Integral hard alloy milling cutter with grooves in front cutter face

Abstract

The invention provides a solid carbide milling cutter with grooves on a front cutter surface, which is characterized in that the grooves are arranged on the front cutter surface of a circumferential blade, the size of each groove along the cutting edge of the circumferential blade is 0.1 mm to 5mm, the distance between two adjacent grooves is 0.5 mm to 25mm, or 2mm to 20mm, or 3mm to 12mm, and under the condition that the grooves do not pass through the cutting edge of the circumferential blade, the distance between two adjacent grooves is 0.5 mm to 25mm, or 2mm to 20mm, or 3mm to 12mm. A circumferential blade second front angle is formed on the groove surface, close to the cutting edge of the circumferential blade, of the groove, and the circumferential blade second front angle is larger than the corresponding circumferential blade first front angle; and under the condition that the groove passes through the cutting edge of the circumferential cutting edge, the groove forms a groove front angle, and the groove front angle ranges from the first front angle of the circumferential cutting edge minus 25 degrees to the first front angle of the circumferential cutting edge plus 25 degrees. According to the milling cutter, the cutting length can be effectively controlled, the stability of workpiece machining is improved, the grooves do not leave extra cutting output or only leave very small extra cutting output for the rear cutting edge, the machining precision of the cutter is effectively improved, and the service life of the cutter is effectively prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of milling cutters, and particularly relates to a whole carbide milling cutter with grooves on the rake face. BACKGROUND

[0002] A milling cutter is a kind of multi-tooth and multi-edge rotary cutter for milling machining, and has high milling speed and no idle stroke. The milling cutter is a kind of high-efficiency cutting machining method, and can be used to machine planes, grooves, steps, threads, splines, gears and other shaped surfaces. During milling machining, the milling cutter rotates around its axis as the main movement, and the workpiece moves as the feed movement. The milling cutter is usually used for high-speed cutting, so the impact during machining is large, and the vibration is also large. The cutter in the prior art cannot meet the requirements of high efficiency and high precision machining. A prominent problem is that the size of the chip cannot be controlled, the chip cannot be discharged in time during the milling process, the friction between the cutter and the workpiece is increased, the chip heat is accumulated, and the machining life, machining efficiency and machining precision of the milling cutter are greatly limited. In the prior art, the shape of the chip can be improved by opening a chip dividing groove, and then the formation, curling and discharge of the chip can be improved. However, the chip dividing groove in the prior art inevitably produces a large amount of cutting residue, which causes a large cutting resistance of the next chip edge, easily causes the collapse of the rear edge, and causes excessive wear of the cutter, thereby reducing the service life of the cutter. SUMMARY

[0003] The present application provides a whole carbide milling cutter with grooves on the rake face, which comprises the following embodiments:

[0004] Embodiment 1. A whole carbide milling cutter with grooves on the rake face, comprising a body portion, an optional shank portion for directly or indirectly connecting with a machine tool, and an optional neck portion connecting the body portion and the shank portion, wherein the body portion is made of whole carbide material,

[0005] The body portion has a plurality of peripheral cutting edges and a plurality of main chip pockets corresponding to the peripheral cutting edges, each of the peripheral cutting edges independently has a peripheral edge rake face and a peripheral edge flank face, and the peripheral edge rake face and the peripheral edge flank face intersect to form a peripheral edge land, wherein the peripheral edge rake face forms a peripheral edge first rake angle at each position of the peripheral edge land, and characterized in that,

[0006] One or more grooves are arranged on the peripheral edge rake face, wherein each groove has a size of 0.1 mm to 5 mm, 0.1 mm to 5 mm, or 0.3 mm to 3 mm along the peripheral edge land, and the distance between two adjacent grooves is 0.5 mm to 25 mm, or 2 mm to 20 mm, or 3 mm to 12 mm when a plurality of grooves are arranged, and the groove passes through the peripheral edge land or does not pass through the peripheral edge land,

[0007] In the case that the groove does not pass the peripheral edge edge, the groove has a groove surface close to the peripheral edge edge, which is a second rake surface, so that the groove surface close to the peripheral edge edge forms a peripheral edge second rake angle, which is greater than the corresponding peripheral edge first rake angle;

[0008] In the case that the groove passes the peripheral edge edge, the groove forms a groove rake angle (i.e. the rake angle of the edge formed by the intersection of the groove and the peripheral edge relief surface), which is between the peripheral edge first rake angle minus 25° and the peripheral edge first rake angle plus 25°, or between the peripheral edge first rake angle minus 35° and the peripheral edge first rake angle plus 35°, or between the peripheral edge first rake angle minus 20° and the peripheral edge first rake angle plus 20°, or between the peripheral edge first rake angle minus 28° and the peripheral edge first rake angle plus 28°, or between the peripheral edge first rake angle minus 30° and the peripheral edge first rake angle plus 30°. In some embodiments, the peripheral edge second rake angle is at least 3°, at least 5°, at least 10°, at least 20°, at least 25°, at least 30° or at least 35° greater than the corresponding peripheral edge first rake angle.

[0009] Embodiment 2. The cemented carbide milling cutter according to embodiment 1, wherein the main flute is a helical flute, and the helical flute has an angle between the direction of the helix and the main spindle axis of the milling cutter, and the angle is between 3 and 55 degrees, such as between 15 and 50 degrees, such as between 25 and 45 degrees.

[0010] Embodiment 3. The cemented carbide milling cutter according to embodiment 1, wherein in the case that a plurality of grooves are provided, the distance between two adjacent grooves is between 2 and 30 times, such as between 5 and 25 times, the dimension along the peripheral edge edge, or the dimension along the peripheral edge edge of each groove is between 0.5 mm and 2.0 mm, and the distance between two adjacent grooves is between 10 and 20 times the dimension along the peripheral edge edge.

[0011] Embodiment 4. The cemented carbide milling cutter according to embodiment 1, wherein the dimension of the groove in the direction perpendicular to the edge along the rake surface is between 0.15 mm and 3 mm, or between 3% and 30% of the diameter of the body portion.

[0012] Embodiment 5. The cemented carbide milling cutter according to embodiment 1, wherein the depth of the groove is between 0.05 and 2 mm, or between 0.3 and 1.5 mm.

[0013] Embodiment 6. The cemented carbide milling cutter according to embodiment 1, wherein the diameter of the body portion is between 1 mm and 50 mm, such as between 5 mm and 40 mm, such as between 6 mm and 25 mm.

[0014] Embodiment 7. The cemented carbide milling cutter according to embodiment 6, characterized in that the depth of the groove is 0.2 to 0.8 times, such as 0.3 to 0.6 times, of the dimension of the groove on the rake face in a direction perpendicular to the cutting edge.

[0015] Embodiment 8. The cemented carbide milling cutter according to embodiment 1, characterized in that the milling cutter has a plurality of bottom surface cutting edges, each independently having a bottom edge rake face, a bottom edge relief face and a bottom edge cutting edge, the bottom surface cutting edges are arranged corresponding to the peripheral cutting edges, the junction between a bottom surface cutting edge and a peripheral cutting edge is a transition edge, a transition edge chip breaker is arranged at the position of the transition edge, optionally, the transition edge is arc-shaped.

[0016] Embodiment 9. The cemented carbide milling cutter according to embodiment 1, characterized in that, in the case that the groove does not pass the peripheral edge cutting edge, the distance between the groove and the peripheral edge cutting edge is greater than or equal to 0.005 mm and less than or equal to 0.2 mm, greater than or equal to 0.006 mm and less than or equal to 0.15 mm, greater than or equal to 0.01 mm and less than or equal to 0.18 mm, greater than or equal to 0.02 mm and less than or equal to 0.17 mm, greater than or equal to 0.008 mm and less than or equal to 0.1 mm, greater than or equal to 0.009 mm and less than or equal to 0.09 mm, greater than or equal to 0.01 mm and less than or equal to 0.015 mm.

[0017] Embodiment 10. The cemented carbide milling cutter according to embodiment 1, characterized in that the milling cutter is one of the following: an end milling cutter, a ball end milling cutter, a taper milling cutter, a ball taper milling cutter, a drum milling cutter.

[0018] Embodiment 11. The solid cemented carbide milling cutter according to embodiment 1, characterized in that, in the case that the groove does not pass the peripheral edge cutting edge, the groove further comprises a third rake angle face adjacent to the second rake angle face, the third rake angle face forms a peripheral edge third rake angle, the peripheral edge third rake angle is greater than the corresponding peripheral edge second rake angle.

[0019] The present application effectively controls the length of the chip by arranging one or more grooves on the peripheral edge rake face, facilitates the timely discharge of the chip, reduces the friction between the tool and the workpiece, reduces the accumulation of cutting heat, greatly improves the machining precision and tool life. At the same time, the way of arranging the groove in the present application will not leave a cutting residual amount at the groove during the milling process, or only leave a very small cutting residual amount, which will not cause excessive wear of the tool or collapse of the relief edge. In the case of effectively controlling the length of the chip, the stability of the workpiece machining is improved. In addition, the way of arranging one or more grooves in the present application is very convenient for laser processing, which brings significant performance improvement with very small changes to the tool, and improves the production efficiency of the tool. BRIEF DESCRIPTION OF DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present disclosure, the drawings of the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present disclosure and not limit the present disclosure.

[0021] Figure 1 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0022] Figure 2 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0023] Figure 3 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0024] Figure 4 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application. Figure 1 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0025] Figure 5 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application. Figure 4 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0026] Figure 6 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0027] Figure 7 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0028] Figure 8 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0029] Figure 9 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application. Figure 6 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0030] Figure 10 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application. Figure 9 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0031] Figure 11 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application. Figure 10 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0032] Figure 12 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0033] Figure 13 The figure is a schematic view of the overall structure of the solid carbide milling cutter of Embodiment 1 of the present application.

[0034] Figure 14 Structure diagram of the body part of the solid carbide milling cutter with multiple chip-breaker grooves on the peripheral flank land for the comparative example of the present application;

[0035] Figure 15 Structure diagram of the body part of the solid carbide milling cutter with multiple chip-breaker grooves on the peripheral flank land for the comparative example of the present application;

[0036] Figure 16 For Figure 14 C-C section view;

[0037] Figure 17 For Figure 16 Partial enlarged view of the C part (i.e. the peripheral cutting edge provided with chip-breaker grooves);

[0038] Figure 18 Partial enlarged view of the edge provided with different grooves or chip-breaker grooves.

[0039] BRIEF DESCRIPTION OF DRAWINGS: 100 - body part, 110 - peripheral cutting edge, 111 - peripheral rake land, 112 - peripheral flank land, 113 - peripheral edge, 120 - main chip-breaker groove, 10 - groove, 11 - groove surface close to the peripheral edge (second rake surface), 12 - third rake surface, 20 - chip-breaker groove, 200 - neck part of the cutter, 300 - shank part of the cutter. DETAILED DESCRIPTION

[0040] In order to make the objects, technical solutions and advantages of the embodiments of the present disclosure clearer, the technical solutions of the embodiments of the present disclosure will be described clearly and completely below with reference to the drawings of the embodiments of the present disclosure. Obviously, the described embodiments are part of the embodiments of the present disclosure, rather than all the embodiments. Based on the described embodiments of the present disclosure, all other embodiments obtained by a person of ordinary skill in the art without any creative effort belong to the scope of protection of the present disclosure.

[0041] The application discloses a whole carbide milling cutter with grooves on the rake face, which comprises a body part, an optional shank part for directly or indirectly connecting with a machine tool, and an optional neck part connecting the body part and the shank part, wherein the body part is made of whole carbide material, the body part has a plurality of peripheral cutting edges and a plurality of main chip flutes corresponding to the peripheral cutting edges, each of the peripheral cutting edges independently has a peripheral edge rake face and a peripheral edge relief face, and the peripheral edge rake face and the peripheral edge relief face intersect to form a peripheral edge cutting edge, wherein the peripheral edge rake face forms a peripheral edge first rake angle at each position of the peripheral edge cutting edge, and one or more grooves are arranged on the peripheral edge rake face, wherein each groove has a size of 0.1 mm to 5 mm or 0.3 mm to 3 mm along the peripheral edge cutting edge, and the distance between two adjacent grooves is 0.5 mm to 25 mm, or 2 mm to 20 mm, or 3 mm to 12 mm in the case of arranging a plurality of grooves, wherein the groove passes through the peripheral edge cutting edge or does not pass through the peripheral edge cutting edge, in the case that the groove does not pass through the peripheral edge cutting edge, the groove has a groove surface close to the peripheral edge cutting edge, which is a second rake angle surface, so that the groove surface close to the peripheral edge cutting edge forms a peripheral edge second rake angle, and the peripheral edge second rake angle is greater than the corresponding peripheral edge first rake angle; in the case that the groove passes through the peripheral edge cutting edge, the groove forms a groove rake angle (i.e. the rake angle of the cutting edge formed by the intersection of the groove and the peripheral edge relief face), and the groove rake angle is between the peripheral edge first rake angle minus 25° and the peripheral edge first rake angle plus 25°. It should be noted that in the technical scheme of the application, at least one groove is arranged on each peripheral cutting edge of the milling cutter.

[0042] The terms in the application have the meanings commonly understood by those skilled in the art, for example, the term "peripheral edge rake face" refers to the surface through which the chip flows on the peripheral cutting edge, the term "peripheral edge relief face" refers to the surface opposite to the surface generated in the cutting of the workpiece on the peripheral cutting edge, and the term "peripheral edge cutting edge" is the edge used for cutting chips.

[0043] The term "peripheral edge first rake angle" in the application has the same meaning as the general term "rake angle" in the art, and the two terms can be used interchangeably, and the term "peripheral edge first rake angle" is used in the application only for the purpose of convenience. The term "peripheral edge second rake angle" in the application refers to the angle formed by the second rake angle surface in the measurement plane of the "peripheral edge first rake angle". That is, the "peripheral edge first rake angle" is formed by the peripheral edge rake face, and the "peripheral edge second rake angle" is formed by the groove surface close to the peripheral edge cutting edge. For a specific selected point on the peripheral edge cutting edge, there are both the peripheral edge first rake angle and the peripheral edge second rake angle, and at this time, the peripheral edge first rake angle is the corresponding peripheral edge first rake angle of the peripheral edge second rake angle of the selected point on the cutting edge.

[0044] The term "flute rake angle" in the present application refers to the rake angle of the cutting edge formed by the intersection of the flute and the rake surface of the peripheral edge when the flute extends through the peripheral edge. The flute rake angle is measured in the first peripheral edge rake angle measurement plane.

[0045] The term "cemented carbide" in the present application has the general meaning understood by those skilled in the art. In the art, cemented carbide is a powder metallurgy product made of micron-sized powder of refractory carbide (WC, TiC) as the main component and cobalt (Co) or nickel (Ni), molybdenum (Mo) as the binder, sintered in a vacuum furnace or a hydrogen reduction furnace. Its resistance is much higher than that of high-speed steel, about 800-1000℃, and the allowable cutting speed is about 4-10 times that of high-speed steel. The hardness is very high, up to (89-91) HRA, and some as high as 93 HRA; but its bending strength is 1.1-1.5 GPa, only half of that of high-speed steel; impact toughness is 0.04 MJ / m 2 2.5 times that of high-speed steel, about 1 / 25-1 / 10 of that of high-speed steel. Due to its good heat resistance and wear resistance, it is increasingly used in tools with less complex blade shapes. The cemented carbide described in the present application includes one selected from the following: for example, tungsten-cobalt (WC-Co) cemented carbide, tungsten-titanium-cobalt (WC-Ti-Co) cemented carbide, tungsten-titanium-tantalum (niobium) (WC-TaC(NbC)-Co) cemented carbide, tungsten-titanium-cobalt-tantalum (niobium) (WC-TiC-TaC(NbC)-Co) cemented carbide, and other WC-based cemented carbides, or TiC-based cemented carbide, fine-grained ultra-fine-grained cemented carbide, steel-bonded cemented carbide, coated cemented carbide, etc.

[0046] The term "cutting residual amount" or "cutting residual depth" in the present application has the same meaning, which refers to the cutting amount reduced by the local cutting edge of the tool after the local cutting edge of the tool is changed.

[0047] The present application defines "one or more flutes are provided on the rake surface of the peripheral edge", the flutes on the rake surface can play a role in chip breaking, and by controlling the distance between two adjacent flutes, the cutting length can be effectively controlled and adjusted, the stability of workpiece machining can be improved, the chip can be discharged and cooled in time, the friction between the tool and the workpiece can be reduced, the cutting heat accumulation can be reduced, and the machining precision and tool life can be greatly improved.

[0048] In the present application, the flutes provided on the rake surface can extend through the peripheral edge or not, "extending through the peripheral edge" means that the flute extends to the peripheral edge flank surface, thereby changing the original peripheral edge, "not extending through the peripheral edge" means that the flute is only provided on the peripheral edge rake surface, without changing the peripheral edge.

[0049] In the case that the groove does not pass the peripheral edge edge, the groove has a groove surface close to the peripheral edge edge and forms a peripheral edge second rake angle greater than the corresponding peripheral edge first rake angle, for example, the peripheral edge second rake angle is greater than the peripheral edge first rake angle by 3 degrees to 45 degrees, for example, 5 degrees to 35 degrees, for example, 6 degrees to 30 degrees, for example, 8 degrees to 25 degrees, for example, 10 degrees to 20 degrees. Thus, the chip breaking effect can be generated without damaging the original edge, in this case, the groove with chip breaking effect does not change the chip shape of the original edge, the relief of the trailing edge is not left, the machining precision is high, and it is suitable for finish machining.

[0050] In some embodiments, the peripheral edge second rake angle is greater than the corresponding peripheral edge first rake angle by at least 3°, at least 5°, at least 10°, at least 20°, at least 25°, at least 30°, or at least 35°.

[0051] In the case that the groove passes the peripheral edge edge, the groove and the peripheral edge relief surface together form a groove rake angle, which is defined in the present application as between the peripheral edge first rake angle minus 25° and the peripheral edge first rake angle plus 25°, for example, between the peripheral edge first rake angle minus 15° and the peripheral edge first rake angle plus 20°, for example, between the peripheral edge first rake angle minus 5° and the peripheral edge first rake angle plus 15°, for example, between the peripheral edge first rake angle minus 0° and the peripheral edge first rake angle plus 10°, for example, between the peripheral edge first rake angle plus 0° and the peripheral edge first rake angle plus 15°, for example, between the peripheral edge first rake angle plus 5° and the peripheral edge first rake angle plus 25°. The groove passing the peripheral edge edge forms a new edge with a groove rake angle, in the case that the groove rake angle is small (for example, the peripheral edge first rake angle minus 25°), it can still ensure that the cutting resistance does not increase significantly while breaking the chip, in the case that the groove rake angle is close to or greater than the peripheral edge first rake angle, the new edge can achieve chip breaking. Moreover, the cutting residual amount under this setting is almost negligible, leaving only a very small additional cutting amount, which will not cause the trailing edge to collapse. Because the cutting residual depth under this setting depends on the clearance angle of the relief surface and the size of the groove in the relief surface in the direction perpendicular to the edge, even if a groove with a large size is set, the cutting residual depth is still very small, suitable for semi-finish machining and rough machining. It should be noted that in the case that each cutting edge has a corresponding groove, the grooves passing the peripheral edge edge can be staggered or not staggered in the axial direction of the tool. In the case of staggered arrangement, the machining precision is higher.

[0052] In comparison, in the prior art, a chip dividing groove is arranged on the relief surface, in order to achieve the effect of chip rolling and dividing, the size cannot be too small, but in the case of arranging a chip dividing groove on the relief surface in the prior art, the large size of the chip dividing groove inevitably brings a large cutting residual amount, reduces the machining precision, and easily causes the trailing edge to collapse.

[0053] In the present application, the size of each groove along the peripheral edge and the distance between two adjacent grooves are measured in the direction along the peripheral edge of the cutting edge on the rake face of the peripheral edge near the cutting edge. The size of the groove and the distance are further defined in the present application, which not only has a good chip breaking effect and can effectively control the size of the chip, but also is very convenient to process and will not bring a significant increase in the cost of tool processing. Those skilled in the art can reasonably set and adjust the size and distance of the groove according to the cutting conditions.

[0054] In some embodiments, the main chip groove is a spiral groove, the angle of the spiral groove is the angle between the direction of the spiral and the spindle of the milling cutter, and the angle of the spiral groove is between 3 and 55 degrees, for example, 15 to 50 degrees, for example, 25 to 45 degrees.

[0055] In some embodiments, where a plurality of grooves are provided, the distance between two adjacent grooves is 2 to 30 times, 5 to 25 times the size of the peripheral edge of the cutting edge, or the size of each groove along the peripheral edge of the cutting edge is 0.5 mm to 2.0 mm, and the distance between two adjacent grooves is 10 to 20 times the size of the peripheral edge of the cutting edge. By adjusting the size of the groove and the distance between the grooves, the length of the chip can be controlled and the tool life can be improved.

[0056] In some embodiments, the size of the groove in the direction perpendicular to the cutting edge on the rake face is 0.15 mm to 3 mm or 3% to 30% of the diameter of the body portion. In the present application, the diameter of the body portion refers to the diameter of the maximum outer circle of the peripheral cutting edge during the operation of the milling cutter.

[0057] In some embodiments 5, the depth of the groove is 0.05 to 2 mm, or 0.3 to 1.5 mm. In the present application, the depth of the groove is measured in the direction perpendicular to the peripheral edge rake face.

[0058] In some embodiments 6, the diameter of the body portion is 1 mm to 50 mm, for example, 5 mm to 40 mm, 6 mm to 25 mm.

[0059] In some embodiments, the depth of the groove is 0.2 to 0.8 times, for example, 0.3 to 0.6 times, the size of the groove in the direction perpendicular to the cutting edge on the rake face.

[0060] In some embodiments, the milling cutter has a plurality of bottom surface cutting edges, each of which independently has a bottom edge rake face, a bottom edge flank face, and a bottom edge cutting edge, and the bottom surface cutting edges are correspondingly arranged with the peripheral cutting edges. The connection between the bottom surface cutting edge and the peripheral cutting edge is a transition edge, a transition edge chip breaker is provided at the position of the transition edge, and optionally, the transition edge is arc-shaped.

[0061] The transition edge chip breaking groove can also break chips, and can improve the sharpness of the transition edge, reduce cutting resistance, and increase the service life of the transition edge.

[0062] In some embodiments, the distance between the groove and the peripheral edge edge is greater than or equal to 0.005 mm and less than or equal to 0.2 mm, greater than or equal to 0.006 mm and less than or equal to 0.15 mm, greater than or equal to 0.01 mm and less than or equal to 0.18 mm, greater than or equal to 0.02 mm and less than or equal to 0.17 mm, greater than or equal to 0.008 mm and less than or equal to 0.1 mm, greater than or equal to 0.009 mm and less than or equal to 0.09 mm, greater than or equal to 0.01 mm and less than or equal to 0.015 mm, when the groove does not pass the peripheral edge edge.

[0063] In some embodiments, the milling cutter is one of the following: an end mill, a ball end mill, a taper end mill, a ball taper end mill, a drum-type milling cutter.

[0064] In some embodiments, the groove further comprises a third rake surface adjacent to the second rake surface, when the groove does not pass the peripheral edge edge, the third rake surface forms a peripheral edge third rake angle, and the peripheral edge third rake angle is greater than the corresponding peripheral edge second rake angle.

[0065] The term "peripheral edge third rake angle" in the present application refers to the angle formed by the third rake surface in the "peripheral edge first rake angle" measurement plane. The peripheral edge first rake angle, the peripheral edge second rake angle and the peripheral edge third rake angle exist simultaneously for a specific selected point on the peripheral edge edge, and the peripheral edge second rake angle is the corresponding peripheral edge second rake angle of the peripheral edge third rake angle of the selected point on the edge.

[0066] By providing the sub-chip groove with the peripheral edge third rake angle, the chip flow can be effectively guided, the cutting resistance can be reduced, the cutting temperature can be reduced, the friction between the chip and the peripheral edge rake surface can be effectively inhibited, the chip removal efficiency can be improved, and the tool life can be further improved.

[0067] The preparation method of the milling cutter of the prior art is known to those skilled in the art, including the following steps: 1. calculating the shape of the milling cutter according to actual needs and selecting suitable hard alloy bar stock, 2. starting from the hard alloy bar stock, the hard alloy bar stock is processed by grinding to form a milling cutter blank, 3. forming a semi-finished product of the milling cutter by fine grinding, and 4. performing PVD coating treatment on the semi-finished product, thereby forming a finished product of the milling cutter.

[0068] The method for preparing a milling cutter according to the present application mainly processes a groove on the basis of the semi-finished product, and then performs PVD coating treatment on the semi-finished product with the groove.

[0069] In some embodiments, the groove is prepared by a machining method that does not cause thermal damage.

[0070] In some embodiments, the grooves are prepared using a femtosecond pulsed laser processing method. The grooves described in this application can be prepared using femtosecond pulsed laser processing, for example, using a precision CNC laser machine purchased from DMG MORI (trade name LASERTEC 50Shape). It is generally believed that laser processing degrades the properties of cemented carbide; for example, picosecond and nanosecond processing can cause thermal damage, forming a thermal damage layer in the groove area, damaging the tool, resulting in very poor surface finish, failing to meet finishing requirements, and drastically reducing tool life. Without theoretical limitations, it is believed that the formation of this thermal damage layer is due to the high temperatures generated during processing causing oxidation of the cemented carbide, altering the microstructure of the alloy, and reducing hardness and wear resistance. This can be clearly seen by comparing the tool life with that of tools without a thermal damage layer; the life of a tool with a thermal damage layer is often less than half that of a tool without a thermal damage layer, and some even deteriorate to one-fifth or less of their normal life. Femtosecond pulsed laser processing, due to its extremely high speed, avoids thermal damage and can achieve a surface finish of 0.1-0.2 nm, even reaching a mirror level, making it suitable for precision machining. With grooves, chip size can be precisely controlled, facilitating timely chip removal, reducing tool-workpiece friction, minimizing cutting heat accumulation, and improving machining speed, efficiency, accuracy, and tool life. This results in high-precision, highly flexible, and highly efficient machining.

[0071] The scope described above can be used alone or in combination. The following examples will make this application easier to understand.

[0072] Example

[0073] Example 1

[0074] like Figures 1 to 3 As shown, this embodiment discloses a solid carbide end mill with a grooved rake face, which includes a body portion 100, a shank portion 300 for direct or indirect connection with a machine tool, and a neck portion 200 connecting the body portion and the shank portion. The body portion is made of solid carbide and has four peripheral cutting edges 110 and four main chip grooves 120 corresponding to the peripheral cutting edges. The main chip grooves are helical grooves with an angle of 20 degrees.

[0075] Figure 2As a partial view of the body part, each of the peripheral cutting edges 110 has a peripheral edge rake face 111 and a peripheral edge flank face 112, which intersect to form a peripheral edge edgelet 113, wherein the peripheral edge rake face forms a peripheral edge first rake angle at each point of the peripheral edge edgelet, characterized in that a plurality of grooves 10 are arranged on the peripheral edge rake face.

[0076] Figure 3 A partial view of the groove 10 is shown. As shown, the groove does not reach the peripheral edge edgelet 113, and the distance between the groove and the peripheral edge edgelet is about 0.07 mm. The size of each groove along the peripheral edge edgelet is 1 mm, and the distance between two adjacent grooves is 8 mm.

[0077] The size of the groove in the rake face along the direction perpendicular to the edgelet is 0.8 mm.

[0078] The depth of the groove is 0.5 mm. Figure 3 In the middle, the size of the groove along the peripheral edge edgelet, i.e., the size labeled as a in the figure, and the size of the groove in the rake face along the direction perpendicular to the edgelet, i.e., the size labeled as b in the figure, and the distance between two adjacent grooves, i.e., the size labeled as c in the figure, are shown. The diameter of the body part is 12 mm.

[0079] Figure 4 In the middle, Figure 1 In the middle, the size of the groove along the peripheral edge edgelet, i.e., the size labeled as a in the figure, and the size of the groove in the rake face along the direction perpendicular to the edgelet, i.e., the size labeled as b in the figure, and the distance between two adjacent grooves, i.e., the size labeled as c in the figure, are shown. The diameter of the body part is 12 mm. Figure 5 In the middle, Figure 4 In the middle, the size of the groove along the peripheral edge edgelet, i.e., the size labeled as a in the figure, and the size of the groove in the rake face along the direction perpendicular to the edgelet, i.e., the size labeled as b in the figure, and the distance between two adjacent grooves, i.e., the size labeled as c in the figure, are shown. The diameter of the body part is 12 mm. Figure 5 In the middle, the size of the groove along the peripheral edge edgelet, i.e., the size labeled as a in the figure, and the size of the groove in the rake face along the direction perpendicular to the edgelet, i.e., the size labeled as b in the figure, and the distance between two adjacent grooves, i.e., the size labeled as c in the figure, are shown. The diameter of the body part is 12 mm.

[0080] The arrangement of the groove can effectively control the length of the chip, improve the stability of the workpiece machining, facilitate the timely discharge and heat dissipation of the chip, reduce the friction between the tool and the workpiece, reduce the accumulation of cutting heat, greatly improve the machining precision and tool life. Since the arrangement of the groove does not change the original chip shape of the edgelet, the residual cutting depth is 0, and the rear edge does not leave additional cutting amount, the machining precision is high, and it is suitable for fine machining.

[0081] Example 2

[0082] As Figures 6 to 8As shown, the embodiment discloses a whole carbide milling cutter with grooves on rake face, which comprises a body part 100, a shank part 300 for connecting with machine tool directly or indirectly, and a neck part 200 connecting the body part and the shank part, wherein the body part is made of whole carbide material, the body part has four peripheral cutting edges 110 and four main flutes 120 corresponding to the peripheral cutting edges, the main flutes are spiral flutes, and the angle of the spiral flutes is 20 degrees.

[0083] Figure 7 As shown in the partial view of the body part, each of the peripheral cutting edges 110 independently has a peripheral edge rake face 111 and a peripheral edge relief face 112, the peripheral edge rake face and the peripheral edge relief face intersect to form a peripheral edge cutting edge 113, wherein the peripheral edge rake face forms a peripheral edge first rake angle at each position of the peripheral edge cutting edge, and characterized in that a plurality of grooves 10 are arranged on the peripheral edge rake face.

[0084] Figure 8 As shown in the partial view of the grooves 10, the grooves pass through the peripheral edge cutting edge 113, the size of each groove along the peripheral edge cutting edge is 1 mm, and the distance between two adjacent grooves is 8 mm. The size of the groove in the direction perpendicular to the cutting edge on the rake face is 1.6 mm.

[0085] The depth of the groove is 0.4 mm. The diameter of the body part is 12 mm.

[0086] Figure 9 As shown in the partial view of the body part, Figure 6 As shown in the B-B sectional view along one of the grooves, Figure 10 As shown in the partial enlarged view of the B part (i.e. the peripheral cutting edge provided with the groove), Figure 9 As shown in the figure, the groove intersects with the peripheral edge relief face to form a groove cutting edge, the rake angle of the groove cutting edge is a groove rake angle, and the groove rake angle is larger than the peripheral edge first rake angle. The angle α shown in the figure is the peripheral edge first rake angle formed by the cutting edge rake face at the section point, and the peripheral edge first rake angle α in the figure is translated to the groove cutting edge. The angle γ is the groove rake angle of the cutting edge formed by the intersection of the groove and the peripheral edge relief face. The peripheral edge first rake angle α is 3 degrees, and the groove rake angle γ is 20 degrees.

[0087] Figure 11 As shown in the partial view of the body part, Figure 10The local enlarged view of the middle D part (i.e. the part of the edge formed by the groove crossing the peripheral edge and the peripheral edge relief surface). The angle θ in the figure is the clearance angle of the peripheral edge relief surface, which is usually between 5 degrees and 15 degrees, and h is the size of the groove crossing the peripheral edge in the direction perpendicular to the edge on the relief surface. The dotted line in the figure shows the edge without the groove. After the groove crossing the peripheral edge is set, the distance of the groove edge formed by the intersection of the groove and the peripheral edge relief surface on the relief surface is the distance shown by h in the figure, which is the size of the groove in the direction perpendicular to the edge on the relief surface. Compared with the cutting without the groove or the groove not crossing the peripheral edge, the cutting residual depth of the groove crossing the peripheral edge in the embodiment is the size marked by d in the figure. The cutting residual depth d, the size of the groove h and the angle θ satisfy the following relationship: d = h sin θ. Since the clearance angle of the relief surface is usually not more than 15 degrees, a larger groove size will still leave a very small cutting residual amount.

[0088] The groove can play a role in chip breaking. By controlling the distance between two adjacent grooves, the cutting length can be effectively controlled and adjusted, the stability of workpiece machining can be improved, the chip can be discharged and cooled in time, the tool and workpiece friction can be reduced, the cutting heat accumulation can be reduced, and the cutting residual depth is still very small under a larger groove size, which will not cause the collapse of the rear edge, thereby improving the tool life and being suitable for semi-finishing and rough machining.

[0089] Embodiment 3

[0090] The embodiment discloses a whole carbide milling cutter with grooves on the rake surface. The milling cutter is basically the same as the milling cutter in embodiment 2. The grooves cross the peripheral edge. The size of each groove along the peripheral edge is 1 mm, and the distance between two adjacent grooves is 5 mm. The size of the groove in the direction perpendicular to the edge on the rake surface is 2 mm. The depth of the groove is 0.2 mm. The diameter of the body part is 12 mm.

[0091] Figure 12A partial view of the peripheral cutting edge of the milling cutter provided with the groove 10 is shown in the figure. The groove intersects the peripheral relief surface to form an edge with a rake angle, which is the rake angle of the groove. The rake angle of the groove is the first peripheral rake angle minus 17°. The dashed part of the figure shows the edge without the groove. The angle a is the first peripheral rake angle formed by the peripheral rake surface of the edge (the first peripheral rake angle a in the figure is translated to the edge of the groove). The angle y is the rake angle of the groove formed by the intersection of the groove and the peripheral relief surface. The first peripheral rake angle a is 5°, and the rake angle of the groove is -12°. The dashed part of the figure shows the edge without the groove. As in Example 2, the residual cutting depth is still small. The rake angle of the groove of -12° still ensures that the groove plays a role in chip breaking. The groove mainly plays a role in chip breaking and still has all the advantages of Example 2. In addition, due to the negative rake angle of the groove, the impact resistance is stronger, and the product is more suitable for machining high-hardness materials and difficult-to-machine materials.

[0092] Example 4

[0093] As Figure 13 shown, this embodiment discloses another solid carbide milling cutter, which is basically the same as Example 1, except that the groove 10 further comprises a third rake surface 12 adjacent to the second rake surface 11, and the third rake surface forms a third peripheral rake angle, which is greater than the corresponding second peripheral rake angle.

[0094] Figure 13 A partial enlarged view of the edge of the peripheral cutting edge provided with the groove is shown in the figure. The first peripheral rake angle a, the second peripheral rake angle b, and the third peripheral rake angle y are shown in the figure. In the same measurement plane, the first peripheral rake angle a is formed by the peripheral rake surface and is 5°, the second peripheral rake angle is formed by the groove surface (i.e., the second rake surface 11) near the peripheral edge, and is 28°, and the third peripheral rake angle y is formed by the third rake surface 12 and is 35°.

[0095] Example 4 can effectively guide the chip flow, reduce the cutting resistance, reduce the cutting temperature, effectively inhibit the friction between the chip and the peripheral rake surface, and improve the chip removal efficiency by providing the secondary chip groove with the third peripheral rake angle. Based on Examples 1 to 3, the tool life is further improved.

[0096] Comparative Example

[0097] As Figures 14 to 17As shown, the present comparative example is a milling cutter with chip-breaker grooves in the prior art, which comprises a body portion 100, a shank portion 300 for directly or indirectly connecting with a machine tool, and a neck portion 200 connecting the body portion and the shank portion, wherein the body portion is made of integral cemented carbide material, the body portion has four peripheral cutting edges 110 and four main chip-breaker grooves 120 corresponding to the peripheral cutting edges, the main chip-breaker grooves are spiral grooves, and the angle of the spiral grooves is 20 degrees.

[0098] Figure 15 As shown in the partial view of the body portion, each of the peripheral cutting edges 110 independently has a peripheral edge rake face 111 and a peripheral edge relief face 112, the peripheral edge rake face and the peripheral edge relief face intersect to form a peripheral edge cutting edge 113, wherein the peripheral edge rake face forms a peripheral edge first rake angle at each of the peripheral edge cutting edges, and a plurality of chip-breaker grooves 20 are arranged on the peripheral edge relief face 112.

[0099] Figure 16 As shown in the partial view of the body portion, Figure 14 As shown in the partial view of the body portion, Figure 17 As shown in the partial view of the body portion, Figure 16 As shown in the partial view of the body portion, Figure 17 As shown in the partial view of the body portion, As shown in the partial view of the body portion, although the chip-breaker grooves arranged on the relief face can improve the formation, curling and discharge of chips during milling, it brings a large amount of cutting residual, and the cutting residual depth is Figure 17 As shown in the partial view of the body portion, the dimension I in the partial view of the body portion. Under a specific feed per tooth, the chip-breaker grooves arranged on the relief face will generate a larger amount of cutting residual, that is, the chip-breaker grooves in the prior art leave a higher amount of cutting for the trailing chip-breaking edge, which affects the stability of the cutting tool during cutting, thereby affecting the machining accuracy, and easily causes the trailing edge to collapse, and causes excessive wear of the cutting tool, thereby reducing the service life of the cutting tool.

[0100] Figure 18 As shown in the partial view of the body portion, the dimension I in the partial view of the body portion. Under a specific feed per tooth, the chip-breaker grooves arranged on the relief face will generate a larger amount of cutting residual, that is, the chip-breaker grooves in the prior art leave a higher amount of cutting for the trailing chip-breaking edge, which affects the stability of the cutting tool during cutting, thereby affecting the machining accuracy, and easily causes the trailing edge to collapse, and causes excessive wear of the cutting tool, thereby reducing the service life of the cutting tool.

[0101] Cutting test

[0102] Metal cutting tests were carried out by using the solid carbide milling cutter of embodiment 1 and embodiment 2 of the present application, the solid carbide milling cutter in the comparative example with the chip breaker groove set on the relief surface as control 1, and the solid carbide milling cutter without the chip breaker groove as control 2. The machining materials were titanium alloy, nickel-based alloy, aluminum alloy and stainless steel, respectively, the workpiece was a 100mm*50mm*25mm inner cavity groove, the C42 machine tool of Hammer Company was used for trial machining, and the SF15 water-soluble cutting fluid of Amite Science and Technology Co., Ltd. was used as the cutting fluid.

[0103] The machining conditions of different machining materials are as follows:

[0104] Table 1 titanium alloy machining conditions

[0105]

[0106] Table 2 nickel-based alloy machining conditions

[0107]

[0108] Table 3 aluminum alloy machining conditions

[0109]

[0110] Table 4 stainless steel machining conditions

[0111]

[0112] From the data in the above table, it can be seen that, compared with the chip breaker groove in the prior art, by setting the groove, the cutting length can be effectively controlled and adjusted, the stability of workpiece machining is improved, the chip is discharged and cooled in time, the tool and workpiece friction is reduced, the cutting heat accumulation is reduced, and the machining linear speed of the tool, the feed per tooth, the machining life and the product surface finish are improved to different degrees.

[0113] The product of embodiment 3 also has the same technical effect as embodiment 2 after testing. In addition, the product of embodiment 3 is particularly suitable for machining heat-treated materials, which have high hardness (Rockwell hardness greater than HR40).

[0114] The above only describes exemplary embodiments of the present disclosure, and is not intended to limit the protection scope of the present disclosure, and the protection scope of the present disclosure is determined by the appended claims.

Claims

1. A solid carbide end mill with gullets on the rake face, comprising a body portion, optionally a shank portion for direct or indirect connection to a machine tool, and optionally a neck portion connecting the body portion and the shank portion, wherein the body portion is of solid carbide material, the body portion has a plurality of peripheral cutting edges and a plurality of primary flutes corresponding to the peripheral cutting edges, each of the peripheral cutting edges independently has a peripheral rake face, a peripheral relief face, the peripheral rake face and the peripheral relief face intersect to form a peripheral cutting edge edge, wherein the peripheral rake face forms a peripheral first rake angle at each of the peripheral cutting edge edge, characterized in that, one or more gullets are provided on the peripheral rake face, wherein each of the gullets has a dimension along the peripheral cutting edge edge of 0.1 mm to 5 mm, 0.2 mm to 4 mm, or 0.3 mm to 3 mm, and in the case of multiple gullets, a distance between two adjacent gullets is 0.5 mm to 25 mm, or 2 mm to 20 mm, or 3 mm to 12 mm, wherein the gullets pass the peripheral cutting edge edge, the gullets form a gullet rake angle, which is between the peripheral first rake angle minus 25° and the peripheral first rake angle plus 25°.

2. A solid carbide end mill with gullets on the rake face, comprising a body portion, optionally a shank portion for direct or indirect connection to a machine tool, and optionally a neck portion connecting the body portion and the shank portion, wherein the body portion is of solid carbide material, the body portion has a plurality of peripheral cutting edges and a plurality of primary flutes corresponding to the peripheral cutting edges, each of the peripheral cutting edges independently has a peripheral rake face, a peripheral relief face, the peripheral rake face and the peripheral relief face intersect to form a peripheral cutting edge edge, wherein the peripheral rake face forms a peripheral first rake angle at each of the peripheral cutting edge edge, characterized in that, one or more gullets are provided on the peripheral rake face, wherein each of the gullets has a dimension along the peripheral cutting edge edge of 0.1 mm to 5 mm, 0.2 mm to 4 mm, or 0.3 mm to 3 mm, and in the case of multiple gullets, a distance between two adjacent gullets is 0.5 mm to 25 mm, or 2 mm to 20 mm, or 3 mm to 12 mm, wherein the gullets do not pass the peripheral cutting edge edge, the gullets have a gullet face near the peripheral cutting edge edge, which is a second rake angle face, so that the gullet face near the peripheral cutting edge edge forms a peripheral second rake angle, which is greater than the corresponding peripheral first rake angle.

3. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that the primary flutes are helical flutes, the helical flutes have a helix angle, which is an angle between a helical direction and a spindle axis of the end mill, the helix angle is between 3 and 55 degrees, for example, 15 degrees to 50 degrees, for example, 25 degrees to 45 degrees.

4. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that wherein in the case of multiple gullets, a distance between two adjacent gullets is 2 to 30 times, 5 to 25 times of the dimension along the peripheral cutting edge edge, or each of the gullets has a dimension along the peripheral cutting edge edge of 0.5 mm to 2.0 mm, and a distance between two adjacent gullets is 10 to 20 times of the dimension along the peripheral cutting edge edge.

5. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that The dimension of the groove in the rake face in a direction perpendicular to the cutting edge is 0.15 mm to 3 mm or 3% to 30% of the diameter of the body portion.

6. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that The depth of the groove is 0.05 to 2 mm or 0.3 to 1.5 mm.

7. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that The diameter of the body portion is 1 mm to 50 mm, for example 5 mm to 40 mm, 6 mm to 25 mm.

8. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that The depth of the groove is 0.2 to 0.8 times, for example 0.3 to 0.6 times, the dimension of the groove in the rake face in a direction perpendicular to the cutting edge.

9. A cemented carbide milling tool according to claim 1 or 2, c h a r a c t e r i z e d in that The milling cutter has a plurality of bottom surface cutting edges, each independently having a bottom edge rake face, a bottom edge relief face and a bottom edge, the bottom surface cutting edges being provided corresponding to the peripheral cutting edges, the junction between a bottom surface cutting edge and a peripheral cutting edge being a transition edge, a transition edge chip breaker being provided at the location of the transition edge, optionally the transition edge being arcuate.

10. The solid cemented carbide milling tool according to claim 2, characterized in that, The groove further comprises a third corner face adjacent to the second corner face, the third corner face forming a peripheral edge third corner, the peripheral edge third corner being greater than the corresponding peripheral edge second corner. The depth of the groove is 0.05 to 2 mm or 0.3 to 1.5 mm. The diameter of the body portion is 1 mm to 50 mm, for example 5 mm to 40 mm, 6 mm to 25 mm. The depth of the groove is 0.2 to 0.8 times, for example 0.3 to 0.6 times, the dimension of the groove in the rake face in a direction perpendicular to the cutting edge. The milling cutter has a plurality of bottom surface cutting edges, each independently having a bottom edge rake face, a bottom edge relief face and a bottom edge, the bottom surface cutting edges being provided corresponding to the peripheral cutting edges, the junction between a bottom surface cutting edge and a peripheral cutting edge being a transition edge, a transition edge chip breaker being provided at the location of the transition edge, optionally the transition edge being arcuate. The groove further comprises a third corner face adjacent to the second corner face, the third corner face forming a peripheral edge third corner, the peripheral edge third corner being greater than the corresponding peripheral edge second corner.

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