Low-wind-resistance disposable cutter and manufacturing process thereof

Abstract

The invention relates to the technical field of cutters, in particular to a low-wind-resistance disposable cutter and a manufacturing process thereof.The low-wind-resistance disposable cutter comprises a cutter assembly, the cutter assembly comprises a cutter holder, an arc-shaped cutter head is integrally formed from a cutter holder body, a blade is installed at the end, away from the cutter holder, of the arc-shaped cutter head, and a threaded hole is formed in the end of the arc-shaped cutter head; the blade is mounted on the threaded hole of the arc-shaped tool bit through a first fastener; the blade is further provided with a blade grain, and the blade grain is provided with a body part and a PCD composite coating arranged on the outer side of the body part in a coating mode. The arc-shaped tool bit comprises a tool body, a first tool face, a second tool face and a third tool face, the first tool face, the second tool face and the third tool face are arranged on the tool body, the blade is installed on the third tool face, the second tool face is a triangular outwards-protruding arc face, and the width of the end, close to the third tool face, of the second tool face is smaller than that of the end, away from the third tool face, of the second tool face. Cutter grains of the blades on the third cutter face make contact with the machining surface of an external component to conduct cutting operation.

Description

Technical Field

[0001] The present invention relates to the technical field of cutting tools, and in particular discloses a low-drag disposable cutting tool and its manufacturing process. Background Art

[0002] Milling cutters are cutting tools used in milling processes in machining. They remove workpiece materials through rotary cutting motion to machine complex geometric shapes such as planes, grooves, curved surfaces, and gears. In the prior art, most milling cutters adopt a split structure, with insufficient wind resistance optimization. Moreover, the fixation of the cutting inserts depends on mechanical screws or welding, resulting in defects such as low positioning accuracy and cumbersome replacement. Summary of the Invention

[0003] In order to overcome the drawbacks and deficiencies existing in the prior art, the purpose of the present invention is to provide a low-drag disposable cutting tool and its manufacturing process.

[0004] To achieve the above purpose, a low-drag disposable cutting tool of the present invention includes a tool assembly. The tool assembly includes a tool holder, and an arc-shaped cutting head integrally formed from the tool holder body. A cutting blade is installed at one end of the arc-shaped cutting head away from the tool holder. A threaded hole is provided at the end of the arc-shaped cutting head, and the cutting blade is installed on the threaded hole of the arc-shaped cutting head via a first fastener; a cutting insert is further installed on the cutting blade. The cutting insert has a body portion and a PCD composite coating coated on the outside of the body portion.

[0005] The arc-shaped cutting head includes a tool body, a first cutting surface, a second cutting surface, and a third cutting surface provided on the tool body. The two sides of the tool body away from each other are the first cutting surface and the second cutting surface respectively. The third cutting surface is the end surface of the free end of the arc-shaped cutting head. The third cutting surface intersects with both the first cutting surface and the second cutting surface. The cutting blade is installed on the third cutting surface. The second cutting surface is a triangular convex arc surface. The width of the second cutting surface near the third cutting surface is smaller than the width of the second cutting surface away from the third cutting surface. When the arc-shaped cutting head rotates, the cutting insert on the third cutting surface contacts the machining surface of the external component for cutting operations.

[0006] The cutting insert is made of cemented carbide, such as tungsten steel. Tungsten steel has high hardness and wear resistance, is suitable for high-speed cutting (linear speed 200 - 300 m / min), has good resistance to plastic deformation, can withstand the cyclic impact load in titanium alloy machining, and has a strong bonding force with the PCD coating (interface bonding force > 500 MPa).

[0007] By adopting the arc-shaped cutting head design, the air resistance generated when the cutting tool rotates or moves at high speed can be effectively reduced, thereby improving the machining efficiency and reducing energy consumption. The multi-surface design of the tool body (the first, second, and third cutting surfaces) forms a heat dissipation channel, and at the same time, the convex arc surface guides the chips to be discharged outward, avoiding chip accumulation from affecting the machining quality.

[0008] Adopting a parabolic arc design, the width of the second cutting surface near the third cutting surface is 5 mm, and it gradually expands to 15 mm towards the tool holder direction to form a flow guiding surface, reducing the generation of air vortices.

[0009] A first groove for installing the blade is provided on the first cutting surface. The first groove is recessed from the third cutting surface, and a first convex limiting portion located within the first groove protrudes therefrom. The first convex limiting portion is used to block the blade to prevent the cutting insert from being displaced when the arc-shaped cutting head rotates.

[0010] The arc-shaped cutting head of the tool is integrally formed on the tool holder. The first cutting surface is provided with a first groove specifically for installing the blade, and a first convex limiting portion is ingeniously designed at the front end of the groove. The blade is not only fixed to the threaded hole of the arc-shaped cutting head by the first fastener, but also physically blocked by the first convex limiting portion, enhancing the fixing effect.

[0011] The tool further includes a plurality of locking members. A plurality of receiving grooves are further formed on the outer side of one end of the arc-shaped cutting head close to the blade, and the plurality of locking members are respectively fixedly connected in the plurality of receiving grooves; a plurality of clamping grooves are formed at one end of the blade close to the locking members, and the clamping grooves are used to cooperate with the locking members to achieve mechanical interlocking to prevent the blade from shifting or falling off during the cutting process.

[0012] Through the mechanical interlocking mechanism of the locking members and the clamping grooves, the stability and safety of the blade during the cutting operation are further enhanced, ensuring the smooth progress of the cutting process. Specifically, during implementation, the blade is not only fixed to the threaded hole of the arc-shaped cutting head by the first fastener, but also blocked by the first convex limiting portion and the mechanical interlocking of the locking members and the clamping grooves. Under the combined action of multiple fixing methods, the blade can remain stable even under the action of high-speed rotation and high-intensity cutting force.

[0013] The locking member is an elastic capsule. The elastic capsule is fixedly connected to the inner end of the receiving groove. The elastic capsule is filled with magnetorheological fluid, and the magnetorheological fluid includes magnetic particles and an oil-based carrier fluid. When the blade is pressed against the arc-shaped cutting head, the magnetorheological fluid is activated by electricity to harden, achieving the fixing and locking of the blade.

[0014] When the blade is installed and pressed against the arc-shaped cutting head, the elastic capsule is deformed under pressure, and at the same time, the magnetorheological fluid is activated by electricity and rapidly hardens. This hardening process causes the magnetorheological fluid to change from a liquid state to a semi-solid state or a solid state, thus achieving the fixing and locking of the blade. This locking method not only has a rapid response but also can be dynamically adjusted as needed, ensuring the high stability of the blade during the cutting process.

[0015] The magnetorheological fluid includes 20-40% magnetic particles and 60-80% oil-based carrier fluid. The proportion of 20-40% magnetic particles ensures that the magnetorheological fluid can generate sufficient shear yield stress when activated, thus achieving firm locking of the blade. At the same time, this proportion also ensures that the magnetorheological fluid has good fluidity and stability when not activated. The proportion of 60-80% oil-based carrier fluid ensures that the magnetorheological fluid has good fluidity when not activated, facilitating the installation and adjustment of the blade. At the same time, this proportion also ensures that the magnetorheological fluid can respond quickly and harden after activation, thus achieving rapid locking of the blade.

[0016] The number of the arc-shaped cutting heads is multiple, and the multiple arc-shaped cutting heads are arranged in a circular array around the tool holder. Each arc-shaped cutting head is equipped with a blade and a cutting insert. The tool holder has an assembly positioning portion protruding from the arc-shaped cutting head. The sides of all the arc-shaped cutting heads away from the assembly positioning portion are arranged coplanarly to form a reference plane, and the cutting inserts are arranged at one end of the blade protruding from the reference plane.

[0017] The circular array layout of multiple arc-shaped cutting heads enables multiple cutting inserts to participate in cutting simultaneously, doubling the processing efficiency, and is suitable for high-efficiency processing scenarios with large feed rates or complex curved surfaces. The design of the coplanar reference plane of all the arc-shaped cutting heads away from the assembly positioning portion ensures that the cutting depths of each cutting insert are consistent, avoids uneven cutting forces caused by installation deviations, reduces the vibration of the machine tool spindle, and extends the service life of the equipment. The design of the cutting inserts protruding from the reference plane makes the cutting action point concentrated at the tip of the cutting insert, reduces the unnecessary contact between the blade substrate and the workpiece, reduces frictional heat and cutting resistance, and ensures stability under high rotational speeds for a long time.

[0018] The arc-shaped cutting head is provided with a diversion channel, which is recessed from the reference plane and penetrates the arc-shaped cutting head. The flowing air during the rotation of the arc-shaped cutting head enters the diversion channel to blow off the waste between the reference plane and the processing surface of the external component.

[0019] The channel inlet of the diversion channel is located at the leading edge of the second cutting surface, and the outlet extends to the first cutting surface, using the negative pressure effect to guide the cutting air flow to be axially discharged.

[0020] The diversion channel runs through the arc-shaped cutting head. By utilizing the centrifugal force and negative pressure effect generated during rotation, the waste chips in the cutting area are sucked in from the channel inlet (the leading edge of the second cutting surface) and pushed axially along the channel to the tail of the tool holder for discharge. This avoids the accumulation of waste chips between the reference surface and the workpiece, prevents scratching of the machined surface, and significantly improves the machining finish. When the air flow passes through the diversion channel, it takes away the heat generated by the friction between the cutting grains and the workpiece, reduces the temperature of the cutting grains (especially the thermally sensitive area of the PCD coating), avoids coating peeling or cutting edge deformation caused by high temperature, and extends the tool life. The channel inlet is located at the leading edge of the second cutting surface (the air flow impact point during high-speed rotation), and the outlet extends to the first cutting surface, forming an axial air flow path of "front suction and rear discharge". A negative pressure area is generated at the tail of the tool holder during rotation, enhancing the air flow suction efficiency, enabling active chip discharge without an additional air pump, and reducing energy consumption.

[0021] The inner wall of the said diversion channel is coated with a low-friction coating to further reduce the air flow resistance. The low-friction coating can significantly reduce the friction coefficient between the coating surface and the air flow, making the air flow flow more smoothly in the channel, reducing energy loss. After coating with the low-friction coating, the flow state of the air flow in the channel may be optimized, reducing adverse factors such as eddy currents and turbulence, making the air flow more stable, and further reducing the resistance.

[0022] A manufacturing process for a low wind resistance throw-away tool includes the following steps:

[0023] S1. According to the three-dimensional model parting design, the mold cavity of the tool holder and the integrally formed arc-shaped cutting head is designed. The convex strip body for forming the diversion channel is preset in the mold cavity, and the mold size tolerance is controlled within ±0.05 mm;

[0024] S2. Heat the titanium alloy base material in a vacuum induction melting furnace to 1450 - 1700 °C, and inject it into the mold cavity at a filling speed of 0.5 - 1.2 m / s through low-pressure casting to form a casting; Use the micro-arc oxidation process to generate a low-friction Al2O3 ceramic layer on the inner wall of the diversion channel in the casting to obtain the tool assembly;

[0025] S3. After the cemented carbide powder is formed by static pressure molding, it is vacuum sintered at 1450 °C to make the cutting grain substrate, and a 10 - 15 μm thick PCD layer is deposited on the surface of the cutting grain by using the hot wire chemical vapor deposition technology;

[0026] S4. Install the cutting grains on the blade, and install the blade on the arc-shaped cutting head via the first fastener.

[0027] The manufacturing process of the low wind resistance throw-away tool further includes the following steps:

[0028] Use the insert tool mechanism to weld the cutting grains on the blade, and lock the blade with the welded cutting grains on the tool holder of the tool assembly;

[0029] The insert tool mechanism includes a frame, a grasping mechanism, a vision positioning system, a pulsed laser mechanism, and a control center installed on the frame. The control center is electrically connected to the grasping mechanism, the vision positioning system, and the pulsed laser mechanism. The grasping mechanism grabs the cutting inserts, positions them through the vision positioning system, and then places them on the blades carried on the frame, making the bottom surface of the cutting inserts fully fit with the blades. The pulsed laser mechanism locally heats the connection between the cutting inserts and the blades, raising the temperature at the connection to 1050°C within 0.5 seconds to achieve the metallurgical bonding between the cutting inserts and the blades. Then, the blades with the inserted cutting inserts are installed onto the tool seats of the tool assemblies.

[0030] The flash body of the casting is inwardly extruded and deformed by a hydraulic micro stamping machine to form a first convex limiting portion, and the first convex limiting portion covers and blocks the blade.

[0031] The grasping mechanism includes a first vertical frame and a grasping mechanism. Sliding rails are provided on both inner walls of the first vertical frame, and the grasping mechanism is slidably arranged on the first vertical frame via the sliding rails. The grasping mechanism further includes a rotary driving member provided at the bottom of the first vertical frame and a rotary support plate installed on the frame. The output end of the rotary driving member is connected to the vertical frame, and the end of the rotary driving member away from the vertical frame is installed on the rotary support plate. When the rotary driving member is activated, it drives the first vertical frame to rotate around the rotary support plate. The rotation of the first vertical frame drives the grasping mechanism to rotate. At the same time, the grasping mechanism slides on the first vertical frame through the sliding rails to achieve movement in the horizontal direction. The grasping mechanism can freely move in three-dimensional space to accurately grasp and place the cutting inserts.

[0032] The grasping mechanism includes a first connecting portion installed on the first vertical frame and a second connecting portion rotatably arranged on the first connecting portion. A grasping portion is provided at the end of the second connecting portion away from the first connecting portion. The grasping portion includes multiple groups of grasping members, and the multiple groups of grasping members can simultaneously grasp multiple groups of cutting inserts for the installation of the cutting inserts and the blades.

[0033] The structural design of the first connecting portion and the second connecting portion allows the grasping portion to perform multi-dimensional movement and adjustment under precise control. This design ensures that the grasping portion can accurately locate each cutting insert and remain stable during the installation process, avoiding installation quality problems caused by inaccurate positioning or shaking.

[0034] The pulsed laser mechanism includes a second vertical frame installed on the frame, a first sliding rail installed on the second vertical frame, a second sliding rail slidably arranged on the first sliding rail, and a laser driving unit slidably arranged on the second sliding rail. The first sliding rail is arranged along the length direction of the frame, and the second sliding rail is vertically arranged on the first sliding rail.

[0035] The first slide rail is arranged along the length direction of the machine frame, which means that the laser driving unit can move freely in this direction, so as to realize the long-distance positioning of the laser on the horizontal plane. The second slide rail is vertically arranged on the first slide rail, which allows the laser driving unit to move vertically on the basis of the movement of the first slide rail. This double-slide rail design provides the precise movement ability in the two-dimensional plane.

[0036] The laser driving unit includes a first support plate and a laser processing part that are slidably arranged on the second slide rail. The first support plate is provided with a third slide rail, and the laser processing part is slidably arranged on the first support plate via the third slide rail. The moving direction of the laser processing part is perpendicular to the moving direction of the first support plate; the laser processing part can approach or move away from the workpiece via the third slide rail.

[0037] The S2 also includes the following steps:

[0038] (a) Immerse the demolded titanium alloy casting in a phosphoric acid-ethylene glycol electrolyte solution, and perform anodic oxidation for 30 minutes at a DC voltage of 60 - 80V and a temperature of 25 ± 2°C to generate a TiO2 oxide film with a thickness of 2 - 3μm;

[0039] (b) Seal the coated casting in deionized water at 90 - 95°C for 40 minutes to reduce the porosity of the oxide film to < 3%.

[0040] The S5 also includes the following steps:

[0041] (a) Use a laser interferometer to detect the flatness of the tool insert mounting plane. If the flatness error > 0.005mm,

[0042] then micro-melt and correct the tool insert substrate with femtosecond laser until the error ≤ 0.003mm;

[0043] (b) Conduct a shear strength test on the metallurgical bonding interface between the tool insert and the blade, apply a progressive load of 0 - 1000N, and require the failure threshold > 800N. If not up to the standard, repeat step S5 and adjust the pulse laser energy density.

[0044] The inner wall of the diversion channel is provided with spiral ribs. The height of the ribs is 10 - 15% of the channel diameter, and the spiral angle is 25 - 35°; the surface of the ribs is coated with a 50 - 100μm thick Al2O3 - TiO2 composite ceramic layer by plasma spraying, and the friction coefficient < 0.15; the distance between adjacent ribs is 1 / 4 - 1 / 3 of the channel circumference, forming an air flow pattern with alternating distribution of turbulent promotion zones and laminar flow stable zones, so that the heat dissipation efficiency is increased by more than 30%. The spiral rib design breaks the laminar boundary layer of the traditional straight channel, enhances heat transfer through turbulence, and at the same time the low-friction coating reduces the pressure loss.

[0045] The blade is composed of multiple layers of gradient materials, and successively includes a first layer, a second layer, and a third layer from the installation end to the cutting insert end. The first layer is a titanium alloy layer, the second layer is a tungsten steel / titanium alloy mixed layer, and the third layer is a pure tungsten steel layer; metallurgical bonding is achieved between each layer through electron beam cladding, and the thermal expansion coefficient gradient transitions (9.5 → 5.0×10 -6 / °C), reducing the interface thermal stress by 60%. The material gradient design matches the thermal-mechanical load distribution, avoiding thermal deformation cracking of traditional homogeneous blades.

[0046] Advantages of the present invention: This low drag disposable tool reduces aerodynamic resistance and improves cutting efficiency through the special design of the first cutting surface, the second cutting surface, and the third cutting surface. The blade adopts high-strength materials and is coated with a PCD composite coating to enhance cutting performance. At the same time, the magnetorheological fluid in the elastic bladder is used to achieve rapid locking of the blade, and the air flow resistance is further reduced through the diversion channel and the low friction coating, significantly improving the cutting efficiency, reducing tool wear, extending the service life, and maintaining high cutting stability and safety. Its manufacturing process is fine, ensuring the high precision and high quality of the tool, and it is suitable for high-speed cutting and processing of difficult-to-machine materials. Description of the Drawings

[0047] Figure 1 is a schematic structural diagram of the whole of the present invention;

[0048] Figure 2 is an exploded view of the whole of the present invention;

[0049] Figure 3 is a schematic structural diagram of the tool holder and the arc-shaped cutting head of the present invention;

[0050] Figure 4 of the present invention Figure 3 is an enlarged schematic view of part A;

[0051] Figure 5 is a cross-sectional view of the whole of the present invention;

[0052] Figure 6 of the present invention Figure 5 is an enlarged schematic view of part B;

[0053] Figure 7 is a schematic structural diagram of the whole of the insert mechanism of the present invention;

[0054] Figure 8 is a schematic structural diagram of the whole of the grasping mechanism of the present invention;

[0055] Figure 9 is a schematic structural diagram of the whole of the pulsed laser mechanism of the present invention;

[0056] Figure 10 is a cross-sectional view of the blade of the present invention;

[0057] Figure 11 This is the process flow chart for manufacturing the low-drag disposable tool of the present invention.

[0058] The reference signs include:

[0059] 1. Tool holder; 2. Arc-shaped cutter head; 3. Blade; 4. Threaded hole; 5. First fastener; 6. Insert; 7. First cutting surface; 8. Second cutting surface; 9. First groove; 11. First convex limiting part; 12. Locking part; 13. Accommodating groove; 14. Card slot; 15. Flow guiding channel; 16. Channel inlet; 17. Inserting tool mechanism; 18. Gripping mechanism; 19. Vision positioning system; 21. Pulse laser mechanism; 22. Machine frame; 23. Control center; 24. First vertical frame; 25. First connecting part; 26. Second connecting part; 27. Gripping part; 28. Gripping piece; 100. Rotary driving part; 110. Rotary supporting plate; 120. Sliding guide rail; 29. Second vertical frame; 31. First sliding rail; 32. Second sliding rail; 33. Laser driving unit; 34. First supporting plate; 35. Laser processing part; 36. Third sliding rail; 37. First layer; 38. Second layer; 39. Third layer; 40. Spiral rib; 111. Tool body; 200. Third cutting surface; 201. Assembly positioning part. Detailed implementation manners

[0060] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with embodiments and the accompanying drawings. The content mentioned in the implementation manners does not limit the present invention.

[0061] Please refer to Figures 1 to 11 As shown, a low-drag disposable tool of the present invention includes a tool assembly. The tool assembly includes a tool holder 1, and an arc-shaped cutter head 2 is integrally formed from the body of the tool holder 1. A blade 3 is installed at one end of the arc-shaped cutter head 2 away from the tool holder 1. A threaded hole 4 is provided at the end of the arc-shaped cutter head 2, and the blade 3 is installed on the threaded hole 4 of the arc-shaped cutter head 2 via a first fastener 5; an insert 6 is further installed on the blade 3, and the insert 6 has a body part and a PCD composite coating coated on the outside of the body part;

[0062] The arc-shaped cutting head 2 includes a tool body 111, a first cutting surface 7, a second cutting surface 8 and a third cutting surface 200 arranged on the tool body 111. The two sides of the tool body 111 away from each other are the first cutting surface 7 and the second cutting surface 8 respectively. The third cutting surface 200 is the end surface of the free end of the arc-shaped cutting head 2. The third cutting surface 200 intersects with both the first cutting surface 7 and the second cutting surface 8. The cutting blade 3 is installed on the third cutting surface 200. The second cutting surface 8 is a triangular convex arc surface. The width of the second cutting surface 8 at one end close to the third cutting surface 200 is smaller than the width of the second cutting surface 8 at one end away from the third cutting surface 200. When the arc-shaped cutting head 2 rotates, the cutting grains 6 of the cutting blade 3 on the third cutting surface 200 contact the processing surface of the external component for cutting operation.

[0063] The cutting grains 6 are made of cemented carbide, such as tungsten steel. Tungsten steel has high hardness and wear resistance, is suitable for high-speed cutting (linear speed 200 - 300 m / min), has good anti-plastic deformation ability, can withstand the periodic impact load in titanium alloy processing, and has a strong bonding force with the PCD coating (interface bonding force > 500 MPa).

[0064] By adopting the design of the arc-shaped cutting head 2, the air resistance generated when the tool rotates or moves at high speed can be effectively reduced, thereby improving the processing efficiency and reducing energy consumption. The multi-faceted design (the first, second, and third cutting surfaces) of the tool body 111 forms a heat dissipation channel. At the same time, the convex arc surface guides the chips to be discharged outward to avoid the influence of chip accumulation on the processing quality.

[0065] Adopting a parabolic arc design, the width of the second cutting surface 8 at the position close to the third cutting surface 200 is 5 mm, and it gradually expands to 15 mm towards the tool holder 1 to form a flow guiding surface, reducing the generation of air vortices.

[0066] A first groove 9 for installing the cutting blade 3 is provided on the first cutting surface 7. The first groove 9 is recessed from the third cutting surface 200. A first convex limiting portion 11 protruding in the first groove 9 is provided in the first groove 9. The first convex limiting portion 11 is used to block the cutting blade 3 to prevent the cutting blade 3 from driving the cutting grains 6 to displace when the arc-shaped cutting head 2 rotates.

[0067] The arc-shaped cutting head 2 of the tool is integrally formed on the tool holder 1. The first cutting surface 7 is provided with a first groove 9 specifically for installing the cutting blade 3, and a first convex limiting portion 11 is ingeniously designed at the front end of the groove. The cutting blade 3 is not only fixed to the threaded hole 4 of the arc-shaped cutting head 2 by the first fastener 5, but also physically blocked by the first convex limiting portion 11, enhancing the fixing effect.

[0068] The tool further includes a plurality of locking members 12. A plurality of receiving grooves 13 are further formed on the outer side of one end of the arc-shaped cutter head 2 close to the blade 3. The plurality of locking members 12 are respectively fixedly connected in the plurality of receiving grooves 13. A plurality of clamping grooves 14 are formed at one end of the blade 3 close to the locking member 12. The clamping grooves 14 are used to cooperate with the locking members 12 to achieve mechanical interlocking and prevent the blade 3 from shifting or falling off during the cutting process.

[0069] Through the mechanical interlocking mechanism of the locking member 12 and the clamping groove 14, the stability and safety of the blade 3 during the cutting operation are further enhanced, ensuring the smooth progress of the cutting process. In specific implementation, the blade 3 is not only fixed to the threaded hole 4 of the arc-shaped cutter head 2 through the first fastener 5, but also blocked by the first convex limiting portion 11 and mechanically interlocked by the locking member 12 and the clamping groove 14. Under the combined action of multiple fixing methods, the blade 3 can remain stable even under the action of high-speed rotation and high-intensity cutting force.

[0070] The locking member 12 is an elastic capsule. The elastic capsule is fixedly connected to the inner end of the receiving groove 13. The elastic capsule is filled with magnetorheological fluid. The magnetorheological fluid includes magnetic particles and an oil-based carrier fluid. When the blade 3 and the arc-shaped cutter head 2 are pressed against each other, the magnetorheological fluid is activated by electricity and hardened to fix and lock the blade 3.

[0071] When the blade 3 is installed and pressed against the arc-shaped cutter head 2, the elastic capsule is deformed under pressure, and at the same time, the magnetorheological fluid is activated by electricity and rapidly hardened. This hardening process causes the magnetorheological fluid to change from a liquid state to a semi-solid state or a solid state, thereby realizing the fixed locking of the blade 3. This locking method not only responds quickly but also can be dynamically adjusted as needed, ensuring the high stability of the blade 3 during the cutting process.

[0072] The magnetorheological fluid includes 20-40% magnetic particles and 60-80% oil-based carrier fluid. The proportion of 20-40% magnetic particles ensures that the magnetorheological fluid can generate sufficient shear yield stress when activated, thereby realizing the firm locking of the blade 3. At the same time, this proportion also ensures that the magnetorheological fluid has good fluidity and stability when not activated. The proportion of 60-80% oil-based carrier fluid ensures that the magnetorheological fluid has good fluidity when not activated, facilitating the installation and adjustment of the blade 3. At the same time, this proportion also ensures that the magnetorheological fluid can respond quickly and harden after activation, thereby realizing the rapid locking of the blade 3.

[0073] The number of the arc-shaped cutter heads 2 is multiple. The multiple arc-shaped cutter heads 2 are arranged in a circular array around the tool holder 1. Each arc-shaped cutter head 2 is provided with a blade 3 and a cutting insert 6. The tool holder 1 has an assembly positioning portion 201 protruding from the arc-shaped cutter head 2. One side of all the arc-shaped cutter heads 2 away from the assembly positioning portion 201 is arranged in a coplanar manner to form a reference plane. The cutting insert 6 is arranged at one end of the blade 3 protruding from the reference plane.

[0074] Multiple arc-shaped cutting heads 2 are arranged in a circular array, enabling multiple cutting grains 6 to participate in cutting simultaneously, doubling the machining efficiency, and being applicable to high-efficiency machining scenarios with large feed rates or complex curved surfaces. The co-planar reference surface design of all arc-shaped cutting heads 2 away from the assembly positioning part 201 ensures that the cutting depths of each cutting grain 6 are consistent, avoids uneven cutting forces caused by installation deviations, reduces the vibration of the machine tool spindle, and extends the equipment life. The design of the cutting grain 6 protruding from the reference surface makes the cutting action point concentrate on the tip of the cutting grain 6, reduces the unnecessary contact between the blade 3 substrate and the workpiece, reduces frictional heat and cutting resistance, and ensures stability at high rotational speeds for a long time.

[0075] The arc-shaped cutting head 2 is provided with a diversion channel 15, which is recessed from the reference surface and penetrates the arc-shaped cutting head 2. The flowing air during the rotation of the arc-shaped cutting head 2 enters the diversion channel 15 to blow off the waste between the reference surface and the machining surface of the external component.

[0076] The channel inlet 16 of the diversion channel 15 is located at the leading edge of the second cutting surface 8, and the outlet extends to the first cutting surface 7, using the negative pressure effect to guide the cutting air flow to be discharged axially.

[0077] The diversion channel 15 penetrates the arc-shaped cutting head 2. Using the centrifugal force and negative pressure effect generated during rotation, the chips in the cutting area are sucked in from the channel inlet 16 (the leading edge of the second cutting surface 8) and axially pushed along the channel to the tail of the tool holder 1 for discharge, avoiding chip accumulation between the reference surface and the workpiece, preventing scratching of the machining surface, and significantly improving the machining finish. When the air flow passes through the diversion channel 15, it takes away the heat generated by the friction between the cutting grain 6 and the workpiece, reduces the temperature of the cutting grain 6 (especially the heat-sensitive area of the PCD coating), avoids coating peeling or tool edge deformation caused by high temperature, and extends the tool life. The channel inlet 16 is located at the leading edge of the second cutting surface 8 (the air flow impact point during high-speed rotation), and the outlet extends to the first cutting surface 7, forming an axial air flow path of "front suction and rear discharge". A negative pressure area is generated at the tail of the tool holder 1 during rotation, enhancing the air flow suction efficiency, and enabling active chip removal without an additional air pump, reducing energy consumption.

[0078] The inner wall of the diversion channel 15 is coated with a low-friction coating to further reduce the air flow resistance. The low-friction coating can significantly reduce the friction coefficient between the coating surface and the air flow, making the air flow more smooth when flowing in the channel, reducing energy loss. After coating with the low-friction coating, the flow state of the air flow in the channel may be optimized, reducing adverse factors such as eddy currents and turbulences, making the air flow more stable, and further reducing the resistance.

[0079] A manufacturing process for a low wind resistance throw-away tool includes the following steps:

[0080] S1. Design the mold cavity for the tool holder 1 and the integrally formed arc-shaped cutting head 2 according to the three-dimensional model parting. A rib body for forming the diversion channel 15 is preset in the mold cavity, and the mold dimensional tolerance is controlled within ±0.05 mm;

[0081] S2. Heat the titanium alloy substrate in a vacuum induction melting furnace to 1450 - 1700 °C, and inject it into the mold cavity at a filling speed of 0.5 - 1.2 m / s by low-pressure casting to form a casting; Generate a low-friction Al2O3 ceramic layer on the inner wall of the diversion channel 15 in the casting by micro-arc oxidation process to obtain the tool assembly;

[0082] S3. After the cemented carbide powder is formed by static pressure, sinter it in vacuum at 1450 °C to make the substrate of the cutting insert 6, and use the hot wire chemical vapor deposition technology to deposit a 10 - 15 μm thick PCD layer on the surface of the cutting insert 6;

[0083] S4. Install the cutting insert 6 on the blade 3, and install the blade 3 on the arc-shaped cutting head 2 via the first fastener 5.

[0084] The manufacturing process of the low wind resistance disposable tool further includes the following steps:

[0085] Weld the cutting insert 6 on the blade 3 by using the insert knife mechanism 17, and lock the blade 3 welded with the cutting insert 6 on the tool holder 1 of the tool assembly;

[0086] The insert knife mechanism 17 includes a frame 22, a grasping mechanism 18 installed on the frame 22, a visual positioning system 19, a pulsed laser mechanism 21 and a control center 23. The control center 23 is electrically connected to the grasping mechanism 18, the visual positioning system 19 and the pulsed laser mechanism 21. The grasping mechanism 18 grasps the cutting insert 6, positions it through the visual positioning system 19 and then places it on the blade 3 carried on the frame 22, so that the bottom surface of the cutting insert 6 is completely attached to the blade 3. The pulsed laser mechanism 21 locally heats the connection part between the cutting insert 6 and the blade 3, and makes the temperature of the connection part reach 1050 °C within 0.5 seconds to realize the metallurgical bonding between the cutting insert 6 and the blade 3, and then install the blade 3 with the inserted cutting insert 6 on the tool holder 1 of the tool assembly;

[0087] Use a hydraulic micro stamping machine to squeeze the flash body of the casting inward to deform and form a first convex limiting part 11, and the first convex limiting part 11 covers and blocks the blade 3.

[0088] The grasping mechanism 18 includes a first vertical frame 24 and the grasping mechanism 18. Sliding guides 120 are provided on the inner walls of both sides of the first vertical frame 24. The grasping mechanism 18 is slidably arranged on the first vertical frame 24 via the sliding guides 120. The grasping mechanism 18 further includes a rotation driving member 100 arranged at the bottom of the first vertical frame 24 and a rotation support plate 110 installed on the machine frame 22. The output end of the rotation driving member 100 is connected to the vertical frame, and the end of the rotation driving member 100 away from the vertical frame is installed on the rotation support plate 110. When the rotation driving member 100 is started, it drives the first vertical frame 24 to rotate around the rotation support plate 110. The rotation of the first vertical frame 24 drives the grasping mechanism 18 to rotate. At the same time, the grasping mechanism 18 slides on the first vertical frame 24 through the sliding guides 120 to achieve movement in the horizontal direction. The grasping mechanism 18 realizes free movement in three-dimensional space and accurately grasps and places the cutting inserts 6.

[0089] The grasping mechanism 18 includes a first connection part 25 installed on the first vertical frame 24 and a second connection part 26 rotatably arranged on the first connection part 25. A grasping part 27 is provided at the end of the second connection part 26 away from the first connection part 25. The grasping part 27 includes multiple groups of grasping members 28, and the multiple groups of grasping members 28 can simultaneously grasp multiple groups of cutting inserts 6 for the installation of the cutting inserts 6 and the blades 3.

[0090] The structural design of the first connection part 25 and the second connection part 26 allows the grasping part 27 to perform multi-dimensional movement and adjustment under precise control. This design ensures that the grasping part 27 can accurately locate each cutting insert 6 and remain stable during the installation process, avoiding installation quality problems caused by inaccurate positioning or shaking.

[0091] The pulsed laser mechanism 21 includes a second vertical frame 29 installed on the machine frame 22, a first slide rail 31 installed on the second vertical frame 29, a second slide rail 32 slidably arranged on the first slide rail 31, and a laser driving unit 33 slidably arranged on the second slide rail 32. The first slide rail 31 is arranged along the length direction of the machine frame 22, and the second slide rail 32 is vertically arranged on the first slide rail 31.

[0092] The first slide rail 31 is arranged along the length direction of the machine frame 22, which means that the laser driving unit 33 can freely move in this direction, thereby realizing long-distance positioning of the laser on the horizontal plane. The second slide rail 32 is vertically arranged on the first slide rail 31, which allows the laser driving unit 33 to move vertically on the basis of the movement of the first slide rail 31. This double-slide rail design provides precise movement ability in a two-dimensional plane.

[0093] The laser driving unit 33 includes a first support plate 34 and a laser processing part 35 that are slidably arranged on the second slide rail 32. The first support plate 34 is provided with a third slide rail 36, and the laser processing part 35 is slidably arranged on the first support plate 34 via the third slide rail 36. The moving direction of the laser processing part 35 is perpendicular to the moving direction of the first support plate 34; the laser processing part 35 can approach or move away from the workpiece via the third slide rail 36.

[0094] The S2 further includes the following steps:

[0095] (a) Immerse the demolded titanium alloy casting in a phosphoric acid-ethylene glycol electrolyte solution, and perform anodic oxidation for 30 minutes at a DC voltage of 60 - 80V and a temperature of 25 ± 2°C to generate a TiO2 oxide film with a thickness of 2 - 3μm;

[0096] (b) Subject the castings with the coated film to sealing treatment in deionized water at 90 - 95°C for 40 minutes to reduce the porosity of the oxide film to < 3%.

[0097] The S5 further includes the following steps:

[0098] (a) Use a laser interferometer to detect the flatness of the installation plane of the cutting insert 6. If the flatness error > 0.005mm, micro-melt and correct the substrate of the cutting insert 6 with femtosecond laser until the error ≤ 0.003mm;

[0099] (b) Conduct a shear strength test on the metallurgical bonding interface between the cutting insert 6 and the blade 3, apply a progressive load of 0 - 1000N, and require the failure threshold > 800N. If not up to standard, repeat step S5 and adjust the pulse laser energy density.

[0100] The inner wall of the diversion channel 15 is provided with spiral ribs 40. The height of the ribs is 10 - 15% of the channel diameter, and the spiral angle is 25 - 35°; the surface of the ribs is coated with a 50 - 100μm thick Al2O3-TiO2 composite ceramic layer by plasma spraying, and the friction coefficient < 0.15; the distance between adjacent ribs is 1 / 4 - 1 / 3 of the channel circumference, forming an air flow pattern with alternating distribution of turbulent promotion areas and laminar flow stable areas, so that the heat dissipation efficiency is increased by more than 30%. The spiral rib design breaks the laminar boundary layer of the traditional straight channel, enhances heat transfer through turbulence, and at the same time, the low-friction coating reduces the pressure loss.

[0101] The blade 3 is composed of multi-layer gradient materials, and sequentially includes a first layer 37, a second layer 38, and a third layer 39 from the installation end to the cutting insert 6 end. The first layer 37 is a titanium alloy layer, the second layer 38 is a tungsten steel / titanium alloy mixed layer, and the third layer 39 is a pure tungsten steel layer; metallurgical bonding is achieved between the layers through electron beam cladding, and the thermal expansion coefficient gradient transitions (9.5 → 5.0×10 -6 / °C), reducing the interfacial thermal stress by 60%. The material gradient design matches the thermal-mechanical load distribution, avoiding the thermal deformation cracking of the traditional homogeneous blade 3.

[0102] The above content is only a preferred embodiment of the present invention. For those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation manner and application scope. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A low drag disposable tool, characterized in that: It includes a knife assembly, which includes a knife holder (1) and an arc-shaped cutter head (2) integrally formed with the knife holder (1). A blade (3) is installed at one end of the arc-shaped cutter head (2) away from the knife holder (1). A threaded hole (4) is provided at the end of the arc-shaped cutter head (2), and the blade (3) is installed on the threaded hole (4) of the arc-shaped cutter head (2) via a first fastener (5); a cutting insert (6) is further installed on the blade (3), and the cutting insert (6) has a body part and a PCD composite coating coated on the outside of the body part. The arc-shaped cutter head (2) includes a cutter body (111), a first cutting surface (7), a second cutting surface (8) and a third cutting surface (200) provided on the cutter body (111). The two sides of the cutter body (111) away from each other are the first cutting surface (7) and the second cutting surface (8) respectively. The third cutting surface (200) is the end surface of the free end of the arc-shaped cutter head (2). The third cutting surface (200) intersects with both the first cutting surface (7) and the second cutting surface (8). The blade (3) is installed on the third cutting surface (200). The second cutting surface (8) is a triangular convex arc surface. The width of the second cutting surface (8) at one end close to the third cutting surface (200) is smaller than the width of the second cutting surface (8) at one end away from the third cutting surface (200). When the arc-shaped cutter head (2) rotates, the cutting insert (6) of the blade (3) on the third cutting surface (200) contacts the processing surface of the external component for cutting operation.

2. The disposable tool with low wind resistance according to claim 1, characterized in that: A first groove (9) for installing the blade (3) is provided on the arc-shaped cutter head (2). The first groove (9) is recessed from the third cutting surface (200). The arc-shaped cutter head (2) protrudes with a first convex limiting part (11) located in the first groove (9). The first convex limiting part (11) is used to block the blade (3) to prevent the blade (3) from driving the cutting insert (6) to displace when the arc-shaped cutter head (2) rotates.

3. The disposable tool with low wind resistance according to claim 1, characterized in that: The tool further includes a plurality of locking parts (12). A plurality of receiving grooves (13) are further opened on the outer side of one end of the arc-shaped cutter head (2) close to the blade (3). The plurality of locking parts (12) are respectively fixedly connected in the plurality of receiving grooves (13); a plurality of card slots (14) are opened on one side of the blade (3) close to the locking part (12). The card slots (14) are used to cooperate with the locking parts (12) to achieve mechanical interlocking.

4. The low-drag disposable tool according to claim 3, characterized in that: The locking part (12) is an elastic capsule. The elastic capsule is fixedly connected to the inner end of the receiving groove (13). The elastic capsule is filled with magnetorheological fluid. The magnetorheological fluid includes magnetic particles and an oil-based carrier fluid. When the blade (3) and the arc-shaped cutter head (2) are pressed against each other, the magnetorheological fluid is activated by electricity to harden to fix and lock the blade (3).

5. The low-drag disposable tool according to claim 4, characterized in that: The magnetorheological fluid includes 20-40% magnetic particles and 60-80% oil-based carrier fluid.

6. The low-drag disposable tool according to claim 1, characterized in that: The number of the arc-shaped cutter heads (2) is multiple. The multiple arc-shaped cutter heads (2) are arranged in a circular array around the knife holder (1). Each arc-shaped cutter head (2) is configured with a blade (3) and a cutting insert (6). The knife holder (1) has an assembly positioning part (201) protruding from the arc-shaped cutter head (2). The sides of all the arc-shaped cutter heads (2) away from the assembly positioning part (201) are arranged in a coplanar manner to form a reference plane. The cutting insert (6) is arranged at one end of the blade (3) protruding from the reference plane.

7. The disposable tool with low wind resistance according to claim 6, characterized in that: The arc-shaped cutter head (2) is provided with a diversion channel (15). The diversion channel (15) is recessed from the reference surface and penetrates through the arc-shaped cutter head (2). The flowing air during the rotation of the arc-shaped cutter head (2) enters the diversion channel (15) to blow off the waste between the reference surface and the processing surface of the external component.

8. A manufacturing process of a low-drag disposable tool, characterized in that, It includes the following steps: S1. According to the three-dimensional model parting design, the mold cavity of the tool holder (1) and the integrally formed arc-shaped cutter head (2) is designed. The convex strip body for forming the diversion channel (15) is preset in the mold cavity, and the mold size tolerance is controlled within ±0.05 mm. S2. Heat the titanium alloy base material in a vacuum induction melting furnace to 1450 - 1700 °C, and inject it into the mold cavity at a filling speed of 0.5 - 1.2 m / s through low-pressure casting to form a casting. A low-friction Al2O3 ceramic layer is formed on the inner wall of the diversion channel (15) in the casting by micro-arc oxidation process to obtain the tool assembly. S3. After the cemented carbide powder is formed by static pressure molding, it is sintered in vacuum at 1450 °C to make the cutting insert (6), and a 10 - 15 μm thick PCD layer is deposited on the surface of the cutting insert (6) by hot wire chemical vapor deposition technology. S4. Install the cutting insert (6) on the blade (3), and install the blade (3) on the arc-shaped cutter head (2) via the first fastener (5).

9. The manufacturing process of a low-drag disposable tool according to claim 8, characterized in that: It also includes the following steps: Use the insert mechanism (17) to weld the cutting insert (6) on the blade (3), and lock the blade (3) welded with the cutting insert (6) on the tool holder (1) of the tool assembly. The insert mechanism (17) includes a frame (22), a grasping mechanism (18) installed on the frame (22), a vision positioning system (19), a pulsed laser mechanism (21), and a control center (23). The control center (23) is electrically connected to the grasping mechanism (18), the vision positioning system (19), and the pulsed laser mechanism (21). The grasping mechanism (18) grasps the cutting insert (6), places it on the blade (3) carried by the frame (22) after being positioned by the vision positioning system (19), so that the bottom surface of the cutting insert (6) is completely attached to the blade (3). The pulsed laser mechanism (21) locally heats the connection between the cutting insert (6) and the blade (3), and makes the temperature at the connection reach 1050 °C within 0.5 seconds to achieve the metallurgical bonding between the cutting insert (6) and the blade (3), and then install the blade (3) with the inserted cutting insert (6) on the tool holder (1) of the tool assembly. Use a hydraulic micro stamping machine to squeeze and deform the flash body of the casting inward to form a first convex limiting part (11), and the first convex limiting part (11) covers and blocks the blade (3).

10. The manufacturing process of a low drag disposable tool according to claim 8, characterized in that: The step S2 also includes the following steps: (a) Immerse the demolded titanium alloy casting in a phosphoric acid - ethylene glycol electrolyte solution, and perform anodic oxidation for 30 minutes at a DC voltage of 60 - 80 V and a temperature of 25 ± 2 °C to generate a 2 - 3 μm thick TiO2 oxide film. (b) Seal the film-covered casting in deionized water at 90 - 95 °C for 40 minutes to reduce the porosity of the oxide film to < 3%.

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