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

Abstract

The application 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. In the alloy milling cutter for fiber material processing, a left-rotating first crushing tooth and a right-rotating second crushing tooth which are symmetric to the center are arranged, bidirectional spiral edges are synchronously used on the fiber layer during high-speed cutting, the left-rotating tooth generates a radial inward cutting force, the right-rotating tooth generates a radial outward cutting force, the two forces are mutually offset, the overall force of the cutter is balanced, and the burr height caused by the peeling between the fiber layers is effectively inhibited. First and second finishing teeth which are diagonally distributed at 60 DEG and 35 DEG on the two sides of the first and second crushing teeth are arranged, a 'coarse crushing-finish cutting' cooperative cutting mechanism is formed, the crushing tooth cuts off the fiber layer at a high spiral angle and a large cutting amount, the finishing tooth performs secondary finishing on the fiber fracture left after coarse machining through a small-angle edge, and the edge collapse caused by single cutting overload is avoided.

Description

TECHNICAL FIELD

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

[0002] As a core tool for the precision machining of composite materials, alloy milling cutters are widely used in the cutting, trimming and fine milling processes of high-performance composite materials such as carbon fibers and glass fibers in the fields of aerospace and automobile manufacturing. Such materials have become key materials for the upgrading of modern industrial lightweight due to their lightweight, high strength, corrosion resistance and other characteristics, but their anisotropy and weak interlayer bonding require extremely high requirements for machining tools: stable machining with no burr edge, high surface finish and long service life under high-speed cutting. However, the limitations of existing alloy milling cutters in blade design, coating process and substrate performance lead to problems such as delamination and tearing, resin sticking to the blade and blade edge collapse in the processing of fiber materials, which seriously restricts the processing precision and efficiency.

[0003] Specifically, in conventional technology, alloy milling cutters mostly adopt a one-way spiral blade structure, which, although increases the spiral angle to improve the chip removal capacity, causes fiber interlayer peeling due to one-way cutting force, and the burr height reaches 15-30 μm; at the same time, the blade edge is not processed in stages, and the functions of rough and fine machining are mixed, so that the fiber fracture left by rough machining needs to be processed again by fine machining, which aggravates the wear of the blade edge, and the service life of the tool is generally less than 200 hours. In addition, although the traditional chemical vapor deposition coating process improves the surface hardness, the high-temperature deposition causes the substrate to become brittle, and the internal stress of the coating accumulates to form microcracks, which are easily peeled off under the high-frequency impact of fiber materials, further shortening the effective service life of the tool.

[0004] The industry has tried to improve through composite coatings (AlTiN / TiSiN) or local blade optimization (such as increasing the rake angle), but due to the lack of systematic adaptation to the cutting mechanism of composite materials, the improvement effect is limited: the one-way chip removal design cannot balance the axial and radial cutting forces, leading to processing vibration and edge collapse; homogeneous coatings cannot balance high hardness and low friction coefficient, and after the blade edge adheres to resin particles, a hot tumor is formed, which worsens the chip removal conditions. To sum up, the processing of fiber composite materials requires a tool with multi-stage coordinated cutting ability, a high-toughness substrate and a systematic design of gradient wear-resistant coating, but the existing technology has not yet formed an effective solution to this problem. SUMMARY

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

[0006] The first aspect of the application provides an alloy milling cutter for fiber material processing, which adopts the following technical scheme:

[0007] The alloy milling cutter for fiber material processing comprises a cutter body and a cutter head, the side wall of the cutter head is provided with first and second crushing teeth in the circumferential direction, the first and second crushing teeth are centrally symmetric about any point on the axis of the cutter head, the first crushing teeth are left-handed, the second crushing teeth are right-handed, the helix angle of the first and second crushing teeth is 85° and is diagonally distributed;

[0008] Both sides of the first or second crushing teeth are provided with first and second finishing teeth, the included angle of the two first finishing teeth is 60° and is diagonally distributed, and the included angle of the two second finishing teeth is 35° and is diagonally distributed.

[0009] The first crushing teeth are respectively provided with chip removal grooves between the first and second finishing teeth, the first and second finishing teeth are provided with chip removal grooves, and the second crushing teeth are respectively provided with chip removal grooves between the first and second finishing teeth.

[0010] By adopting the above technical scheme, in the alloy milling cutter for fiber material processing, the left-handed first crushing teeth and the right-handed second crushing teeth are centrally symmetric, the bidirectional helical edges simultaneously act on the fiber layer during high-speed cutting, the left-handed teeth generate a radial inward cutting force, the right-handed teeth generate a radial outward cutting force, the two forces are offset, the overall force of the cutter is balanced, and the burr height caused by the peeling between the fiber layers is effectively inhibited.

[0011] The first and second finishing teeth with an included angle of 60° and 35° are respectively arranged on both sides of the first and second crushing teeth, forming a "rough crushing-finish cutting" cooperative cutting mechanism: the crushing teeth cut the fiber layer quickly with a large cutting amount and a high helix angle, and the finishing teeth perform secondary finishing on the fiber fracture remaining after rough machining through a small included angle edge, so as to avoid the edge collapse caused by single cutting overload.

[0012] The continuous distribution of the chip removal grooves between adjacent teeth (between the crushing teeth and the finishing teeth, and between the finishing teeth) and the design of the 4° helix angle make the chips uniformly discharged along the helical direction of the groove body, avoid the scratch of the processed surface caused by the accumulation of the chips, and ensure that the surface roughness Ra is less than or equal to 0.8 μm. The multi-stage cutting structure greatly improves the service life of the cutter, reduces the frequency of tool replacement, and greatly improves the processing efficiency.

[0013] Optionally, the first and second crushing teeth of the cutter body are alternately arranged at an angle of 62° and 70°, the helix angle of the chip removal grooves between the first finishing teeth and the first crushing teeth and between the second finishing teeth and the second crushing teeth is 4°, and the helix angle of the chip removal groove between the first and second finishing teeth is 4°.

[0014] By adopting the technical scheme, the periodic cutting load change is formed during axial feeding through the alternate arrangement of different helix angles of the tooth shapes, the cutting heat accumulation is dispersed, the local temperature rise of the blade edge is reduced, and the micro-crack expansion caused by the thermal stress of the titanium metal coating is slowed down. 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 makes the long fiber chips generated during rough machining be guided by the groove wall and flow in layers with the small chips generated by the finishing tooth, so as to avoid the groove blockage caused by the chip removal interference and improve the chip removal efficiency by 30%. The same-angle helix structure of the chip removal groove between the finishing teeth ensures the rapid discharge of the finishing chips, and further reduces the wear of the blade edge caused by the chip adhesion. The synergistic effect of the interactive configuration and the chip removal structure greatly reduces the vibration amplitude of the tool in the carbon fiber laminated plate machining and greatly reduces the edge chipping rate.

[0015] Optionally, the tool body surface is coated with a titanium metal physical vapor deposition coating, and the thickness of the titanium metal physical vapor deposition coating is 2-3 microns, and the friction coefficient is less than or equal to 0.15.

[0016] By adopting the technical scheme, the 2-3 microns titanium metal physical vapor deposition coating coated on the tool body surface is deposited at a low temperature of 400-450°C through an unbalanced magnetron sputtering process, which avoids the grain coarsening of the hard alloy substrate caused by high temperature and increases the bonding strength between the coating and the substrate. The TiAlN / TiSiN multilayer alternating structure forms a gradient hardness distribution, the surface layer has high hardness to resist fiber impact, and the inner layer has high toughness to inhibit crack initiation.

[0017] The coating surface with a friction coefficient of less than or equal to 0.15 significantly reduces the adhesion tendency of the resin and greatly improves the chip removal smoothness.

[0018] Optionally, the root circular arc radius R of the first crushing tooth and the second crushing tooth is 0.1-0.15 mm, and the top circular arc radius R is 0.05-0.08 mm.

[0019] By adopting the technical scheme, the cutting force is concentrated in the top circular arc area by optimizing the tooth shape curvature to match the fiber layer shear strength, so as to avoid the tooth root fracture caused by stress concentration. At the same time, the small top circular arc radius design enhances the blade edge cutting ability, reduces the cutting resistance at the same feeding speed, realizes non-vibration cutting with a helix angle of 85°, and the machining surface waviness Wz is less than or equal to 2 microns.

[0020] Optionally, the blade edge passivation radius of the first finishing tooth is 0.01-0.02 mm, and the blade edge passivation radius of the second finishing tooth is 0.005-0.01 mm.

[0021] By adopting the technical scheme, the first and second fine teeth are subjected to the grading passivation treatment, so that the rough cutting edge has moderate micro-edge strength to withstand the fiber impact, and the fine cutting edge realizes the "mirror surface" cutting effect through the ultra-small passivation radius. The actual measurement shows that the surface residual stress of the fine machining area is adjusted from -200 MPa (compressive stress) to -50 MPa, the warping deformation of the laminated plate after the fiber composite material is machined is effectively inhibited, and the edge collapse rate is reduced to 0.1 times per ten thousand revolutions.

[0022] Optionally, the bottom of each of the chip removal grooves is provided with a nano-hydrophobic coating, and the contact angle is greater than or equal to 150 degrees.

[0023] By adopting the technical scheme, the nano-hydrophobic coating at the bottom of the chip removal groove forms a fluorosilane molecular layer through a chemical vapor deposition process, so that the adhesion between the chip and the groove body is reduced to below 0.1 N / mm². The hydrophobic property and the 4° helical angle chip removal groove enable the chip to be removed in the form of rolling instead of sliding friction, and the groove body wear rate is reduced by 60%. In particular, in the processing of glass fibers, SiO2 chips and metal groove body abrasive wear can be avoided, and the chip removal efficiency remains stable throughout the tool life cycle.

[0024] Optionally, the titanium metal physical vapor deposition coating is a TiAlN / TiSiN multilayer alternating structure, the single-layer thickness is 0.2-0.3 μm, and the total number of layers is 10-15.

[0025] By adopting the technical scheme, the TiAlN / TiSiN multilayer coating is alternately deposited by 10-15 layers, and the thickness of each layer is strictly controlled to be 0.2-0.3 μm, so as to block the crack from expanding across the layers by using the interlayer interface effect. The TiAlN layer provides high-temperature stability, and the TiSiN layer fills the interstitial gap between the columnar crystals through amorphous phase, so that the porosity of the coating is less than or equal to 0.5%.

[0026] The structure has excellent thermal shock resistance in intermittent cutting of fiber composite materials, and no peeling occurs after 1000 times of cold and hot cycles (ΔT = 800℃), and the coating life is doubled compared with the single-layer structure.

[0027] The second aspect of the present application provides a machining process of an alloy milling cutter for processing fiber materials, based on any one of the alloy milling cutters for processing fiber materials in the first aspect, comprising the following steps:

[0028] S1: an ultra-fine grain cemented carbide powder is used to make a cutter blank through low-pressure sintering, the sintering temperature is 1420-1450℃, the holding pressure is 6-8 MPa, and the grain size is less than or equal to 0.5 μm;

[0029] S2: mirror polishing is performed on the tool tooth rake angle, the roughness Ra is less than or equal to 0.05 μm, and after polishing, liquid nitrogen deep treatment is performed, the treatment temperature is -196℃, and the duration is 2 hours;

[0030] S3: synchronously machining the first crushing tooth and the second crushing tooth by a five-axis linkage grinding machine, with a helix angle tolerance of ±0.5° and a blade edge blunting radius of 0.01-0.02 mm;

[0031] S4: depositing a titanium metal coating on the surface of the tool body by a non-equilibrium magnetron sputtering process, with a target 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.

[0032] By adopting the above processing technology, the ultra-fine grain hard alloy tool blank is subjected to low-pressure sintering at 1420-1450°C (grain size ≤0.5μm), the bending strength of the matrix reaches 4500MPa or above, which is increased by 30% compared with the conventional sintering process. The tool tooth rake mirror is polished (Ra≤0.05μm) and combined with liquid nitrogen cryogenic treatment (-196°C for 2 hours, 3 cycles), so that the dislocation density of the blade edge is reduced to the order of 10^8 / cm², the residual austenite content is less than 1%, and the micro collapse size of the blade edge is controlled within 0.5μm. The five-axis linkage grinding machine synchronously machines the crushing tooth and the finishing tooth, with a helix angle tolerance of ±0.5°, ensuring that the phase synchronization accuracy of the bidirectional cutting edge is ≤0.01mm, and realizing high consistency processing without repeated cutting marks.

[0033] Further, the liquid nitrogen cryogenic treatment in step S2 includes: placing the polished tool blank in a liquid nitrogen environment, cooling at a rate of 5°C / min to -196°C, holding for 2 hours, then warming to room temperature at a rate of 2°C / min, and the cycle number is ≥3 times;

[0034] The non-equilibrium 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 deposition chamber pressure of 0.3-0.5Pa, and a target-to-tool body distance of 80-100mm.

[0035] By adopting the above technical solution, the liquid nitrogen cryogenic treatment avoids thermal stress cracking of the matrix by cooling at a gradient of 5°C / min, and the martensite transformation is fully converted by warming at a rate of 2°C / min, so that the hardness of the matrix is increased from HRC62 to HRC65, and the toughness is increased by 20%. In the non-equilibrium magnetron sputtering process, the argon-nitrogen flow ratio is 5:1, the coating density is increased to more than 98% by high-energy argon ion bombardment, the 0.3-0.5Pa low-pressure environment in the deposition chamber reduces the incorporation of gas impurities, the oxygen content of the coating is ≤0.5at%, and the high-temperature oxidation resistance is significantly improved (oxidation weight gain <1mg / cm² at 1000°C).

[0036] A processing technology of an alloy milling cutter for processing fiber materials, further comprising the following steps:

[0037] S5: Put the coated tool in the vacuum furnace, and heat to 600℃ at 10℃ / min, and keep for 1 hour, and then quench to below 200℃ with inert gas;

[0038] S6: Perform micro-sand blasting treatment on the coating surface, sand blasting pressure is 0.2-0.3MPa, abrasive is alumina particles (particle size 20-30μm), and sand blasting time is 30-60 seconds.

[0039] 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-sand blasting treatment (alumina 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 of resin debris and the coating surface, and increases the critical peeling force of the adhesive from 0.5N / mm² to 2.0N / mm², achieving the "self-cleaning" cutting effect with the hydrophobic coating.

[0040] In summary, the present application includes at least one of the following beneficial technical effects:

[0041] 1. The alloy milling cutter for processing fiber materials in the scheme is provided with a left-hand first crushing tooth and a right-hand second crushing tooth which are centrally symmetrical, so that the bidirectional helical edges of the two teeth simultaneously act on the fiber layer when high-speed cutting, the left-hand tooth generates a radial inward cutting force, the right-hand tooth generates a radial outward cutting force, the two forces offset each other, the overall force of the cutter is balanced, and the burr height caused by the peeling between the fiber layers is effectively inhibited.

[0042] 2. The first crushing tooth and the second crushing tooth are respectively provided with first finishing teeth and second finishing teeth which are diagonally distributed at 60° and 35°, so as to form a "coarse crushing-finish cutting" cooperative cutting mechanism: the crushing tooth cuts off the fiber layer quickly with a large cutting amount and a high helix angle, and the finishing tooth performs secondary finishing on the fiber fracture left by coarse machining through a small-angle edge, so as to avoid the edge collapse caused by single cutting overload. The continuous distribution of the chip removal grooves between the adjacent teeth (between the crushing tooth and the finishing tooth, and between the finishing teeth) and the design of the 4° helix angle make the chips uniformly discharged along the helical direction of the groove body, avoid the scratch of the chips on the machined surface, and ensure that the surface roughness Ra≤0.8μm. The multi-stage cutting structure makes the cutter life more than 500 hours, reduces the frequency of tool replacement, and improves the processing efficiency by 40%.

[0043] 3. The first crushing tooth and the second crushing tooth are alternately arranged at 62° and 70°, so that the periodic change of cutting load is formed when the tool is axially fed, the cutting heat accumulation is dispersed, the local temperature rise of the edge is reduced, and the micro-crack expansion caused by the thermal stress of the titanium metal coating is slowed down.

[0044] 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 chips generated during rough machining to be guided by the groove wall and flow in layers with the fine chips generated during finishing, avoiding groove blockage caused by chip interference and improving chip removal efficiency by 30%;

[0045] 5. The same-angle helix structure of the chip removal groove between the finishing teeth ensures the rapid discharge of finishing 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 in carbon fiber laminate processing from 0.1 mm to less than 0.03 mm, and the edge chipping rate is reduced by 70%;

[0046] 6. The ultra-fine grain cemented carbide blank is sintered at 1420-1450°C under low pressure (grain size ≤0.5μm), and the bending strength of the matrix is above 4500MPa, which is 30% higher than that of the conventional sintering process. The rake angle mirror of the tool teeth is polished (Ra≤0.05μm) and combined with liquid nitrogen deep cryogenic treatment (-196℃ for 2 hours, 3 cycles), which 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 chipping size of the cutting edge is controlled within 0.5μm. The five-axis linkage grinding machine synchronously processes the crushing teeth and finishing teeth, the helix angle tolerance is ±0.5°, which ensures the phase synchronization accuracy of the bidirectional cutting edge ≤0.01mm, and realizes high consistency processing without repeated cutting marks. BRIEF DESCRIPTION OF DRAWINGS

[0047] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0048] Figure 1 is the overall structure schematic diagram of the alloy milling cutter in the present application;

[0049] Figure 2 is Figure 1 the partial structure schematic diagram of the tool head of the alloy milling cutter in the present application;

[0050] Figure 3 is Figure 2 the plane view of the tool head end;

[0051] Figure 4 is Figure 1 the parameter schematic diagram of the first perspective of the alloy milling cutter in the present application;

[0052] Figure 5 is Figure 1 the parameter schematic diagram of the second perspective of the alloy milling cutter in the present application.

[0053] 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

[0054] The following will be described in detail with reference to the accompanying drawings Figures 1-5 The application is further described in detail.

[0055] The application discloses an alloy milling cutter for fiber material processing. Referring to Figure 1 , Figure 2 and Figure 3 , the cutter body 1 and the cutter head 2 are provided with the first crushing tooth 3 and the second crushing tooth 4 on the side wall of the cutter head 2 in the circumferential direction, the first crushing tooth 3 and the second crushing tooth 4 are centrally symmetric about any point on the axis of the cutter head 2, the first crushing tooth 3 is left-handed, the second crushing tooth 4 is right-handed, the helix angle of the first crushing tooth 3 and the second crushing tooth 4 is 85° and is diagonally distributed.

[0056] The first crushing tooth 3 or the second crushing tooth 4 is provided with the first finishing tooth 5 and the second finishing tooth 6 on both sides, the included angle of the two first finishing teeth 5 is 60° and is diagonally distributed, and the included angle of the two second finishing teeth 6 is 35° and is diagonally distributed.

[0057] Referring to Figure 1 and Figure 2 , the first crushing tooth 3 is provided with the chip removal groove 7 between the first finishing tooth 5 and the second finishing tooth 6, the first finishing tooth 5 and the second finishing tooth 6 are provided with the chip removal groove 7, and the second crushing tooth 4 is provided with the chip removal groove 7 between the first finishing tooth 5 and the second finishing tooth 6.

[0058] In the scheme, the alloy milling cutter for fiber material processing is provided with the centrally symmetric left-handed first crushing tooth 3 and the right-handed second crushing tooth 4, the bidirectional helical edges are synchronously used on the fiber layer during high-speed cutting, the left-handed tooth generates the cutting force radially inward, the right-handed tooth generates the cutting force radially outward, the two forces are mutually offset, the overall force of the cutter is balanced, the burr height caused by the peeling between the fiber layers is effectively inhibited, and the burr height is reduced from the conventional 15-30 μm to below 5 μm.

[0059] The first crushing tooth 3 and the second crushing tooth 4 are respectively provided with the first finishing tooth 6 and the second finishing tooth 6 with an included angle of 60° and 35° diagonally distributed on both sides, forming a “coarse crushing-finish cutting” cooperative cutting mechanism.

[0060] Although the existing part of the technology exists the combination of rough milling teeth + fine milling teeth, such as the disclosure number CN119304971A, in this scheme, the rough milling teeth and the fine milling teeth only realize the function superposition through the simple axial arrangement, the rough milling teeth are in front, the fine milling teeth are in back, the cutting paths of the two are independent, and the mechanical correlation is not formed. Its effect is only the sequential execution of rough machining and fine machining, and the following problems are not solved:

[0061] The vibration of rough milling is directly transmitted to the fine milling teeth through the tool body, causing the residual chatter marks on the fine machining surface, the large chips generated by rough milling are mixed with the fine chips, blocking the chip removal groove, and the rough milling and fine milling need to be adjusted in steps, such as speed, feed rate, etc., reducing the efficiency.

[0062] And the one-way spiral design of the rough milling teeth causes the cutting force to concentrate in a single direction, which cannot offset the transverse shear stress between the fiber layers, and the risk of layer separation still exists (burr height > 10 μm). Although the fine milling teeth improve the surface quality through the small rake angle design, the fine machining effect is limited (Ra ≈ 1.2 μm) due to the vibration transmission of the rough milling teeth.

[0063] As disclosed in the disclosure number TWM643904U, the rough milling teeth and the fine milling teeth share the same direction of the chip removal groove 7, the large chips generated by rough machining are mixed and accumulated with the fine chips generated by fine machining, causing local blockage of the chip removal groove 7 (blockage rate > 30%), the cutting heat cannot be discharged in time, and the blade temperature rises above 600℃, accelerating the coating peeling.

[0064] The technical scheme in the present application performs mechanical balance design on the left-handed and right-handed first crushing teeth 3 and second crushing teeth 4, not only forms independent channels for the chip removal grooves 7 of the first crushing teeth 3 and second crushing teeth 4 and the chip removal grooves 7 of the first fine machining teeth 5 and second fine machining teeth 6, but also physically isolates the drainage paths, greatly reduces the possibility of residual chatter marks on the fine machining surface, the left-handed chips are discharged to the left side of the tool along the left spiral groove, the right-handed chips are discharged to the right side of the tool along the right spiral groove, and the fine machining chips are discharged to the axial direction through the middle groove. This design realizes the physical shunt of chips according to size / type, reduces the blockage rate of the chip removal groove 7 from 30% to 5%, and reduces the cutting temperature from 600℃ to below 400℃.

[0065] And the first fine machining teeth 5 and second fine machining teeth 6 and the chip removal groove 7 are cooperatively optimized, so that the first crushing teeth 3 generate a radial inward component force F1 when cutting, the second crushing teeth 4 generate a radial outward component force F2, and the resultant force tends to be balanced, i.e. F1+F2 is approximately equal to 0, thereby eliminating the transverse shear stress of the fiber layer and reducing the burr height to below 3 μm. And the left-handed and right-handed form bidirectional spiral teeth, the bidirectional spiral teeth form a "shearing-tension" complex effect, the fiber layer is cut into uniform fractures in the rough milling stage, avoiding the fiber filament phenomenon caused by the one-way cutting in the existing technology.

[0066] And the first crushing tooth 3 and the second crushing tooth 4 cut off the fiber layer at a high spiral angle and a large cutting amount, and the first finishing tooth 5 and the second finishing tooth 6 perform secondary finishing on the fiber fracture remaining after rough machining through a small included angle blade, so as to avoid blade edge collapse caused by single cutting overload.

[0067] The cooperation between the first finishing tooth 5, the second finishing tooth 6 and the chip removal groove 7 is reflected in staged cutting and directional chip removal.

[0068] The first finishing tooth 5 cuts off the fiber burrs remaining after rough milling at an included angle of 60°, and the second finishing tooth 6 performs mirror surface finishing at an included angle of 35°, so as to realize three-level cooperation of “rough crushing-semi-finish-fine polishing”, and the surface roughness Ra≤0.4μm (the existing technology Ra≈1.2μm).

[0069] The spiral angle of the chip removal groove 7 is matched with the rotation direction of the bidirectional helical tooth, the chip of the first crushing tooth 3 (left-handed tooth) is discharged along the left helical groove, the chip of the second crushing tooth 4 (right-handed tooth) is discharged along the right helical groove, and the finishing chip is discharged through the middle groove, so as to avoid mixing and blockage, and the chip removal efficiency is improved by 50%.

[0070] Compared with the related technology (TWM643904U), the blockage rate of the chip removal groove 7 is 30%, and the blockage rate of the chip removal groove 7 is reduced to 5% in the present scheme, and the finishing efficiency is improved by 80% (the finishing time is shortened to 1 / 3 under the same machining amount).

[0071] Further, the continuous distribution of the chip removal groove 7 between adjacent teeth (between the crushing tooth and the finishing tooth, and between the finishing tooth and the finishing tooth) combined with the design of the 4° spiral angle makes the chip uniformly discharged along the spiral direction of the groove body, avoids scratching the machined surface due to chip accumulation, and ensures that the surface roughness Ra≤0.8μm. The multi-stage cutting structure makes the tool life improved to more than 500 hours, reduces the tool changing frequency, and improves the machining efficiency by 40%.

[0072] Referring to Figure 4 and Figure 5 , the first crushing tooth 3 and the second crushing tooth 4 of the tool body 1 are respectively arranged alternately at an included angle of 62° and 70°, the spiral angle of the chip removal groove 7 between the first finishing tooth 5 and the first crushing tooth 3 and the spiral angle of the chip removal groove 7 between the second finishing tooth 6 and the second crushing tooth 4 are both 4°, and the spiral angle of the chip removal groove 7 between the first finishing tooth 5 and the second finishing tooth 6 is 4°.

[0073] Through the alternate arrangement of different spiral angle tooth shapes, periodic cutting load changes are formed during axial feeding, cutting heat accumulation is dispersed, local blade temperature rise is reduced, the actual cutting zone temperature is reduced from the conventional 600℃ to below 450℃, and the expansion of micro-cracks caused by thermal stress of titanium metal coating is slowed down.

[0074] The 4° helix angle of the chip removal groove 7 between the first finishing tooth 5 and the crushing tooth and between the second finishing tooth 6 and the crushing tooth is designed to make the long fiber chips generated in rough machining flow in layers under the guidance of the groove wall and separate from the fine chips generated by the finishing tooth, avoiding the blockage of the groove caused by the interference of chip removal, and improving the chip removal efficiency by 30%.

[0075] The same-angle helix structure of the chip removal groove 7 between the finishing teeth ensures the rapid discharge of finishing chips, further reducing the wear of the blade edge caused by chip adhesion. The synergistic effect of the interactive configuration and the chip removal structure reduces the vibration amplitude of the tool in the processing of carbon fiber laminates from 0.1 mm to less than 0.03 mm, and reduces the edge collapse rate by 70%.

[0076] The tool body 1 is coated with a titanium metal physical vapor deposition coating with a thickness of 2-3 μm and a friction coefficient of ≤0.15. The 2-3 μm titanium metal physical vapor deposition coating on the surface of the tool body 1 is deposited at a low temperature of 400-450°C by a non-equilibrium magnetic control sputtering process, avoiding the grain coarsening of the hard alloy substrate caused by high temperature (the substrate grain size is maintained ≤0.5 μm), and the coating and substrate bonding strength reaches 80 N or more.

[0077] The TiAlN / TiSiN multi-layer alternating structure (single layer 0.2-0.3 μm, total layers 10-15 layers) forms a gradient hardness distribution, with high surface hardness (HV3200) to resist fiber impact and high toughness (fracture toughness KIC≥6 MPa・m^1 / 2) to inhibit crack initiation. The coating surface with a friction coefficient of ≤0.15 significantly reduces the adhesion tendency of the resin, and the actual cutting blade adhesion weight is only 0.5 mg after 500 hours of cutting (the conventional coating is 3 mg), the chip flow smoothness is improved by 50%, and the tool durability reaches 1.5 times or more of the industry standard.

[0078] The root arc radius R of the first crushing tooth 3 and the second crushing tooth 4 is 0.1-0.15 mm, and the top arc radius R is 0.05-0.08 mm. By optimizing the tooth shape curvature to match the shear strength of the fiber layer (the shear strength between carbon fiber layers is about 80 MPa), the cutting force is concentrated in the top arc area, avoiding tooth root fracture caused by stress concentration, and the tooth root fracture probability is reduced from 10% to 0.5% or less.

[0079] At the same time, the small top arc radius design enhances the edge cutting ability, and the cutting resistance is reduced by 20% at the same feed speed, and the 85° helix angle realizes non-vibration cutting, and the processing surface waviness Wz≤2 μm.

[0080] The edge blunt radius of the first finishing tooth 5 is 0.01-0.02 mm, and the edge blunt radius of the second finishing tooth 6 is 0.005-0.01 mm. The grading blunt treatment of the edges of the first finishing tooth 5 and the second finishing tooth 6 makes the rough finishing blade have moderate micro-blade strength to withstand fiber impact, and the finishing blade realizes the'mirror surface' cutting effect through the ultra-small blunt radius. The actual measurement shows that the surface residual stress of the finishing area can be adjusted from-200 MPa (compressive stress) to-50 MPa, the warping deformation of the laminated plate after the fiber composite material is processed is effectively inhibited, the deformation amount is less than or equal to 0.1 mm / m, and the edge collapse rate is reduced to 0.1 times per 10,000 revolutions.

[0081] The bottom of each chip groove 7 is provided with a nano-hydrophobic coating with a contact angle greater than or equal to 150°. The nano-hydrophobic coating (contact angle greater than or equal to 150°) at the bottom of the chip groove 7 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 less than or equal to 0.1 N / mm².

[0082] The hydrophobic property combined with the 4° helical angle chip groove 7 enables the debris to be discharged in the form of rolling rather than sliding friction, and the groove wear rate is reduced by 60%. In particular, in the processing of glass fibers, abrasive wear between SiO2 debris and metal groove body can be avoided, and the chip removal efficiency of the tool remains stable throughout its life cycle.

[0083] The titanium metal physical vapor deposition coating is a TiAlN / TiSiN multilayer alternating structure, with a single layer thickness of 0.2-0.3 microns and a total number of layers of 10-15. The TiAlN / TiSiN multilayer coating is deposited alternately for 10-15 layers, with each layer strictly controlled to have a thickness of 0.2-0.3 microns. The interlayer interface effect is used to block crack propagation across layers, reducing the crack propagation rate from 10^-6 m / cycle to 10^-8 m / cycle. The TiAlN layer (Al content of 30 at%) provides high-temperature stability, and the TiSiN layer (Si content of 10 at%) fills the interstitial gaps between columnar crystals through amorphous phase, so that the porosity of the coating is less than or equal to 0.5%.

[0084] This structure exhibits excellent thermal shock resistance in intermittent cutting of fiber composites, and no peeling occurs after 1000 cycles of cold and hot cycles (ΔT=800℃), and the coating life is increased by 2 times compared with a single layer structure.

[0085] The implementation principle of the alloy milling cutter for processing fiber materials in the embodiment of the application is as follows: by arranging the left-handed first crushing tooth 3 and the right-handed second crushing tooth 4 which are centrally symmetrical, the bidirectional helical edges simultaneously act on the fiber layer during high-speed cutting, the left-handed tooth generates a radial inward cutting force, the right-handed tooth generates a radial outward cutting force, the two forces cancel each other out, the overall force of the cutter is balanced, and the burr height caused by the peeling between the fiber layers is effectively inhibited.

[0086] The first and second finishing teeth 6 are respectively arranged on both sides of the first crushing tooth 3 and the second crushing tooth 4 at diagonal angles of 60° and 35°, forming a "coarse 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 use a small angle cutting edge to perform secondary finishing on the fiber fractures remaining after rough processing, avoiding edge chipping caused by single cutting overload.

[0087] The continuous distribution of chip flutes (7) between adjacent teeth (between crushing and finishing teeth, and between finishing teeth) combined with a 4° helix angle ensures uniform chip removal along the spiral direction of the flutes, preventing chip accumulation from scratching the machined surface and ensuring a surface finish of Ra ≤ 0.8μm. This multi-stage cutting structure increases tool life to over 500 hours, reduces tool change frequency, and improves machining efficiency by 40%.

[0088] The synergy of this application stems from the systematic 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-tooth timing cutting, and independent chip flutes for physical diversion, it solves core challenges in fiber material processing, such as interlayer delamination, chip blockage, and short coating life, achieving exponential improvements in processing quality and tool life.

[0089] The present application also discloses a process for processing an alloy milling cutter for processing fiber materials. The process is based on any of the above-mentioned alloy milling cutters for processing fiber materials, and includes the following steps:

[0090] S1: Ultrafine-grained cemented carbide powder is sintered at low pressure to form a blade blank, with a sintering temperature of 1420-1450°C, a holding pressure of 6-8 MPa, and a grain size of ≤0.5 μm;

[0091] S2: The tooth rake angle is mirror polished to a roughness of Ra ≤ 0.05 μm. After polishing, liquid nitrogen cryogenic treatment is performed at a temperature of -196°C for 2 hours.

[0092] 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, holding it for 2 hours, and then returning it to room temperature at a rate of 2°C / min, with the number of cycles being ≥3 times;

[0093] 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 body 1 of 80-100 mm.

[0094] 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 blunting radius of 0.01-0.02mm;

[0095] S4: Titanium metal coating is deposited on the surface of the tool body 1 by using a non-equilibrium magnetron sputtering process, the purity of the target material 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.

[0096] S5: The coated tool is placed in a vacuum furnace, heated to 600°C at a rate of 10°C / min, and held for 1 hour, and then quenched to below 200°C with an inert gas;

[0097] S6: The coating surface is subjected to micro-sandblasting treatment, the sandblasting pressure is 0.2-0.3MPa, the abrasive is aluminum oxide particles (particle size 20-30μm), and the sandblasting time is 30-60 seconds.

[0098] The ultra-fine grain cemented carbide tool blank is subjected to low-pressure sintering at 1420-1450°C (grain size ≤0.5μm), and the bending strength of the matrix reaches 4500MPa or more, which is 30% higher than that of the conventional sintering process.

[0099] The rake face of the tool is mirror polished (Ra≤0.05μm) and combined with liquid nitrogen cryogenic treatment (holding at -196°C for 2 hours, and cycling 3 times), so that the dislocation density of the cutting edge is reduced to the order of 10^8 / cm², the residual austenite content is <1%, and the micro-crack size of the cutting edge is controlled within 0.5μm.

[0100] The five-axis linkage grinding machine synchronously processes the crushing teeth and finishing teeth, the helix angle tolerance is ±0.5°, the phase synchronization accuracy of the bidirectional cutting edges is ≤0.01mm, and high consistency processing without repeated cutting marks is realized.

[0101] The liquid nitrogen cryogenic treatment avoids thermal stress cracking of the matrix by reducing the temperature at a gradient of 5°C / min, and the martensite transformation is fully realized by increasing the temperature at a rate of 2°C / min, so that the hardness of the matrix is increased from HRC62 to HRC65, and the toughness is increased by 20%. In the non-equilibrium magnetron sputtering process, the argon-nitrogen flow ratio is 5:1, the coating density is increased to more than 98% by high-energy argon ion bombardment, the low-pressure environment of 0.3-0.5Pa in the deposition chamber reduces the incorporation of gas impurities, the oxygen content of the coating is ≤0.5at%, and the high-temperature oxidation resistance is significantly improved (oxidation weight gain <1mg / cm² at 1000°C).

[0102] The vacuum annealing at 600℃ after coating relaxes the internal stress of the multi-layer coating from -2.5GPa (compressive stress) to -1.0GPa, avoiding interlayer peeling under the impact of cutting. The micro-sandblasting treatment (alumina 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 of the resin debris and the coating surface, and raising the critical peeling force of the adhesive from 0.5N / mm² to 2.0N / mm², achieving the "self-cleaning" cutting effect with the hydrophobic coating.

[0103] Through the optimization of material-process-structure, the performance system of "anti-impact-anti-adhesion-anti-crack" is formed by controlling the substrate grain size (grain ≤0.5μm), grading the blade edge passivation and depositing the gradient coating, systematically improving the machining quality and tool life.

[0104] The above are optional embodiments of the present application, and do not limit the protection scope of the present application, therefore: any equivalent changes made according to the structure, shape, principle of the present application should be covered within 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) has a left-handed rotation, while the second crushing tooth (4) has a right-handed rotation. The helical 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 processing fiber materials 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 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) both have a helical angle of 4°; and the chip groove (7) between the first finishing tooth (5) and the second finishing tooth (6) has a helical angle of 4°.

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

6. The alloy milling cutter for processing fiber materials 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 processing fiber materials 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 process for producing an alloy milling cutter for processing fiber materials, based on the alloy milling cutter for processing fiber materials according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1: Ultrafine-grained cemented carbide powder is sintered at low pressure to form a blade blank, with a sintering temperature of 1420-1450°C, a holding pressure of 6-8 MPa, and a grain size of ≤0.5 μm; S2: The tooth rake angle is mirror polished to a roughness of Ra ≤ 0.05 μm. After polishing, liquid nitrogen cryogenic treatment is performed 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 blunting radius of 0.01-0.02mm; S4: A titanium metal coating is deposited on the surface of the blade (1) using an unbalanced magnetron sputtering process, with a target 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 process for processing an alloy milling cutter for processing fiber materials 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, holding it for 2 hours, and then returning it to room temperature at a rate of 2°C / min, with the number of cycles being ≥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 (1) of 80-100 mm.

10. The process for processing an alloy milling cutter for processing fiber materials 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, hold it for 1 hour, and then quench it with inert gas to below 200°C. S6: Micro-sandblasting is performed on the coating surface with a blasting pressure of 0.2-0.3 MPa, abrasives of aluminum oxide particles, and a blasting time of 30-60 seconds.

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