A precision grinding method for a tool assembly, a tool assembly and an application

Abstract

The application discloses a precision grinding method for a cutter assembly, the cutter assembly and application, and the cutter assembly has a precision ground cutter head, cutter square and cutter rod, and the precision grinding method comprises the following steps: welding the cutter head to the end of the cutter square which is processed by grinding to form an integrated cutter; coarsely grinding the cutter by fixing the cutter on a coarse grinding seat, determining the zero point of the cutter head, adjusting the first grinding wheel based on the cutter band parameters and the first grinding parameters and the zero point to coarsely grind the two sides and the end of the cutter head, and obtaining left and right cutter surfaces and a coarsely ground auxiliary surface; finely grinding the cutter by fixing the cutter on a fine grinding seat, determining the cutter reference surface, adjusting the second grinding wheel based on the second grinding parameters and the zero point to finely grind the two sides of the cutter head, and obtaining left and right cutter bands; and adjusting and positioning the finely ground cutter by performing a planar finishing treatment on the finely ground cutter and adjusting the cutter to be fixed on the cutter rod according to a preset rotation radius. The application can stably and efficiently prepare the cutter with high precision, excellent blade geometry and surface quality.

Description

A precision grinding method for tool assemblies, tool assemblies and applications Technical Field

[0001] This invention belongs to the field of cutting tool grinding technology, specifically relating to a precision grinding method for cutting tool assemblies, as well as the cutting tool assembly and its application. Background Technology

[0002] In high-end manufacturing fields such as modern precision machining, medical device manufacturing, and semiconductor testing, the performance of specialized tooling components is a core factor determining the final product's machining quality, production efficiency, and cost control. These industries place extremely stringent requirements on cutting tools: they must possess extremely high dimensional accuracy (such as micron-level tolerances), excellent surface finish, highly rational and consistent cutting edge geometry, and superior wear resistance and service life. Accordingly, these tools are often manufactured using difficult-to-machine materials such as cemented carbide and high-performance ceramics, and their precision grinding and shaping is a key technology.

[0003] However, existing tool grinding and manufacturing technologies still have many limitations, making it difficult to reliably and efficiently meet the aforementioned high-end demands. These limitations are manifested in the following aspects:

[0004] 1. Grinding process parameter control relies heavily on experience, resulting in poor precision and consistency: Traditional grinding processes heavily depend on the skills and experience of operators, lacking precise, stable, and digitally closed-loop control methods for key parameters such as the axial / radial feed rate of the grinding wheel and the depth of grinding. This leads to unstable thermo-mechanical effects during the grinding process, easily causing micro-damage in the tool cutting edge area (such as grinding burns and micro-cracks), geometric accuracy discrepancies (such as poor straightness and angle consistency of the cutting edge), and surface quality fluctuations, making it impossible to guarantee the uniformity and reliability of tool performance in mass production.

[0005] 2. Difficulty in Achieving and Stably Reproducing Complex Cutting Edges: To improve cutting performance, the ideal tool cutting edge needs to be designed as a complex three-dimensional geometric shape, including specific rake angles, clearance angles, inclination angles, and even precise edge rounding (or requiring absolute sharpness without any radius), based on the characteristics of the material being machined. Traditional grinding methods relying on manual or semi-automatic equipment are insufficient in achieving accurate modeling and stable grinding of such complex cutting edges, resulting in the tool's cutting efficiency, chip removal capacity, and service life not reaching their optimal state.

[0006] 3. Insufficient adaptability to the processing characteristics of new materials: With the application of new high-performance tool materials such as ultrafine-grained cemented carbide and cermet, their high hardness and brittleness have greatly increased their sensitivity to grinding processes. Traditional grinding methods easily lead to defects such as chipping and coating peeling in the processing of new material tools, failing to effectively utilize the inherent wear resistance and high strength advantages of the new materials, and even causing waste.

[0007] 4. Neglecting the macroscopic geometric parameters of the cutting tool leads to reduced cutting performance: Some existing solutions focus excessively on achieving the ultimate microscopic morphological precision or breakthroughs in specific machining processes. The tools manufactured by these solutions have good sharpness or surface finish under laboratory conditions, but their macroscopic angular parameters have not been optimized in a coordinated manner for core service performance such as stress dispersion, friction-strength balance, and chip removal control. As a result, in actual cutting, the sharpness of the cutting edge cannot be effectively converted into long-term durability. The tool is prone to chipping due to stress concentration, or the pursuit of sharpness may sacrifice the strength of the base material. Furthermore, it is impossible to guide the chips to be smoothly removed. Ultimately, the advantage of the tool's ultimate microscopic precision is rapidly worn away in the complex cutting mechanics environment, making it difficult to achieve stable, efficient, and long-life comprehensive cutting performance. For example, patent CN112025530B discloses a method for preparing nanodiamond cutting tools and its application. The method uses diamond as raw material and includes cutting and shaping, polishing, and edge machining processes. In addition, it specifically includes a pretreatment process before the cutting and shaping process and a surface modification process after the edge machining process. The pretreatment process is used to eliminate defects in the diamond as much as possible; the surface modification process is used to form a protective layer on the edge surface; in the polishing process: the diamond tool substrate is first inspected to identify the crystal facets of the diamond, and then the crystal facets or crystal faces of the diamond are selected for subsequent polishing, and the polished crystal facets are used as the rake facets; the edge machining process uses a protective grinding method or a laser directional cleavage method.

[0008] 5. Low tool installation accuracy in grinding: Traditional solutions lack standardized and stable design for the manufacturing-application interface, easily leading to a high dependence on manual tool setting and adjustment during subsequent tool installation. This not only introduces uncontrollable reference transfer errors and severely damages the precision results at the manufacturing end, but also results in low tool changing efficiency and poor performance reproducibility, making it difficult to translate laboratory-level superior performance into stable and efficient productivity in the workshop. For example, patent CN120395692A discloses a method for pre-forming a grinding tool. In the method for pre-forming a grinding tool, an apparatus, particularly a gear grinding machine, is provided for fine hard machining of workpieces and pre-forming grinding tools. The apparatus includes: a workpiece spindle for rotating the workpiece; a grinding spindle that can feed at least along the transverse feed axis X of the grinding spindle to rotate a grinding tool, particularly a grinding worm or grinding wheel; and a forming device with a fixed first forming plate. The grinding tool blank, particularly a grinding worm blank, is disposed on the grinding spindle of the apparatus. The device is placed in the forming configuration. The grinding spindle is fed until the grinding tool blank is operatively connected to the first forming plate. Finally, the grinding tool blank is pre-formed.

[0009] In summary, existing tool grinding technologies suffer from significant bottlenecks in both machining and installation. These problems directly lead to deficiencies in the precision, performance, consistency, and machining efficiency of high-end tool components, becoming key obstacles restricting technological progress and quality improvement in related high-end manufacturing industries. Therefore, providing a novel and efficient precision tool grinding technology and process solution that can systematically address these shortcomings is a technical problem urgently needing to be solved by those skilled in the art. Summary of the Invention

[0010] In view of the deficiencies in the prior art, the present invention provides a precision grinding method for tool components, as well as tool components and applications, which can stably and efficiently produce tool components with high precision, excellent cutting edge geometry and surface quality, and equipment compatibility.

[0011] In a first aspect, the present invention provides a precision grinding method for a tool assembly, the tool assembly having a precision-ground cutting head, a cutting edge, and a cutting shank, the precision grinding method comprising the following steps:

[0012] Welding the cutting head: Welding the cutting head to the ground-smoothed square end of the cutting head to form a single cutting tool;

[0013] Rough grinding: Fix the tool to the rough grinding stand, determine the tool setting zero point of the tool head, and perform rough grinding on both sides and the end of the tool head based on the tool belt parameters and the first grinding parameters and the tool setting zero point to obtain the left and right tool faces and the rough grinding auxiliary surface.

[0014] Fine grinding: Fix the tool on the fine grinding stand, determine the tool reference surface, and fine grind both sides of the tool head according to the second grinding parameters and the tool zero point adjustment to obtain the left and right tool belts;

[0015] Adjustment and positioning: The precision-ground tool is subjected to planar finishing treatment and adjusted and fixed to the tool holder according to the preset rotation radius.

[0016] This invention achieves graded control and error isolation that balances precision and efficiency for tool components through a phased manufacturing process involving welding, rough grinding, fine grinding, and adjustment and positioning. Specifically, by integrating the tool head and the ground tool face with the theoretically maximum effective contact area, excellent connection strength is achieved while providing an accurate and stable initial reference for subsequent rough and fine grinding processes. Furthermore, after obtaining the finely ground tool, the tool, especially the tool face, undergoes planar finishing to improve its flatness, ensuring precise adjustment and alignment of the tool and tool holder.

[0017] Furthermore, the welding of the cutting head includes:

[0018] Select the initial cutting edge and grind each surface smooth;

[0019] A groove is made at the initially flattened blade end to accommodate the blade head, and the groove is then coarsely ground.

[0020] Apply solder paste into the groove and place the cutting head to form the initial cutting tool. After drying and setting, remove excess solder paste.

[0021] After vacuum welding and heat treatment of the initial tool, a one-piece tool is obtained.

[0022] Furthermore, the coarse grinding step includes:

[0023] Fix the cutting tool (e.g., using a jig) to the rough grinding stand and determine the tool zero point;

[0024] Based on the determined zero point of tool setting and the preset tool belt parameters, the first grinding wheel is adjusted to perform rough grinding on the left side of the tool head, resulting in a rough grinding cutting edge on the left side with an angle of 30°±5° with the tool axis, and a left back face with a back angle of 15°±2°.

[0025] Based on the determined zero point of tool setting and the preset tool belt parameters, the first grinding wheel is adjusted to rough grind the right side of the tool head to obtain a right rough grinding cutting edge with an angle of 30°±5° with the tool axis and a right back face with a back angle of 15°±2°.

[0026] Based on the determined tool setting zero point and auxiliary surface grinding parameters, the first grinding wheel is adjusted to perform rough grinding on the intersection of the left and right flank faces to obtain a rough grinding auxiliary surface with an angle of 55°±5° with the tool axis.

[0027] Further, the first grinding wheel is adjusted to perform rough grinding on the left side of the cutter head, including: adjusting the first grinding wheel to tilt towards the left side of the cutter head to a first position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head to obtain a rough grinding cutting edge on the left side; adjusting the first grinding wheel to rotate around the left rough grinding cutting edge as the axis to a second position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head until the preset cutting edge parameters are met to obtain a left rear cutting edge;

[0028] The first grinding wheel is adjusted to perform rough grinding on the right side of the cutter head, including: adjusting the first grinding wheel to tilt towards the right side of the cutter head to the third position, driving the first grinding wheel to rotate and feed grinding on the right side of the cutter head to obtain the right rough grinding cutting edge; adjusting the first grinding wheel to rotate around the right rough grinding cutting edge as the axis to the third position, driving the first grinding wheel to rotate and feed grinding on the right side of the cutter head until the preset cutting edge parameters are met to obtain the right back face;

[0029] The first grinding wheel is adjusted to perform rough grinding on the intersection of the left and right flank faces, including: adjusting the first grinding wheel to rotate to the fifth position on a pivot perpendicular to the tool axis, driving the first grinding wheel to rotate and grind the intersection of the left and right flank faces until the auxiliary surface grinding parameters are met, thus obtaining the rough grinding auxiliary surface;

[0030] In this configuration, the first grinding wheel is at an angle of 30°±5° to the tool axis in both the first and third positions, and is parallel to the tool cutting direction; the first grinding wheel is at an angle of 15°±2° to the tool cutting direction in both the second and fourth positions, and at an angle of 35°±5° to the tool cutting direction in the fifth position.

[0031] Furthermore, the coarse grinding step also includes:

[0032] While the first grinding wheel performs rough grinding on the cutter head in the second, fourth, and fifth positions to obtain the left rear cutting face, the right rear cutting face, and the rough grinding auxiliary surface, the cutter face is simultaneously rough ground to obtain multiple cutting face surfaces that are parallel to the left rear cutting face, the right rear cutting face, and the rough grinding auxiliary surface.

[0033] Furthermore, the fine grinding process includes:

[0034] Fix the cutting tool (e.g., using a jig) to the precision grinding stand, and use one side of the cutting tool as the tool reference surface. Level the tool using a dial indicator based on the tool reference surface.

[0035] Adjust the second grinding wheel to fine grind the cutting edge surface on the left side of the cutter head, which is parallel to the cutting direction of the tool and has passed the rough grinding edge on the left side, to obtain a left cutting edge with an angle of 35°±5° with the tool axis and a left fine grinding cutting edge surface with a back angle of 7°±1°;

[0036] Adjust the second grinding wheel to fine grind the right side of the cutter head, which is parallel to the cutting direction of the tool and has passed the rough grinding edge on the right side, to obtain a right cutting edge with an angle of 35°±5° with the tool axis and a right fine grinding edge with a back angle of 7°±1°.

[0037] Optionally, the rough grinding auxiliary surface can be finely ground using a second grinding wheel, with a fine grinding depth of less than 0.1 mm.

[0038] Furthermore, the first grinding wheel has a mesh size of 500-1500, and the second grinding wheel has a mesh size of 3000-12000.

[0039] Furthermore, the calibration and positioning steps include:

[0040] At least the tool square to be fixed surface of the precision-ground tool shall be polished and made ultra-flat so that the flatness of the tool is ≤0.015μm. The tool square to be fixed surface is used to fit and fix the precision-ground tool to the tool shank groove corresponding to the tool shank.

[0041] The precision grinding tool is pre-placed into the tool holder groove according to the maximum insertion amount;

[0042] Based on the tool holder rotation axis, the insertion amount of the tool placed in the tool holder groove is measured and adjusted to a predetermined insertion amount, wherein the predetermined insertion amount is matched with the preset rotation radius of the tool;

[0043] The tool in the tool holder groove is lifted and adjusted to the preset parallelism, and then the tool is fixed.

[0044] In a second aspect, the present invention provides a tool assembly manufactured by the above-described precision grinding method, the tool assembly comprising an integral tool formed by a precision grinding head and a tool square, and a tool holder for fixing the tool;

[0045] Among them, the flatness of the cutting tool is ≤0.015μm, the surface roughness of the left and right cutting faces is ≤0.2μm, the cutting diameter tolerance of the left and right cutting edges is ±10μm, and the angle tolerance is ≤0.3°.

[0046] Furthermore, the cutting tip is made of single-crystal diamond, with a cutting diameter tolerance of ±5μm and an angle tolerance of ≤0.2°.

[0047] Furthermore, the tool holder has a tool holder groove for adjusting and fixing the tool, and parallelism adjustment holes are provided on both sides of the bottom of the tool holder groove, which are used to lift and adjust the two ends of the tool placed in the tool holder groove so that the tool reaches a preset parallelism.

[0048] At least one side wall of the tool holder groove is provided with a locking hole for locking and fixing the tool after parallelism adjustment.

[0049] Thirdly, the present invention also provides an application of the above-described tool assembly in the manufacture of a probe.

[0050] Furthermore, the probe includes a noble metal probe, such as a palladium alloy probe.

[0051] Furthermore, the tool assembly is used for cutting precious metal probes. This tool assembly achieves a sharp cutting effect, ensuring the precious metal probe has a burr-free cross-section and a high surface finish. Simultaneously, the tool assembly itself is designed for easy grinding and maintenance. In terms of installation, the tool holder enables rapid and precise clamping, and allows for fine-tuning to ensure accurate alignment with the machine tool and workpiece (precious metal probe). Throughout its service life, it maintains preset geometric accuracy and cutting performance, ultimately achieving a balance between high-efficiency machining, high-quality output, and convenient maintenance.

[0052] The present invention provides a precision grinding method for tool assemblies, as well as the tool assembly and its application, which has at least the following beneficial effects:

[0053] (1) This invention provides a tool assembly with a precision grinding head, a tool square and a tool holder. Based on the existing technology which mainly focuses on the grinding effect of the head, it further improves the comprehensive performance such as the flatness of the tool square and the adaptability of the tool holder. By optimizing the integrated design of the head and the tool square, and the spatial adjustment of the head and the tool square on the tool holder, a multi-angle and all-round tool precision control scheme is formed, providing a tool assembly that is more adaptable to processing machine tools and other equipment and more precise in operation.

[0054] (2) This invention achieves graded control and error isolation that balances precision and efficiency for tool components through staged manufacturing processes such as welding, rough grinding, fine grinding, and adjustment and positioning. Welding provides physical bonding; rough grinding uses the zero point of the tool tip position as a reference for rapid shaping and removal of most of the excess material; fine grinding switches to a more stable machined surface (tool reference surface) as a reference for high-precision shaping of key tool bands, which can effectively isolate previous errors; finally, adjustment and positioning are used to calibrate the tool and tool holder as a whole, compensating for the cumulative deviations in manufacturing and assembly. Segmented high-precision grinding can better ensure the final geometric accuracy, batch consistency, and installation adjustability of the tool, improving the cutting performance, process reliability, and equipment adaptability of tool components from the manufacturing source. Attached Figure Description

[0055] Figure 1 is a process flow diagram of the precision grinding method for tool assemblies according to the present invention;

[0056] Figure 2 is a schematic diagram of the structure of a cutting tool provided in a certain embodiment of the present invention;

[0057] Figure 3 is a front view of a cutting head provided in a certain embodiment of the present invention;

[0058] Figure 4 is a perspective view of a blade provided in a certain embodiment of the present invention;

[0059] Figure 5 is a schematic diagram of the tool assembly provided in a certain embodiment of the present invention;

[0060] Figure 6 is a right view of a cutting tool assembly provided in a certain embodiment of the present invention;

[0061] Figure 7 is a bottom view of a cutting tool assembly provided in a certain embodiment of the present invention;

[0062] Figure 8 is a top view of a cutting tool assembly provided in one embodiment of the present invention.

[0063] Explanation of reference numerals in the attached diagram: 1-cutter head, 11-left flank face, 12-right flank face, 13-rough grinding auxiliary surface, 14-tool reference surface, 151-left cutting edge, 152-left fine grinding tool surface, 161-right cutting edge, 162-right fine grinding tool surface, 2-tool square, 21-tool square, 3-tool shank, 31-tool shank groove, 32-parallelism adjustment hole, 33-locking hole;

[0064] v represents the cutting direction of the tool, and L represents the tool axis. Detailed Implementation

[0065] To better understand the above technical solutions, a detailed description of the solutions will be provided below in conjunction with the accompanying drawings and specific embodiments. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0066] The terminology used in the embodiments of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The singular forms “a,” “the,” and “the” as used in the embodiments of this invention and the appended claims are also intended to include the plural forms, and “multiple” generally includes at least two unless the context clearly indicates otherwise.

[0067] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that an article or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or device. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or device that includes said element.

[0068] As shown in Figures 1-8, in a first aspect, the present invention provides a precision grinding method for a tool assembly, a tool assembly, and its application, wherein the tool assembly has a precision-ground cutting head 1, a cutting tool square 2, and a cutting tool shank 3.

[0069] As shown in Figure 1, the precision grinding method includes the following steps:

[0070] Welding the cutting head: Weld the cutting head 1 to the end of the ground cutting square 2 to form an integral cutting tool;

[0071] Rough grinding: Fix the tool to the rough grinding seat, determine the zero point of the tool head 1, and perform rough grinding on both sides and the end of the tool head 1 based on the tool belt parameters and the first grinding parameters and the zero point of the tool setting, to obtain the left and right tool surfaces and the rough grinding auxiliary surface 13.

[0072] Fine grinding: Fix the tool on the fine grinding seat, determine the tool reference surface 14, and fine grind both sides of the tool head 1 according to the second grinding parameters and the tool zero point adjustment to obtain the left and right tool belts;

[0073] Adjustment and positioning: The finely ground tool is subjected to planar finishing treatment and adjusted and fixed to the tool holder 3 according to the preset rotation radius.

[0074] The welding head step 1 may include:

[0075] Select initial cutting edge 2 and grind each surface smooth;

[0076] A groove is made at the end of the initially flattened blade 2 to accommodate the blade head 1, and the groove is roughly ground.

[0077] Apply solder paste into the groove and place the cutting head 1 to form the initial cutting tool. After drying and shaping, remove excess solder paste.

[0078] After vacuum welding and heat treatment of the initial tool, an integral tool is obtained; preferably, the heat treatment is carried out for 2 hours.

[0079] In practical applications, rough grinding of the groove can remove microcracks, heat-affected layers, oxide scale, and oil contaminants generated during grooving, providing a chemically active and clean metal substrate. This ensures that the solder can effectively wet and bond with the base material of the initial cutter head 2. Rough grinding also refines the groove shape, ensuring a high-order surface fit between the groove and the cutter head 1, reducing assembly gaps, and resulting in uniform solder paste thickness. This facilitates the formation of thin and uniform welds and reduces welding stress. Rough grinding achieves controllable and uniform surface roughness. A moderately rough surface significantly increases the actual bonding area and enhances mechanical bonding force through the anchoring effect. Simultaneously, regular micro-grooves facilitate solder paste flow, filling, and venting. The groove roughness range is 1.6~3.2μm, which can be determined based on solder flowability, capillary action, and material properties to achieve optimal solder filling and minimize porosity.

[0080] When placing the cutting head 1 into the groove, it must be positioned at the center of the groove and kept parallel to the bottom. This ensures that the solder is evenly distributed within the gap between the cutting head 1 and the groove, forming a weld of uniform thickness. A uniform weld shrinks evenly during cooling and solidification, minimizing residual stress concentration and preventing cracking or deformation due to uneven stress. This parallel and centered positioning maintains equidistant contact between the cutting head 1 and the groove, achieving the theoretically maximum effective bonding area and thus the highest connection strength. It also provides an accurate and stable initial reference for subsequent rough and fine grinding processes.

[0081] As shown in Figures 2 to 4, after the cutting head 1 and the cutting tool 2 are welded together, the entire welded cutting tool can be rough ground. The rough grinding steps may include:

[0082] The cutting tool is fixed to the rough grinding stand using a fixture, and the tool setting zero point is determined. The tool setting zero point is the coordinate reference point of the machine tool control system when the cutting tool is being machined; it can be the center point of the cutting tool tip to be ground.

[0083] Based on the determined zero point of tool setting and the preset tool belt parameters, the first grinding wheel is adjusted to rough grind the left side of the tool head 1 to obtain a left rough grinding cutting edge with an angle of 30°±5° with the tool axis L, and a left back cutting face 11 with a back angle of 15°±2°.

[0084] Based on the determined zero point of tool setting and the preset tool belt parameters, the first grinding wheel is adjusted to rough grind the right side of the tool head 1 to obtain a right rough grinding cutting edge with an angle of 30°±5° with the tool axis L, and a right back face 12 with a back angle of 15°±2°.

[0085] Based on the determined zero point of the tool setting and the grinding parameters of the auxiliary surface, the first grinding wheel is adjusted to perform rough grinding on the intersection of the left flank face 11 and the right flank face 12 to obtain a rough grinding auxiliary surface 13 with an angle of 55°±5° with the tool axis L; wherein, the mesh number of the first grinding wheel is 500-1500 mesh, preferably, an 800 mesh first grinding wheel can be used for grinding.

[0086] The process of adjusting the first grinding wheel to perform rough grinding on the left side of the cutter head 1 includes: adjusting the first grinding wheel to tilt towards the left side of the cutter head 1 to a first position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head 1 to obtain a rough grinding cutting edge on the left side; adjusting the first grinding wheel to rotate around the left rough grinding cutting edge as the axis to a second position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head 1 until the preset cutting edge parameters are met, to obtain the left rear cutting face 11.

[0087] The first grinding wheel is adjusted to perform rough grinding on the right side of the cutter head 1, including: adjusting the first grinding wheel to tilt to the right side of the cutter head 1 to the third position, driving the first grinding wheel to rotate and feed grinding on the right side of the cutter head 1 to obtain a rough grinding cutting edge on the right side; adjusting the first grinding wheel to rotate around the right rough grinding cutting edge as the axis to the third position, driving the first grinding wheel to rotate and feed grinding on the right side of the cutter head 1 until the preset tool band parameters are met to obtain the right back face 12; the first grinding wheel is at an angle of 30°±5° to the tool axis L in both the first and third positions, and is parallel to the tool cutting direction v; the first grinding wheel is at an angle of 15°±2° to the tool cutting direction v in both the second and fourth positions.

[0088] The first grinding wheel is adjusted to perform rough grinding on the intersection of the left flank face 11 and the right flank face 12. This includes: adjusting the first grinding wheel to rotate to the fifth position around a pivot perpendicular to the tool axis L; driving the first grinding wheel to rotate and grind the intersection of the left flank face 11 and the right flank face 12 until the auxiliary surface grinding parameters are met, thus obtaining the rough grinding auxiliary surface 13; the first grinding wheel is at a 35°±5° angle to the tool cutting direction v in the fifth position. The tool cutting direction has opposite directions depending on the situation. For example, in this embodiment, the tool cutting direction v shown in Figure 4 is used to illustrate the case where the tool assembly cuts the workpiece by rotating itself. Correspondingly, when the tool assembly itself rotates to cut the workpiece, the tool cutting direction is opposite to that shown in Figure 4.

[0089] During rough grinding of the cutting tool by adjusting the first grinding wheel, the first grinding wheel is adjusted to a predetermined position parameter by adjusting the tool zero point, and then the feed rate of the first grinding wheel is adjusted to obtain a cutting tool with predetermined parameters. Specifically, during rough grinding, the first grinding wheel is adjusted first, and then the left side of the cutting head 1 is fed and ground until a left rough grinding cutting edge with an angle of 30°±5° with the tool axis L is obtained; then the first grinding wheel is adjusted again, and the left side of the cutting head 1 is fed and ground until the tool path parameters meet the preset tool path parameters, resulting in a left flank face 11 with a clearance angle of 15°±2°. Similarly, the right flank face 12 and the rough grinding auxiliary surface 13 are fed and ground using the same first grinding wheel adjustment method. After the left flank face 11 and the right flank face 12 are formed, corresponding tool path surfaces are obtained on both sides of the cutting head 1.

[0090] In practical applications, rough grinding produces a left and right rough grinding cutting edge with an included angle of 30°, a left flank face 11 and a right flank face 12 with a clearance angle of 15°, and a rough grinding auxiliary face 13 with an included angle of 55°. This combination of angles results in a tool with good structural strength. Specifically, the 30° included angle design creates an appropriate wedge angle on the cutting edge, effectively dispersing stress during cutting and reducing the risk of cutting edge breakage. The 15° clearance angle ensures a reasonable clearance between the tool and the workpiece surface to reduce friction while avoiding the problem of weakened tool strength due to an excessively large clearance angle, allowing the tool to maintain structural stability even under certain cutting forces. The 55° rough grinding auxiliary face 13 optimizes the stress distribution on the tool, further enhancing its overall rigidity and helping to extend its service life. In addition, the cutting tool with this angle combination can bring about more ideal cutting performance; specifically, the 30° included angle makes the cutting edge relatively sharp, which is convenient for cutting into the workpiece material and reducing cutting resistance; the 15° clearance angle reduces the friction between the tool and the machined surface, which can lower the cutting temperature, reduce the work hardening phenomenon on the workpiece surface, and improve the quality of the machined surface; the 55° roughing auxiliary surface 13 makes the chip removal direction during cutting more reasonable, which can promptly remove chips from the cutting area, avoid chip accumulation affecting the continuity and stability of the cutting process, and also reduce the scratches of chips on the machined surface, thereby improving cutting efficiency and workpiece machining accuracy.

[0091] During the rough grinding of the cutting head 1, the cutting tool 2 can also be rough ground simultaneously. Specifically, the rough grinding steps can include: while the first grinding wheel rough grinds the cutting head 1 at the second, fourth, and fifth positions to obtain the left flank face 11, the right flank face 12, and the rough grinding auxiliary face 13, the cutting tool 2 is simultaneously rough ground to obtain multiple cutting surfaces 21 parallel to the left flank face 11, the right flank face 12, and the rough grinding auxiliary face 13. This simultaneous rough grinding method can achieve the effect of unified reference and coordinated removal of allowance. Specifically, it ensures that the cutting part of the cutting head 1 and the mounting part of the cutting tool 2 form a consistent spatial orientation during the rough machining stage, reducing the cumulative error caused by step-by-step machining; at the same time, multi-face rough grinding is completed in one clamping, improving machining efficiency and providing a uniform and stable allowance distribution and reliable positioning reference for subsequent fine grinding, thereby enhancing the overall geometric consistency and assembly stability of the tool and laying a solid foundation for the final fine grinding and adjustment.

[0092] After rough grinding, the tool is finished by fine grinding to create a tool that finally meets the requirements. Specifically, the fine grinding step may include:

[0093] The cutting tool is fixed to the fine grinding seat by a fixture, and one side of the cutting tool 2 is used as the cutting tool reference surface 14. The tool reference surface 14 is used for leveling. The cutting tool reference surface 14 is one side of the cutting tool. Preferably, it can be the left side of the cutting tool 2 that connects with the left rear cutting surface 11 / left rough grinding cutting edge.

[0094] Adjust the second grinding wheel to fine grind the cutting edge surface on the left side of the cutter head 1, which is parallel to the cutting direction v of the tool and has passed the rough grinding edge on the left side, to obtain the left cutting edge 151 with an angle of 35°±5° with the tool axis L, and the left fine grinding cutting edge surface 152 with a back angle of 7°±1°.

[0095] Adjust the second grinding wheel to fine grind the cutting edge surface on the right side of the cutter head 1, which is parallel to the cutting direction v of the tool and has passed the rough grinding edge on the right side, to obtain the right cutting edge 161 with an angle of 35°±5° with the tool axis L, and the right fine grinding cutting edge surface 162 with a back angle of 7°±1°.

[0096] Optionally, the rough grinding auxiliary surface 13 can be finely ground using a second grinding wheel to a depth of less than 0.1 mm. Based on the determined tool setting zero point and tool tip preset parameters, the second grinding wheel can also be adjusted to rough grind the intersection of the left fine grinding tool surface 152 and the right fine grinding tool surface 162 to obtain the fine grinding auxiliary surface.

[0097] In practical applications, when leveling the tool reference surface 14, the dial indicator is used to ensure that the feed axis of the second grinding wheel and the tool reference surface 14 are at a 90° angle. During the dial indicator leveling, if the feed axis is higher at the front and lower at the back, the angle needs to be slightly adjusted to the right (R). Then, the feed axis is adjusted back and forth to level the tool reference surface, and this process is repeated until the tool reference surface 14 and the feed axis of the second grinding wheel form a 90° angle. When fine grinding to obtain the left-side fine-grind tool face 152, the second grinding wheel is adjusted using the second grinding parameters to successively grind a left cutting edge angle of 35°±5° and a clearance angle of 7°±1°. The second grinding wheel feed is 0.0001mm, and the left-right oscillation is 0.5mm. Fine grinding is achieved through reciprocating oscillation until the tool face is free of chipping, thus obtaining the corresponding left-side fine-grind tool face 152. Similarly, the right-side fine-grind tool face 162 is ground using the same method.

[0098] Through rough grinding and fine grinding, precise control and high-efficiency stability in the machining process can be achieved. In the rough grinding stage, preset parameters such as wheel grit size and feed rate significantly improve the dimensional accuracy and surface smoothness of the cutting tool, laying a solid foundation for subsequent fine grinding. During fine grinding, based on even finer parameters, such as finer-grained wheels and smaller feed rates, the microstructure of the cutting tool surface can be further refined, significantly reducing surface roughness and achieving a mirror-like finish on the tool's cutting edge. Simultaneously, strict adherence to the preset parameters in both rough and fine grinding ensures a high degree of consistency in the machining quality of each tool, avoiding errors caused by the subjectivity and randomness of manual operation, and improving product yield and stability. This is particularly suitable for precision parts machining applications with high accuracy requirements.

[0099] After fine grinding, a 60°~80° end mill cutter, preferably a 70° end mill cutter, is obtained. The cutter and tool holder 3 are then assembled by adjusting and positioning the tool (as shown in Figures 5 to 8), ultimately forming the required tool assembly. Specifically, the adjustment and positioning steps may include:

[0100] At least the tool square to be fixed surface of the precision-ground tool shall be polished and made ultra-flat so that the flatness of the tool is ≤0.015μm. The tool square to be fixed surface is used to fit and fix the precision-ground tool to the tool shank groove 31 corresponding to the tool shank 3.

[0101] The precision grinding tool is pre-placed into the tool holder groove 31 according to the maximum placement amount; wherein, the maximum placement amount can be the distance from the tail of the tool square 2 to the groove opening of the tool holder groove 31 near the tool head, that is, the maximum length of the tool in the tool holder groove 31 when the tool is placed into the tool holder groove 31.

[0102] Based on the rotation axis of the tool holder 3, the insertion amount of the tool placed in the tool holder groove 31 is measured and adjusted to a predetermined insertion amount, wherein the predetermined insertion amount is matched with the preset rotation radius of the tool;

[0103] The tool in the tool holder groove 31 is lifted and adjusted to the preset parallelism, and then the tool is fixed.

[0104] In practical applications, measuring and adjusting the placement of the cutting tool in the tool holder groove 31 to the predetermined placement amount can be achieved using a micrometer. Specifically, the micrometer is inserted parallel to the tool holder groove 31 and held against the tail of the cutting tool (the other end of the tool head 1 is provided on the tool side 2). The placement amount of the cutting tool in the tool holder groove 31 can be determined by the reading on the micrometer. Then, the cutting tool is moved by adjusting the micrometer until the predetermined placement amount is reached.

[0105] The tool holder includes a fixed rod and a fixed block. The center of the fixed block is integrally formed with one end of the fixed rod. The fixed rod is perpendicular to the rotation plane of the fixed block. A tool holder groove, perpendicular to the fixed rod, is formed on the side of the fixed block away from the fixed rod. The width and depth of the tool holder groove are greater than the length and / or width of the tool. The fixed block has a sliding groove communicating with the tool holder groove. A slider that extends into or away from the tool holder groove is located within the sliding groove. The slider has a locking hole 33 and a matching fixing bolt. The fixed block has multiple parallelism adjustment holes 32, which pass through the fixed block and communicate with the tool holder groove. Matching adjusting bolts are located within the parallelism adjustment holes 32. After the tool is placed in the tool holder groove, the parallelism of the tool is first adjusted using the adjusting bolts within the parallelism adjustment holes 32 to ensure that the tool reference plane is perpendicular to the fixed rod. Then, the distance from the tool tip to the rotation center of the tool holder is adjusted (this adjustment can also be done before adjusting the parallelism). Finally, the fixing bolts within the locking holes 33 drive the slider towards the tool, ultimately fixing the tool by engaging the slider with the tool holder groove. By precisely fixing the cutting tool within a tool holder that facilitates direct installation, the manufacturing-application interface can be standardized and designed for stability, resulting in higher tool installation accuracy and improved tool change efficiency and performance reproducibility.

[0106] Furthermore, the side of the tool opposite the slider is provided with a wedge-shaped groove along its own axial direction (the side of the tool opposite the slider is on the same side as the chip removal surface of the tool head), and the end of the slider is provided with a wedge-shaped part that matches the wedge-shaped groove. In practical applications, when the slider moves toward the tool for fixation, the wedge-shaped part of the slider will embed into the inclined surface of the wedge-shaped groove. This wedge engagement method generates a radial (perpendicular to the clamping direction) constraint component, which can effectively resist the circumferential rotation or lateral movement of the tool under the action of cutting force, avoiding the slippage risk that may occur with planar friction clamping, making the clamping more secure and reliable. The wedge-shaped groove also has a guiding function, which can guide the slider to automatically push the tool to a certain, repeatable lateral reference position during the clamping process; at the same time, it can cooperate with the adjusting bolt in the parallelism adjustment hole 32 to further improve the clamping and fixing effect of the tool. In addition, the design of the wedge-shaped groove also simplifies the manual alignment operation during installation, ensures the consistency of the tool's position in the horizontal direction during each clamping, and improves the repeatability of positioning after tool change. Furthermore, the clamping force applied to the tool by the slider can be transmitted and dispersed to a deeper area of ​​the tool body through the inclined surface of the wedge groove, avoiding excessive localized stress concentration on the tool surface. This reduces the risk of surface indentation or deformation caused by clamping and also prevents the risk of microcracks arising from the clamping point due to stress concentration, which is particularly beneficial for protecting expensive high-performance tools (such as diamond tools).

[0107] Furthermore, the structural features of the cutting tool and tool holder together enable fast, precise, and stable tool installation. Specifically, after placing the tool into the tool holder slot, the bottom and sides of the tool receive initial support and restraint. Subsequently, by rotating the adjusting bolts located on both sides of the bottom of the tool holder slot, the front or rear end of the tool can be independently lifted, achieving precise leveling of the working height of the tool tip. This process is intuitive and precise, ensuring the ideal relative position of the cutting edge and the workpiece surface. After leveling, tightening the fixing bolts drives the slider to press against the wedge groove of the tool body. At this point, the tool is constrained in multiple directions: the bottom is supported by the adjusting bolts, one side is restrained by the side wall of the tool holder slot, and the other side is locked by the wedge groove and the slider. This structure creates mechanical over-positioning, enabling the tool to maintain extremely high clamping rigidity when subjected to complex cutting forces (such as radial and tangential forces), effectively suppressing vibration and making loosening extremely difficult. The entire installation process integrates the placement, leveling, and locking functions into a compact tool holder. The wedge groove and slider mechanism achieve high-rigidity, dial indicator-free centering to a certain extent, while the bottom adjusting bolt provides fine-tuning and leveling capabilities without shims. This allows for the rapid and reliable installation of precision tools, which are extremely sensitive to installation accuracy, to the optimal working state on the machining site. It seamlessly and stably converts the tool's inherent properties into actual cutting performance, significantly reducing the risk of performance loss or tool damage due to improper clamping.

[0108] Furthermore, the wedge-shaped groove on the cutting tool is positioned close to the tool's reference surface, which maximizes the preservation of the core material of the tool body and avoids weakening its structural strength by slotting in the center area of ​​the tool where the greatest stress is experienced. This is crucial for cutting tools requiring high rigidity. Simultaneously, the structure and position of this wedge-shaped groove form a precise edge positioning reference, which, through its interaction with the slider, determines the precise horizontal coordinates of the tool. Moreover, the placement of this wedge-shaped groove ensures that the tool can determine a single correct insertion direction (the side with the wedge-shaped groove facing the slider). This avoids incorrect installation orientation, providing a natural error-proofing effect and simplifying operation.

[0109] The present invention provides a tool assembly manufactured by the above-described precision grinding method, the tool assembly comprising an integral tool formed by a precision grinding head and a tool square, and a tool holder for fixing the tool;

[0110] Specifically, the tool's flatness is ≤0.015μm, the surface roughness of the left and right tool faces is ≤0.2μm, the corresponding cutting diameter tolerance of the left and right tool edges is ±10μm, and the angle tolerance is ≤0.3°. The flatness of the tool refers to the flatness of the tool face to be fixed after polishing and achieving an ultra-flat finish. Furthermore, the chip removal surface of the tool can be treated to achieve a surface roughness ≤0.2μm, which reduces frictional resistance and cutting energy consumption during chip removal, effectively suppressing the generation and accumulation of cutting heat, thus protecting both the tool and the workpiece. Simultaneously, it promotes regular chip morphology and smooth chip removal, significantly reducing the risk of built-up edge formation, abnormal tool wear, and chip clogging. Overall, it significantly improves tool durability and machining process stability, ultimately resulting in superior workpiece surface quality, higher dimensional accuracy, and lower overall production costs.

[0111] In practical applications, the cutting tip can be made of single-crystal diamond, with a cutting diameter tolerance of ±5μm for the left and right cutting edges and an angle tolerance of ≤0.2°.

[0112] The tool holder has a tool holder groove for adjusting and fixing the tool. Parallelism adjustment holes 32 are provided on both sides of the bottom of the tool holder groove, which are used to lift and adjust the two ends of the tool placed in the tool holder groove so that the tool reaches the preset parallelism.

[0113] At least one side wall of the tool holder groove is provided with a locking hole 33 for locking and fixing the tool after parallelism adjustment.

[0114] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention. Clearly, those skilled in the art can make various alterations and modifications to the invention without departing from its spirit and scope. Thus, if these modifications and modifications of the invention fall within the scope of the claims and their equivalents, the invention is also intended to include these modifications and modifications.

Claims

1. A precision grinding method for tool assemblies, characterized in that, The tool assembly has a precision-ground tool head, a tool square, and a tool shank. The precision grinding method includes the following steps: welding the tool head: welding the tool head to the end of the ground tool square to form an integral tool. Rough grinding: Fix the tool to the rough grinding stand, determine the tool setting zero point of the tool head, and perform rough grinding on both sides and the end of the tool head based on the tool belt parameters and the first grinding parameters and the tool setting zero point to obtain the left and right tool faces and the rough grinding auxiliary surface. Fine grinding: Fix the tool on the fine grinding stand, determine the tool reference surface, and fine grind both sides of the tool head according to the second grinding parameters and the tool zero point adjustment to obtain the left and right tool belts; Adjustment and positioning: The precision-ground tool undergoes planar finishing and is fixed to the tool holder according to a preset rotation radius. The rough grinding step includes: fixing the tool to the rough grinding stand and determining the tool zero point; based on the determined zero point and preset tool path parameters, adjusting the first grinding wheel to rough grind the left side of the tool head, obtaining a left rough grinding cutting edge with an angle of 30°±5° to the tool axis and a left flank face with a clearance angle of 15°±2°; based on the determined zero point and preset tool path parameters, adjusting the first grinding wheel to rough grind the right side of the tool head, obtaining a right rough grinding cutting edge with an angle of 30°±5° to the tool axis and a right flank face with a clearance angle of 15°±2°; based on the determined zero point and auxiliary surface grinding parameters, adjusting the first grinding wheel to rough grind the intersection of the left and right flank faces, obtaining a rough grinding auxiliary surface with an angle of 55°±5° to the tool axis.

2. The precision grinding method as described in claim 1, characterized in that, The welding process for the cutting head includes: selecting an initial cutting head and grinding each surface flat; opening a groove at the end of the ground initial cutting head to accommodate the cutting head and rough grinding the groove; applying solder paste into the groove and placing the cutting head to form an initial cutting head; drying and shaping the initial cutting head and removing excess solder paste; vacuum welding the initial cutting head and heat treating it to obtain an integral cutting head.

3. The precision grinding method as described in claim 1, characterized in that, The first grinding wheel is adjusted to perform rough grinding on the left side of the cutter head, including: adjusting the first grinding wheel to tilt towards the left side of the cutter head to a first position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head to obtain a rough grinding cutting edge on the left; adjusting the first grinding wheel to rotate around the left rough grinding cutting edge as the axis to a second position, driving the first grinding wheel to rotate and feed grinding on the left side of the cutter head until the preset tool belt parameters are met, to obtain a left rear cutting face; the first grinding wheel is adjusted to perform rough grinding on the right side of the cutter head, including: adjusting the first grinding wheel to tilt towards the right side of the cutter head to a third position, driving the first grinding wheel to rotate and feed grinding on the right side of the cutter head to obtain a rough grinding cutting edge on the right; adjusting the first grinding wheel to rotate around the right rough grinding cutting edge as the axis to a fourth position, driving the first grinding wheel to rotate and set the tool... The right side of the head is fed and ground until the preset tool band parameters are met, resulting in the right flank face. The first grinding wheel is adjusted to perform rough grinding on the intersection of the left and right flank faces, including: adjusting the first grinding wheel to rotate to the fifth position on a pivot perpendicular to the tool axis, driving the first grinding wheel to rotate and grind the intersection of the left and right flank faces until the auxiliary surface grinding parameters are met, resulting in a rough grinding auxiliary surface; wherein, in the first and third positions, the first grinding wheel is at an angle of 30°±5° to the tool axis and parallel to the tool cutting direction; in the second and fourth positions, the first grinding wheel is at an angle of 15°±2° to the tool cutting direction, and in the fifth position, the first grinding wheel is at an angle of 35°±5° to the tool cutting direction.

4. The precision grinding method according to any one of claims 1-3, characterized in that, The fine grinding steps include: fixing the tool on the fine grinding stand, using one side of the tool as the tool reference surface, and leveling it using a dial indicator; adjusting the second grinding wheel to fine grind the tool head's left side, which is parallel to the tool cutting direction and has passed through the left rough grinding edge, to obtain a left cutting edge with an angle of 35°±5° to the tool axis and a left fine grinding tool head with a clearance angle of 7°±1°; adjusting the second grinding wheel to fine grind the tool head's right side, which is parallel to the tool cutting direction and has passed through the right rough grinding edge, to obtain a right cutting edge with an angle of 35°±5° to the tool axis and a right fine grinding tool head with a clearance angle of 7°±1°.

5. The precision grinding method as described in claim 4, characterized in that, The rough grinding auxiliary surface is then finely ground using a second grinding wheel, with a fine grinding depth of less than 0.1 mm.

6. The precision grinding method as described in claim 4, characterized in that, The first grinding wheel has a mesh size of 500-1500, and the second grinding wheel has a mesh size of 3000-12000.

7. The precision grinding method as described in claim 4, characterized in that, The adjustment and positioning steps include: polishing the surface of the precision-ground tool to be fixed to an ultra-flat state, so that the flatness of the tool is ≤0.015μm, wherein the surface to be fixed is used to fit and fix the precision-ground tool to the tool holder groove corresponding to the tool holder; pre-placing the precision-ground tool into the tool holder groove according to the maximum placement amount; measuring and adjusting the placement amount of the tool in the tool holder groove to a predetermined placement amount based on the tool holder rotation axis, wherein the predetermined placement amount matches the preset rotation radius of the tool; lifting and adjusting the tool in the tool holder groove to a preset parallelism, and then fixing the tool.

8. A tool assembly manufactured using the precision grinding method as described in any one of claims 1 to 7, characterized in that, The tool assembly includes an integral tool formed by a precision grinding head and a tool square, and a tool shank for fixing the tool; wherein, the flatness of the tool is ≤0.015μm, the surface roughness of the left and right tool faces is ≤0.2μm, the cutting diameter tolerance of the left and right tool edges is ±10μm, and the angle tolerance is ≤0.3°.

9. The cutting tool assembly as claimed in claim 8, characterized in that, The tool holder has a tool holder groove for adjusting and fixing the tool. Parallelism adjustment holes are provided on both sides of the bottom of the tool holder groove, which are used to lift and adjust the two ends of the tool placed in the tool holder groove so that the tool reaches a preset parallelism. At least one side wall of the tool holder groove is provided with a locking hole, which is used to lock and fix the tool after the parallelism adjustment.

10. Use of the cutting tool assembly of claim 8 or 9 in the manufacture of a probe.

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