Manufacturing method of PCD tool with internal cooling channel and PCD tool

Abstract

The invention provides a manufacturing method of a PCD cutter with an inner cooling channel, which comprises a base and a multi-station index plate arranged on the base in a rotatable manner, a plurality of cutter fixing stations arranged on the multi-station index plate at intervals; the tool clamping mechanism is arranged above the multi-station index plate; the blade surface cleaning mechanism comprises a cleaning roller which is arranged above the cutter fixing station and can move up and down and rotate; the blade surface detection mechanism comprises a first visual camera and a first light source which are arranged above the cutter fixing station; the lantern ring press-fitting mechanism comprises a lantern ring feeding channel, an air cylinder and a pressing rod, the tail section of the lantern ring feeding channel is located over the cutter, and the air cylinder is connected with the hollow pressing rod; each cutter fixing station can be correspondingly matched with the blade face cleaning mechanism, the blade face detecting mechanism and the lantern ring press-fitting mechanism when rotating along with the multi-station index plate. The automatic lantern ring detection system can realize blade face detection of cutters with different specifications and can automatically sleeve qualified and non-defective products with lantern rings.

Description

Technical Field

[0001] The present invention belongs to the technical field of tool processing equipment, and in particular relates to a manufacturing method of a PCD tool with an inner cooling channel and the PCD tool. Background Art

[0002] Polycrystalline diamond (PCD) cutting tools, due to their exceptional hardness, wear resistance, and cutting performance, are widely used in high-precision applications such as machining nonferrous metals, composite materials, and non-metallic materials. To further enhance the performance of PCD cutting tools in high-speed or dry cutting environments, some tools are designed with internal cooling mechanisms. Coolant is delivered directly to the cutter head through cooling channels within the tool body, achieving efficient heat dissipation, chip removal, and extending tool life.

[0003] However, the manufacture of such PCD tools, especially when connecting the PCD tool head to the tool handle, usually adopts the brazing (vacuum welding) process. During the brazing process, due to the small size of the internal cooling channels, the liquid brazing material is very easy to siphon under the capillary action, seeping into and clogging these precise internal cooling channels. Once the channel is blocked, the internal cooling function of the tool will fail, seriously affecting the performance and service life of the tool, and even causing it to be scrapped. In the prior art, due to the difficulty in effectively controlling the blockage problem during the brazing process, the processing yield of PCD tools with internal cooling channels is generally low.

[0004] Therefore, how to efficiently and reliably prevent the internal cooling channel from being blocked during brazing and ensure the smooth flow of the channel after brazing, thereby improving the processing yield, is a technical problem that needs to be solved urgently in the field of PCD internal cooling tool manufacturing. Summary of the Invention

[0005] In view of a series of technical problems existing in the prior art, the present invention proposes a manufacturing method of a PCD tool with an inner cooling channel and a PCD tool to solve the above problems.

[0006] According to a first aspect of the present invention, a method for manufacturing a PCD tool having an internal cooling channel is provided, comprising:

[0007] S1: providing a PCD tool semi-finished product, the PCD tool semi-finished product comprising a shank portion and a cutter head portion, wherein the shank portion is formed with an axially penetrating internal cooling channel, and the cutter head portion is a composite structure of PCD and tungsten carbide;

[0008] S2: A first step is formed at one end of the shank, and a second step is formed at the tungsten carbide portion of the head. The diameter of the second step is slightly smaller than the diameter of the inner cooling channel of the first step.

[0009] S3: a radial water outlet hole communicating with the inner cooling channel is machined in the first section;

[0010] S4: Use a plug to insert and close the radial water outlet hole, insert the second section into the inner cooling channel, and connect the cutter head and the handle by vacuum welding;

[0011] S5: Using laser processing to remove the obstruction to restore the communication between the radial water outlet hole and the inner cooling channel;

[0012] S6: Process the PCD on the tool head to form a cutting edge and complete the tool forming.

[0013] This method solves the problem of brazing and plugging holes in internally cooled tools in the prior art, significantly improves the processing yield, and provides a reliable and efficient manufacturing approach for the mass production of PCD tools.

[0014] In some specific embodiments, the internal cooling channel includes an outlet channel at the front end of the shank and an inlet channel at the rear end. The inlet channel has a diameter within the range of 0.9-1.1 mm, and the outlet channel has a diameter within the range of 0.1-0.3 mm. This arrangement helps maintain a stable coolant flow rate and pressure, ensuring effective cooling of the PCD tool during cutting.

[0015] In some specific embodiments, the liquid inlet channel and the liquid outlet channel are connected by a conical transition, which ensures that the coolant can flow smoothly and efficiently from the liquid inlet channel to the liquid outlet channel, thereby optimizing the overall cooling efficiency.

[0016] In some specific embodiments, the diameter of the first section portion is within the range of 0.9-1.1 mm, the length is within the range of 1-4 mm, and the first section portion is connected to the handle portion through a tapered transition.

[0017] In some specific embodiments, the diameter of the second step portion is within the range of 0.15-0.25 mm, and the length is within the range of 0.1-0.3 mm.

[0018] In some specific embodiments, the diameter of the radial water outlet hole is within the range of 0.15-0.25 mm, and the distance between the axis of the radial water outlet hole and the end surface of the first segment is within the range of 0.1-0.4 mm. This arrangement ensures effective discharge of the coolant and optimizes the cooling effect.

[0019] In some specific embodiments, the obstruction is a short tungsten steel rod, which is easy to insert and fix in a narrow channel and also facilitates subsequent precise removal by laser.

[0020] In some specific embodiments, radial water holes extend through the first segment to form at least two water holes in the first segment. This arrangement helps provide a more uniform or sufficient coolant flow, improving the overall cooling efficiency and chip evacuation capability of the tool, thereby further optimizing cutting performance and tool life.

[0021] In some specific embodiments, the distance between the axis of the radial water outlet and the cutting edge is within a range of 1.0-1.5 mm. This precise distance between the axis of the radial water outlet and the cutting edge allows coolant to be precisely sprayed into the cutting area, maximizing cooling efficiency, effectively reducing cutting heat, and preventing tool wear and workpiece burns, thereby significantly improving machining quality and tool life.

[0022] According to a second aspect of the present invention, a PCD tool is provided, which is manufactured using the above-mentioned method for manufacturing a PCD tool with an inner cooling channel.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] The manufacturing method of the PCD tool with an internal cooling channel and the PCD tool of the present invention, during the vacuum brazing process, use a high-melting-point, high-hardness tungsten steel short rod or other obstruction to accurately and temporarily close the radial water outlet hole inside the tool, and use the second section of tungsten carbide on the tool head to insert into the internal cooling channel to assist in closing the axial passage, thereby fundamentally solving the industry problem of the brazing material being siphoned into the tiny cooling channel due to capillary action and causing blockage. After the brazing is completed, high-precision laser processing technology is used to accurately remove the obstruction and restore the smooth flow of the internal cooling channel. This method not only effectively eliminates the blockage of the internal cooling channel and significantly improves the manufacturing yield of PCD internal cooling tools, but also ensures the efficient operation of the internal cooling system of the tool and the precise injection of the coolant, thereby greatly improving the cutting performance of the tool, extending its service life, and ultimately improving the processing accuracy and efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated into and constitute a part of this specification. The accompanying drawings illustrate the embodiments and, together with the description, serve to explain the principles of the present invention. Other embodiments and many of the expected advantages of the embodiments will be readily apparent as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale with respect to each other. Like reference numerals designate corresponding similar parts.

[0026] Figure 1 is a flow chart of a method for manufacturing a PCD tool with an internal cooling channel according to one embodiment of the present invention;

[0027] Figure 2This is a schematic structural diagram of a handle portion and a cutter head portion of a semi-finished tool according to a specific embodiment of the present invention;

[0028] Figure 3 It is a structural schematic diagram of a first step portion formed by processing a tool handle portion according to a specific embodiment of the present invention;

[0029] Figure 4 2 is a schematic structural diagram of a tool head portion processed to form a second step portion according to a specific embodiment of the present invention;

[0030] Figure 5 2. It is a structural schematic diagram of a radial water outlet hole connected to an inner cooling channel processed in a first segment according to a specific embodiment of the present invention;

[0031] Figure 6 is a schematic diagram of a plugging object inserted into and closing a radial water outlet according to a specific embodiment of the present invention;

[0032] Figure 7 This is a structural diagram of a specific embodiment of the present invention in which the second segment portion is inserted into the inner cooling channel and the cutter head portion and the cutter handle portion are connected by vacuum welding;

[0033] Figure 8 It is a schematic diagram of the tool structure after the blockage is removed by laser processing according to a specific embodiment of the present invention.

[0034] The meanings of the numbers in the figure are: handle part 1, liquid inlet channel 11, liquid outlet channel 12, first section part 13, radial water outlet hole 14, tungsten steel short rod 15, cutter head 2, PCD 21, tungsten carbide 22, second section part 221. DETAILED DESCRIPTION

[0035] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are intended only to illustrate the invention and are not intended to limit the invention. It should also be noted that, for ease of description, only portions relevant to the invention are shown in the accompanying drawings.

[0036] Figure 1 FIG. 4 shows a flow chart of a method for manufacturing a PCD tool having an inner cooling channel according to an embodiment of the present invention. Figure 1 As shown, the method includes the following steps:

[0037] S1: A PCD tool semi-finished product is provided. The PCD tool semi-finished product includes a shank portion and a cutter head portion. An axially penetrating internal cooling channel is formed in the shank portion. The cutter head portion is a composite structure of PCD and tungsten carbide.

[0038] In a specific embodiment, Figure 2FIG. 1 shows a schematic structural diagram of a semi-finished tool handle and tool head according to a specific embodiment of the present invention. Figure 2 As shown, the semi-finished PCD tool comprises a shank 1 and a head 2. Shank 1 has an axially extending internal cooling channel, including a liquid inlet channel 11 at the rear end of the shank and a liquid outlet channel 12 at the front end. The head 2 is a composite structure of PCD 21 and tungsten carbide 22.

[0039] In a specific embodiment, the aperture of the liquid inlet channel 11 is within the range of 0.9-1.1 mm, adapted to the coolant connector or pipeline connection to ensure stable liquid inlet pressure; the aperture of the liquid outlet channel 12 is within the range of 0.1-0.3 mm, which facilitates the coolant to form a high-pressure fine stream for ejection. The liquid inlet channel 11 and the liquid outlet channel 12 are connected by a conical transition, which is conducive to the stable passage of the fluid and avoids dead corners of the liquid flow. The length of the shank portion 1 is within the range of 39.9-40.1 mm, and the depth of the liquid inlet channel 11 is within the range of 19-21 mm. The diameter of the cutter head 2 is 1.5 mm, and the length is within the range of 0.95-1.05.

[0040] S2: A first step is formed at one end of the shank, and a second step is formed at the tungsten carbide portion of the head. The diameter of the second step is slightly smaller than the aperture of the inner cooling channel of the first step.

[0041] In a specific embodiment, Figure 3 FIG. 1 shows a schematic structural diagram of a tool handle portion processed to form a first step portion according to a specific embodiment of the present invention. Figure 3 As shown, the diameter of the first segment portion 13 is within the range of 0.9-1.1 mm, the length is within the range of 1-4 mm, and the first segment portion 13 is connected to the handle portion 1 through a tapered transition. Figure 4 FIG. 1 shows a schematic diagram of a structure in which a tool head portion is processed to form a second segment difference portion according to a specific embodiment of the present invention. Figure 4 As shown, the diameter of the second section 221 is within the range of 0.15-0.25 mm, and the length is within the range of 0.1-0.3 mm. The size of the second section 221 is slightly smaller than the aperture of the liquid outlet channel 12, which facilitates the plug-in connection.

[0042] S3: A radial water outlet hole communicating with the inner cooling channel is processed in the first section.

[0043] In a specific embodiment, Figure 5 FIG. 1 shows a schematic diagram of a structure in which a radial water outlet hole connected to an inner cooling channel is processed in a first segment according to a specific embodiment of the present invention. Figure 5As shown, the diameter of the radial water outlet holes 14 is within the range of 0.15-0.25 mm, and the distance between the axis of the radial water outlet holes 14 and the end surface of the first segment 13 is within the range of 0.1-0.4 mm. The radial water outlet holes 14 extend through the first segment 13 to form at least two water outlet holes. The design of multiple radial water outlet holes facilitates multi-directional jet distribution, improves cooling uniformity, and adapts to complex cutting conditions.

[0044] S4: Use a plug to insert and close the radial water outlet hole, insert the second section into the inner cooling channel, and connect the cutter head and the handle by vacuum welding.

[0045] In a specific embodiment, Figure 6 FIG. 1 shows a schematic diagram of a plugging object inserted into and closing a radial water outlet according to a specific embodiment of the present invention, as shown in FIG. Figure 6 As shown, the blockage is a tungsten steel short rod 15. Figure 7 FIG. 1 shows a schematic diagram of a structure in which the second segment difference portion is inserted into the inner cooling channel and the tool head portion and the tool handle portion are connected by vacuum welding according to a specific embodiment of the present invention. Figure 7 As shown, the second section 221 of the cutter head 2 is inserted into and matched with the axial inner cooling channel of the first section 13, and the cutter head and the handle are connected by vacuum welding. During welding, the solder is blocked by the tungsten steel short rod 15, and the solder will not enter the liquid outlet channel 12 after the radial water outlet hole 14, thereby avoiding blockage of the liquid outlet channel 12.

[0046] S5: Laser processing is used to remove the obstruction to restore the communication between the radial water outlet hole and the inner cooling channel.

[0047] In a specific embodiment, Figure 8 FIG. 1 shows a schematic diagram of a tool structure after removing a blockage by laser processing according to a specific embodiment of the present invention. Figure 8 As shown, after the welding is completed and cooled, the obstruction 15 is removed by laser ablation to restore the flow function of the radial water outlet 14. High-precision laser processing is usually used to ensure that the wall of the radial water outlet 14 or the internal cooling channel is not damaged when the tungsten steel short rod 15 is removed, thereby restoring the connectivity between the radial water outlet 14 and the internal cooling channel.

[0048] S6: Process the PCD on the tool head to form a cutting edge and complete the tool forming.

[0049] In a specific embodiment, the PCD 21 of the tool head is processed using precision grinding or laser finishing to form a cutting edge that meets the required specifications. This step results in a high-performance PCD tool with internal cooling channels, suitable for high-load, high-precision machining scenarios. After machining, the radial water outlet 14 is positioned within a range of 1.0-1.5 mm from the cutting edge, ensuring precise coolant delivery to the cutting edge and effectively reducing heat buildup.

[0050] The above-mentioned manufacturing method can produce a PCD tool with a stable structure and high cooling efficiency. This tool realizes the organic combination of controllable coolant injection, firm connection of the tool head and efficient heat removal through the precisely machined internal cooling channel, tool head-shank matching structure, vacuum welding and plugging process. In particular, the tool head composed of the composite structure of PCD and tungsten carbide, while having excellent cutting performance, forms an integral structure with the tool holder that is plugged in and welded fixed, which not only ensures the cooling effect of the cutting area, but also effectively improves the structural strength and service life of the tool. Therefore, this PCD tool has a wide range of industrial application prospects and is particularly suitable for precision machining scenarios in high-speed, high-precision, and high-temperature environments.

[0051] While the above describes specific embodiments of the present invention, the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be readily conceived by a person skilled in the art within the technical scope disclosed herein are intended to be encompassed within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

[0052] In the description of the present invention, it should be understood that the terms "upper", "lower", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "one" or "an" preceding an element does not exclude the presence of a plurality of such elements. The simple fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used for improvement. Any reference signs in the claims should not be interpreted as limiting the scope.

Claims

1. A method for manufacturing a PCD tool with an internal cooling channel, characterized in that: include: S1: providing a PCD tool semi-finished product, the PCD tool semi-finished product comprising a shank portion and a cutter head portion, the shank portion having an axially penetrating internal cooling channel formed therein, and the cutter head portion being a composite structure of PCD and tungsten carbide; S2: forming a first step portion at one end of the tool handle, and forming a second step portion at the tungsten carbide portion of the tool head, wherein the diameter of the second step portion is slightly smaller than the aperture of the inner cooling channel of the first step portion; S3: machining a radial water outlet hole in communication with the inner cooling channel in the first section; S4: inserting a plug into and closing the radial water outlet hole, inserting the second segment portion into the inner cooling channel, and connecting the tool head portion and the tool handle portion by vacuum welding; S5: removing the obstruction by laser processing to restore the communication between the radial water outlet hole and the inner cooling channel; S6: Processing the PCD of the tool head to form a cutting edge, thereby completing tool forming.

2. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1, wherein: The inner cooling channel includes a liquid outlet channel at the front end of the shank portion and a liquid inlet channel at the rear end. The aperture of the liquid inlet channel is within the range of 0.9-1.1 mm, and the aperture of the liquid outlet channel is within the range of 0.1-0.3 mm.

3. The method for manufacturing a PCD tool with an inner cooling channel according to claim 2, wherein: The liquid inlet channel and the liquid outlet channel are connected via a conical transition.

4. The method for manufacturing a PCD tool with an inner cooling channel according to claim 2, wherein: The diameter of the first step portion is within the range of 0.9-1.1 mm, and the length is within the range of 1-4 mm. The first step portion is connected to the handle portion through a tapered transition.

5. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1, wherein: The diameter of the second step portion is within the range of 0.15-0.25 mm, and the length is within the range of 0.1-0.3 mm.

6. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1, wherein: The diameter of the radial water outlet hole is within the range of 0.15-0.25 mm, and the distance between the axis of the radial water outlet hole and the end surface of the first step portion is within the range of 0.1-0.4 mm.

7. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1, wherein: The blocking object is a tungsten steel short rod.

8. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1 or 6, characterized in that: The radial water outlet hole penetrates the first step portion to form at least two water outlet holes in the first step portion.

9. The method for manufacturing a PCD tool with an inner cooling channel according to claim 1 or 6, characterized in that: The distance between the axis center of the radial water outlet and the cutting edge is within the range of 1.0-1.5 mm.

10. A PCD tool, characterized in that: The PCD tool having an inner cooling channel is manufactured using the method for manufacturing the PCD tool according to any one of claims 1 to 9.

Images