problems of interlayer peeling, chip blockage, and short coating life in fiber material processing, achieving an exponential improvement in processing quality and tool life.

[0067] The present application also discloses a processing technology of an alloy milling cutter for processing fiber materials, based on any of the above-mentioned alloy milling cutters for processing fiber materials, comprising the following steps: S1: Ultrafine-grained cemented carbide powder is used to make a blade blank through low-pressure sintering, the sintering temperature is 1420-1450℃, the insulation pressure is 6-8MPa, and the grain size is ≤0.5μm; S2: The front angle of the cutter teeth is mirror polished, with a roughness of Ra ≤ 0.05 μm. After polishing, liquid nitrogen cryogenic treatment is used at a temperature of -196°C for 2 hours. The liquid nitrogen cryogenic treatment in step S2 includes: placing the polished blade blank in a liquid nitrogen environment, cooling it to -196°C at a rate of 5°C / min, and then heating it to room temperature at a rate of 2°C / min after keeping it for 2 hours, and the number of cycles is ≥3 times; The unbalanced magnetron sputtering process in step S2 includes: alternately introducing argon and nitrogen during the deposition process, with an argon-nitrogen flow ratio of 5:1, a pressure in the deposition chamber of 0.3-0.5 Pa, and a distance between the target material and the blade body 1 of 80-100 mm.

[0068] S3: The first crushing tooth 3 and the second crushing tooth 4 are processed synchronously by a five-axis linkage grinder, with a helix angle tolerance of ±0.5° and a cutting edge passivation radius of 0.01-0.02mm; S4: A titanium metal coating is deposited on the surface of the blade body 1 by an unbalanced magnetron sputtering process, with a target material purity of ≥99.99%, a deposition temperature of 400-450°C, a bias voltage of -80V to -120V, and a coating deposition rate of 0.3μm / h.

[0069] S5: Place the coated tool in a vacuum furnace, heat it to 600°C at 10°C / min, keep it at that temperature for 1 hour, and then quench it to below 200°C with inert gas; S6: The coating surface is micro-sandblasted, the blasting pressure is 0.2-0.3MPa, the abrasive is aluminum oxide particles (particle size 20-30μm), and the blasting time is 30-60 seconds.

[0070] The ultrafine-grained carbide blade blank is sintered at 1420-1450℃ under low pressure (grain size ≤ 0.5μm), and the bending strength of the matrix reaches more than 4500MPa, which is 30% higher than that of the conventional sintering process.

[0071] The mirror polishing of the front angle of the blade teeth (Ra≤0.05μm) combined with liquid nitrogen cryogenic treatment (-196℃ for 2 hours, 3 cycles) reduces the dislocation density of the cutting edge to the order of 10^8 / cm², the retained austenite content is less than 1%, and the micro-chip size of the cutting edge is controlled within 0.5μm.

[0072] The five-axis linkage grinder processes the crushing teeth and finishing teeth simultaneously, with a helix angle tolerance of ±0.5°, ensuring the phase synchronization accuracy of the bidirectional cutting edge ≤0.01mm, achieving highly consistent processing without repeated cutting marks.

[0073] Liquid nitrogen cryogenic treatment uses a gradient cooling of 5℃ / min to avoid thermal stress cracking of the substrate, and the temperature recovery rate is 2℃ / min to fully transform the martensite. The substrate hardness is increased from HRC62 to HRC65, and the toughness is increased by 20%. In the unbalanced magnetron sputtering process, the argon-nitrogen flow ratio is 5:1. The coating density is over 98% through high-energy argon ion bombardment. The low-pressure environment of 0.3-0.5Pa in the deposition chamber reduces the incorporation of gas impurities, and the oxygen content of the coating is ≤0.5at%, which significantly improves the high-temperature oxidation resistance (oxidation weight gain at 1000℃ <1mg / cm²).

[0074] After coating, vacuum annealing at 600℃ relaxes the internal stress of the multilayer coating from -2.5GPa (compressive stress) to -1.0GPa, avoiding interlayer peeling under cutting impact. Micro-sandblasting (aluminum oxide particles 20-30μm, 0.2-0.3MPa) forms a uniform roughness of Ra=0.1-0.2μm on the coating surface, increasing the mechanical bite resistance between resin debris and the coating surface, and increasing the critical peeling force of the adhesive from 0.5N / mm² to 2.0N / mm², and cooperates with the hydrophobic coating to achieve a "self-cleaning" cutting effect.

[0075] By optimizing the entire chain of materials, processes, and structures, from matrix grain size control (grains ≤ 0.5μm), edge passivation grading to gradient coating deposition, a three-in-one tool performance system of "impact resistance, anti-adhesion, and anti-crack" is formed to systematically improve processing quality and tool life.

[0076] The above are all optional embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. An alloy milling cutter for processing fiber materials, comprising a cutter body (1) and a cutter head (2), characterized in that: The side wall of the cutter head (2) is provided with a first crushing tooth (3) and a second crushing tooth (4) along the circumferential direction, the first crushing tooth (3) and the second crushing tooth (4) are symmetrical about any point on the axis of the cutter head (2), the first crushing tooth (3) is left-handed, and the second crushing tooth (4) is right-handed, and the helix angles of the first crushing tooth (3) and the second crushing tooth (4) are both 85° and are diagonally distributed; A first finishing tooth (5) and a second finishing tooth (6) are provided on both sides of the first crushing tooth (3) or the second crushing tooth (4); the included angle of the two first finishing teeth (5) is 60° and they are diagonally distributed; the included angle of the two second finishing teeth (6) is 35° and they are diagonally distributed; A chip removal groove (7) is provided between the first crushing tooth (3) and the first finishing tooth (5) and the second finishing tooth (6), a chip removal groove (7) is provided between the first finishing tooth (5) and the second finishing tooth (6), and a chip removal groove (7) is provided between the second crushing tooth (4) and the first finishing tooth (5) and the second finishing tooth (6).

2. The alloy milling cutter for fiber material processing according to claim 1, characterized in that: The first crushing teeth (3) and the second crushing teeth (4) of the cutter body (1) are alternately arranged at 62° and 70° respectively; the helix angles of the chip groove (7) between the first finishing tooth (5) and the first crushing tooth (3) and the chip groove (7) between the second finishing tooth (6) and the second crushing tooth (4) are both 4°; the helix angle of the chip groove (7) between the first finishing tooth (5) and the second finishing tooth (6) is 4°.

3. The alloy milling cutter for fiber material processing according to claim 1, characterized in that: The surface of the blade body (1) is coated with a titanium metal physical vapor deposition coating, the thickness of the titanium metal physical vapor deposition coating is 2-3 μm, and the friction coefficient is ≤0.

15.

4. The alloy milling cutter for fiber material processing according to claim 1, characterized in that: The tooth root arc radius R of the first crushing tooth (3) and the second crushing tooth (4) is 0.1-0.15 mm, and the tooth top arc radius R is 0.05-0.08 mm.

5. The alloy milling cutter for fiber material processing according to claim 1, characterized in that: The edge passivation radius of the first finishing tooth (5) is 0.01-0.02 mm, and the edge passivation radius of the second finishing tooth (6) is 0.005-0.01 mm.

6. The alloy milling cutter for fiber material processing according to claim 2, characterized in that: The bottom of each chip removal groove (7) is provided with a nano-hydrophobic coating with a contact angle of ≥150°.

7. The alloy milling cutter for fiber material processing according to claim 3, characterized in that: The titanium metal physical vapor deposition coating is a TiAlN / TiSiN multi-layer alternating structure, with a single layer thickness of 0.2-0.3 μm and a total number of layers of 10-15.

8. A processing technology of an alloy milling cutter for processing fiber materials, based on the alloy milling cutter for processing fiber materials as claimed in any one of claims 1 to 7, characterized in that: The following steps are involved: S1: Ultrafine-grained cemented carbide powder is used to make a blade blank through low-pressure sintering, the sintering temperature is 1420-1450℃, the insulation pressure is 6-8MPa, and the grain size is ≤0.5μm; S2: The front angle of the cutter teeth is mirror polished, with a roughness of Ra ≤ 0.05 μm. After polishing, liquid nitrogen cryogenic treatment is used at a temperature of -196°C for 2 hours. S3: The first crushing tooth (3) and the second crushing tooth (4) are synchronously processed by a five-axis linkage grinder, with a helix angle tolerance of ±0.5° and a cutting edge passivation radius of 0.01-0.02 mm; S4: A titanium metal coating is deposited on the surface of the blade (1) by an unbalanced magnetron sputtering process, with a target material purity of ≥99.99%, a deposition temperature of 400-450°C, a bias voltage of -80V to -120V, and a coating deposition rate of 0.3μm / h.

9. The processing technology of the alloy milling cutter for fiber material processing according to claim 8, characterized in that: The liquid nitrogen cryogenic treatment in step S2 comprises: placing the polished blade blank in a liquid nitrogen environment, cooling it to -196°C at a rate of 5°C / min, and then heating it to room temperature at a rate of 2°C / min after keeping it for 2 hours, and the number of cycles is ≥3 times; The unbalanced magnetron sputtering process in step S2 includes: alternately introducing argon and nitrogen during the deposition process, with an argon-nitrogen flow ratio of 5:1, a pressure in the deposition chamber of 0.3-0.5 Pa, and a distance between the target material and the blade body (1) of 80-100 mm.

10. The processing technology of the alloy milling cutter for fiber material processing according to claim 8, characterized in that: The following steps are involved: S5: Place the coated tool in a vacuum furnace, heat it to 600°C at 10°C / min, keep it at that temperature for 1 hour, and then quench it to below 200°C with inert gas; S6: The coating surface is micro-sandblasted, the blasting pressure is 0.2-0.3MPa, the abrasive is aluminum oxide particles (particle size 20-30μm), and the blasting time is 30-60 seconds.

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