Method for machining diamond cutter with helical angle and cutter

Abstract

A diamond cutter is provided with a forming groove body and a front cutter face and is characterized in that the front cutter face is in a spiral shape, a diamond cutting edge has a spiral angle of 10-55 degrees, the front angle of the whole cutting edge is consistent, the diamond cutter further comprises a notch formed in a rod-shaped base material, the notch extends in the axial direction of the base material to form a first groove body, and the first groove body extends in the axial direction of the base material to form a second groove body. The first groove body at least comprises a first groove bottom surface; and the diamond compact is attached to the bottom face of the first groove, so that the upper surface of the diamond compact is inclined to the axis of the base material. Compared with a common PCD cutter, the diamond cutter has the advantage that the machining resistance can be reduced by more than 30%.

Description

[0001] This divisional application is filed based on the original application with the filing date of March 24, 2021, application number 202110317560.X, and invention title "Method for Processing Diamond Tool with Helix Angle and Tool". Technical Field

[0002] The present invention relates to a forming method of a material, in particular to a method for processing a diamond material to form a helix angle, for use in manufacturing tools for precision machining. Background Art

[0003] A diamond tool is a machining cutting tool made by installing a diamond blade or diamond coating on a substrate material (such as cemented carbide). It has extremely high hardness and wear resistance, low friction coefficient, high elastic modulus, high thermal conductivity, low thermal expansion coefficient, and small affinity with non-ferrous metals, and is used for precision machining of non-metallic brittle materials such as graphite, highly wear-resistant materials, composite materials, high-silicon aluminum alloy, and other ductile non-ferrous metal materials.

[0004] Taking the machining of aluminum alloy materials as an example, improving the edge sharpness of diamond tools is beneficial to improving machining efficiency and tool life. The main technical means to improve sharpness is to increase the rake angle and clearance angle of the cutting edge, and reduce the nose radius. Increasing the helix angle is a common technical method to achieve the purpose of increasing the rake angle.

[0005] The chip-mounted PCD tool is a currently mainstream machining tool. It uses the edge inclination angle instead of the helix angle to obtain an angle with a helix degree of 5-7 degrees, and can only be used for short tools. The disadvantage is that it is difficult to manufacture diamond tools with a large helix angle (more than 10 degrees). The diamond-coated tool is another common machining tool, which is manufactured by first forming a helix angle on a cemented carbide substrate and then applying a diamond coating. Although the obtained helix angle is not limited, it will cause the nose radius of the edge to be too large, reducing the edge sharpness, and the manufacturing technology is not yet mature, resulting in a low yield.

[0006] To solve the above technical problems, the third solution is to process the PCD material into a spiral shape as a whole. Although it overcomes the above technical defects, the manufacturing cost is too high and the price is too high, making it difficult to be widely used. Summary of the Invention

[0007] One object of the present invention is to provide a method for processing a diamond tool with a helix angle, reducing the machining resistance of the diamond tool in metal machining cutting.

[0008] Another object of the present invention is to provide a method for processing a diamond tool with a helix angle, making the rake angle of the entire edge consistent and preventing partial edge damage in advance.

[0009] Another object of the present invention is to provide a diamond tool with a large helix angle, which can effectively reduce the machining resistance of the diamond tool in metal machining cutting and improve the machining efficiency.

[0010] Another object of the present invention is to provide a diamond tool with a large helix angle, which can perform precision machining on metal materials and improve the service life of the tool.

[0011] Lasers generally use pulsed or ultrafast lasers with a pulse width ranging from 100 microseconds to 100 femtoseconds. During processing, energy is transferred to the lattice of the material in the form of heat or light within the pulse period, causing the material to vaporize or be etched to achieve the purpose of removing the material.

[0012] Metals are composed of metallic elements. Most metals are excellent conductors of electricity and heat, have ductility, a relatively large density, and a relatively high melting point. In Chinese characters, the names of these elements mostly have the "gold" radical (radical).

[0013] Non-ferrous alloys belong to metals and generally refer to all metals except iron, chromium, and manganese, such as: aluminum, magnesium, potassium, sodium, calcium, strontium, barium, copper, lead, zinc, tin, cobalt, nickel, antimony, mercury, cadmium, bismuth, gold, silver, platinum, ruthenium, rhodium, palladium, osmium, iridium, beryllium, lithium, rubidium, cesium, titanium, zirconium, hafnium, vanadium, niobium, tantalum, tungsten, molybdenum, gallium, indium, thallium, germanium, rhenium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, yttrium, thorium, and non-ferrous alloys, such as: but not limited to aluminum alloys, copper alloys, magnesium alloys, nickel alloys, tin alloys, tantalum alloys, titanium alloys, zinc alloys, molybdenum alloys, and zirconium alloys, etc. These substances are used alone or in combination in the present invention and are the direct objects of the technical solutions of the present invention.

[0014] Diamond, it is a mineral composed of carbon elements, is an allotrope of graphite, with the chemical formula C, and is also the original body of common diamonds. Graphite can form artificial diamonds under high temperature and high pressure. The hardness of diamond has directionality, the hardness of the octahedral crystal face is greater than that of the rhombic dodecahedral crystal face, and the hardness of the rhombic dodecahedral crystal face is greater than that of the hexahedral crystal face.

[0015] Diamond composite sheets, also known as polycrystalline diamond composite sheets, are sintered from diamond micropowders and cemented carbide substrates under ultra-high pressure and high temperature conditions, including a cemented carbide layer and a diamond layer. They have both the high hardness, high wear resistance, and thermal conductivity of diamond, and the strength and impact toughness of cemented carbide. They are ideal materials for manufacturing the cutting edges of cutting tools and generally have a mirror-polished upper surface to facilitate tool making.

[0016] A method for machining a diamond tool with a helix angle includes:

[0017] A notch is pre-formed on a rod-shaped substrate material (such as cemented carbide). The notch extends along the axial direction of the substrate material to form a first groove body, and the first groove body at least includes a first groove bottom surface. Then, a diamond composite sheet is bonded to the first groove bottom surface, such that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material, forming an angle of 5° to 45° with the axis of the substrate material, and preferably 5° to 10°. Finally, laser etching or electro-etching is used to process the first groove body with the diamond composite sheet bonded thereto as a whole to form a formed groove body and a rake face that meet the composite processing requirements. The formed rake face is spiral, having a spiral angle of 10° to 55°, preferably 15° to 25°, and the rake angle of the entire cutting edge is consistent.

[0018] To facilitate the bonding of the diamond composite sheet to the first groove bottom surface, a flat surface is preferably selected.

[0019] To manufacture a spiral rake face, the thickness of the diamond layer of the diamond composite sheet applicable to the method of the present invention is greater than 1.0 mm.

[0020] The present invention provides a diamond tool, the diamond cutting edge of which has a spiral angle of 15° to 25°, effectively reducing the processing resistance during the machining of metals by the diamond tool, improving the processing efficiency, performing precision machining on metal materials, and improving the processing efficiency.

[0021] Beneficial effects achieved by the technical solution of the present invention:

[0022] With the technical means provided by the present invention, that is, only by arranging the diamond composite sheet inclined to the axis of the substrate material, a tool without a processed spiral angle is used for the milling of aluminum alloy. Tests show that compared with a common PCD tool, the processing resistance can be reduced by about 15%.

[0023] The diamond tool manufactured by adopting the solution provided by the present invention has a spiral rake face, and the spiral angle is 10° to 55°. Using this tool for the milling of aluminum alloy, tests show that compared with a common PCD tool (such as a straight groove tool), the processing resistance can be reduced by more than 30%.

[0024] Since the tool manufactured by the method provided by the present invention has a consistent rake angle throughout the entire cutting edge, it can effectively reduce the occurrence of premature damage of some cutting edges, improve the service life of the tool, and compared with a tool made of a stereosintered PCD material, the material cost is significantly reduced (more than 3 times). Description of the Drawings

[0025] Figure 1 Schematic diagram of an embodiment of the first groove body with a diamond composite sheet bonded to the substrate material;

[0026] Figure 2Schematic diagram of an embodiment of a formed cutting tool made by laser or electric etching. Detailed implementation manners

[0027] The technical solutions of the present invention will be described in detail below with reference to the accompanying drawings. The embodiments of the present invention are only used to illustrate the technical solutions of the present invention rather than to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered by the scope of the claims of the present invention.

[0028] Figure 1 Schematic diagram of an embodiment of the first groove for bonding a diamond composite sheet on a substrate material. As Figure 1 shown, a notch is pre-formed on a rod-shaped substrate material 100 (such as cemented carbide), and the notch extends along the axial direction of the substrate material to form a first groove body 110. The first groove body 110 at least includes a first groove bottom surface. Then, the diamond composite sheet 200 is bonded to the first groove bottom surface, so that the upper surface of the diamond composite sheet 200 is inclined to the axis of the substrate material 100, forming an angle of 5° to 45° with the axis of the substrate material, and preferably 5° to 10°. Finally, laser etching or electric etching is used to process the first groove body 110 with the diamond composite sheet 200 bonded thereto as a whole to form a formed groove body 300 and a rake face 400 that meet the composite processing requirements. The formed rake face 400 is spiral, with a spiral angle of 10° to 55°, preferably 15° to 25°, and the rake angle of the entire cutting edge is consistent.

[0029] To facilitate the bonding of the diamond composite sheet to the first groove bottom surface, a plane is preferably selected. The thickness of the diamond layer of the diamond composite sheet is greater than 1.0 mm.

[0030] The side milling of a 7075 aluminum alloy is carried out with a vertical milling cutter on a vertical machining center. The tool diameter is uniformly 10 mm, the cutting edge length is 20 mm × 2 cutting edges. Except for the differences listed in Table 1 below, other design and manufacturing parameters are the same. External cooling cutting is used, the tool speed is 3,500 / min, the feed is 1,200 mm / min, and the cutting depth is 0.1 mm, etc. to test the cutting noise (the cutting noise reflects the magnitude of the cutting resistance) and the service life. The results are shown in Table 1 below.

[0031] Table 1

[0032]

[0033]

[0034] The diamond cutting tool prepared by the method provided in this embodiment is used for the milling of aluminum alloy. Tests show that, compared with ordinary PCD cutting tools, the processing resistance can be reduced by more than 30%, effectively reducing the processing resistance of diamond cutting tools in metal machining cutting and improving the processing efficiency.

Claims

1. A diamond cutting tool having a formed groove body and a rake face, characterized in that The rake face is spiral, the diamond cutting edge has a spiral angle of 10° to 55°, and the rake angle of the entire cutting edge is consistent. It also includes: A notch formed on a rod-shaped substrate material, the notch extends along the axial direction of the substrate material to form a first groove body, and the first groove body at least includes a first groove bottom surface; the diamond composite sheet is bonded to the first groove bottom surface so that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material; The first groove bottom surface is a plane.

2. The diamond cutting tool according to claim 1, wherein The spiral angle is 15° to 25°.

3. The diamond tool according to claim 1, wherein The thickness of the diamond layer of the diamond composite sheet is greater than 1.0 mm.

4. The diamond tool according to claim 1, characterized in that The diamond composite sheet forms an angle of 5° to 45° with the axis of the substrate material.

5. The diamond cutting tool according to claim 1, wherein The diamond composite sheet forms an angle of 5° to 10° with the axis of the substrate material.

6. The diamond cutting tool according to claim 1, wherein The diamond composite sheet is PCD.

7. The diamond cutting tool according to claim 1, characterized in that The first groove body with the diamond composite sheet bonded to it is processed as a whole to form a formed groove body and a rake face that meet the processing requirements.

8. The diamond cutting tool according to claim 1, characterized in that It is used for cutting aluminum alloy materials, effectively reducing the processing resistance of diamond tools in metal machining cutting.

9. The diamond cutting tool according to claim 1, wherein It is used for cutting aluminum alloy materials, and compared with straight groove tools, it reduces the processing resistance by more than 30%.

10. A method for manufacturing the diamond cutting tool according to claim 1, characterized in that It includes: A notch is pre-formed on a rod-shaped substrate material, the notch extends along the axial direction of the substrate material to form a first groove body, and the first groove body at least includes a first groove bottom surface; then, the diamond composite sheet is bonded to the first groove bottom surface so that the upper surface of the diamond composite sheet is inclined to the axis of the substrate material; finally, the first groove body with the diamond composite sheet bonded to it is processed as a whole by laser etching or electro-etching to form a formed groove body and a rake face that meet the composite processing requirements, and the formed rake face is spiral.

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