Integrated compound tool for machining specific shape and machining method of integrated compound tool

Abstract

The invention discloses an integrated composite cutter for machining a specific shape and a machining method thereof, and relates to the field of machining cutters. The integrated composite cutter comprises a cutter body, a main cutting edge part embedded in the cutter body, an auxiliary forming part which is in smooth transition connection with the main cutting edge part and is located on the cutter body, and a cutter handle connecting part arranged at one end of the cutter body. The functions of two independent cutters are integrated into a single cutter body, so that the machining efficiency is greatly improved, and the cost is remarkably reduced.

Description

Technical Field

[0001] This invention relates to the field of machining tool technology, specifically to an integrated composite tool for machining specific shapes and its machining method. Background Technology

[0002] In the field of machining, for workpieces with complex curved surfaces or special structures (such as...) Figure 3 The shape to be machined is shown. Traditional machining methods typically employ a combination of multiple cutting tools (such as...). Figure 1 The two independent cutting tools shown are a and b). This machining method has the following significant drawbacks: low efficiency: it requires multiple clamping and tool changes, increasing auxiliary time; high cost: the procurement, maintenance and management costs of multiple cutting tools are high; limited accuracy: multiple clamping can easily cause positioning errors, affecting machining accuracy; complex process: it requires precise coordination of the machining paths and timing of multiple cutting tools. Summary of the Invention

[0003] In view of this, the present invention aims to propose an integrated composite tool and its machining method for machining specific shapes, which is suitable for replacing the traditional multi-tool combination machining method, improving machining efficiency and reducing production costs.

[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0005] An integrated composite tool for machining specific shapes includes a tool body, a main cutting edge portion pre-embedded in the tool body, an auxiliary forming portion smoothly connected to the main cutting edge portion and located on the tool body, and a tool holder connecting portion disposed at one end of the tool body.

[0006] In some embodiments, the transition between the main cutting edge and the auxiliary forming part is a rounded corner with a radius of R2mm.

[0007] In some embodiments, the rake angle of the main cutting edge is 15°, the clearance angle is 12°, and the helix angle is 30°.

[0008] In some embodiments, the main cutting edge has a cutting length of 35 mm and a diameter of 12 mm.

[0009] In some embodiments, the forming profile tolerance of the auxiliary forming part is ±0.01 mm.

[0010] In some embodiments, the tool holder connection is a BT40 standard interface with a runout accuracy of ≤0.005mm.

[0011] In some embodiments, the cutter body is provided with a double helical chip removal groove.

[0012] In some embodiments, the helix angles of the double-helix chip removal grooves are 30° and 35°, respectively.

[0013] A machining method using the aforementioned integrated composite tool for machining specific shapes includes the following steps: clamping the tool holder connection of the integrated composite tool onto the spindle of a machining center; merging the roughing trajectory of the first independent tool with the finishing trajectory of the second independent tool to design a continuous cutting profile; and controlling the integrated composite tool to complete the machining of the workpiece in one clamping operation according to the continuous cutting profile.

[0014] In some embodiments, during machining, an integrated force sensor monitors changes in cutting force in real time and automatically compensates for tool wear based on the monitored data.

[0015] In some embodiments, the cutting parameters during the machining process are: spindle speed 10000-15000 rpm, feed rate 1500-2500 mm / min.

[0016] In some embodiments, when machining irregular grooves in aerospace parts, a layered cutting strategy is adopted, with each layer having a cutting depth of 0.2-0.5 mm.

[0017] The present invention discloses an integrated composite tool for machining specific shapes and its machining method, which integrates the functions of two independent tools into a single tool body, thereby achieving a significant improvement in machining efficiency and a significant reduction in cost. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0019] Figure 1 A schematic diagram of a combination of multiple cutting tools used in traditional machining.

[0020] Figure 2 This is a schematic diagram of an integrated composite tool of the present invention used for machining specific shapes.

[0021] Figure 3 The workpieces in the embodiments of the present invention have complex curved surfaces or special structures.

[0022] Explanation of reference numerals in the attached figures

[0023] 1. Auxiliary forming part; 2. Main cutting edge part; 3. Tool body; 4. Tool holder connecting part. Detailed Implementation

[0024] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0025] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] The following is for reference. Figures 1 to 3 The present invention describes, in conjunction with embodiments, an integrated composite cutting tool for machining specific shapes and its machining method.

[0027] This application discloses an integrated composite tool and its machining method for processing specific shapes, aiming to overcome the shortcomings of existing multi-tool combination machining methods, such as low efficiency, high cost, and limited precision. This integrated composite tool is a one-piece molded structure, manufactured through precision forging and CNC grinding processes, integrating all the functions of two independent tools in traditional machining, enabling the one-time machining of specific complex shapes.

[0028] like Figure 2 As shown in the illustration, this application provides an integrated composite cutting tool for machining specific shapes, comprising a tool body 3, a main cutting edge 2, an auxiliary forming part 1, and a tool holder connecting part 4. The tool body 3 is made of alloy steel and serves as the base of the entire tool. The main cutting edge 2 is embedded in the tool body 3, made of WC-Co cemented carbide, with a rake angle of 15°, a clearance angle of 12°, a helix angle of 30°, a cutting length of 35mm, and a diameter of 12mm. The auxiliary forming part has a cutting length of 20mm and a maximum diameter of 8mm. The overall tool length is 150mm. The auxiliary forming part 1 is smoothly connected to the main cutting edge 2 and is located on the tool body 3. The auxiliary forming part 1 is also made of WC-Co cemented carbide and is connected to the tool body 3 by welding. The transition between the main cutting edge 2 and the auxiliary forming part 1 is a rounded corner with a radius of R2mm, ensuring the continuity of the cutting process. The forming profile tolerance of the auxiliary forming part 1 is ±0.01mm. The tool holder connection part 4 is located at one end of the tool body 3 and is used to connect with the machine tool spindle. In this embodiment, the tool holder connection part 4 is a BT40 standard interface with a runout accuracy of ≤0.005mm, which ensures the installation accuracy of the tool.

[0029] To effectively remove chips generated during machining and prevent chip accumulation from affecting machining quality and tool life, the tool body 3 is equipped with a double-helix chip removal groove. In a preferred embodiment, the helix angles of this double-helix chip removal groove are 30° and 35° respectively. This double-helix angle design optimizes the chip removal path and improves chip removal efficiency.

[0030] This application also discloses a machining method using the aforementioned integrated composite tool for machining specific shapes. The method includes the following steps: First, the tool holder connecting part 4 of the integrated composite tool is clamped onto the spindle of a machining center, ensuring a secure clamping and that the runout accuracy meets requirements. Next, path planning is performed, merging the roughing trajectory of the first independent tool with the finishing trajectory of the second independent tool to design a continuous cutting profile. This step is crucial for transforming traditional segmented machining into continuous machining. Finally, based on the designed continuous cutting profile, the integrated composite tool is controlled to complete the machining of the workpiece in a single clamping operation, thereby avoiding positioning errors and tool change time caused by multiple clamping operations. Figure 3 When machining the cylinder block plane as shown, the planar milling and hole chamfering are completed simultaneously.

[0031] As a further optimization of this machining method, a force sensor is integrated into the machining process to monitor changes in cutting force in real time and automatically compensate for tool wear based on the monitored data. This achieves intelligent monitoring, ensuring the stability of the machining process and the long-term sustainability of machining accuracy. Cutting parameters can be optimized according to the workpiece material and machining requirements, typically set to a spindle speed of 10,000-15,000 rpm and a feed rate of 1,500-2,500 mm / min. When machining irregular grooves on aerospace parts, a layered cutting strategy can be adopted, with each layer having a cutting depth of 0.2-0.5 mm, to reduce the cutting load and ensure machining quality. Based on the cutting force data from the above machining method, a tool wear model can be established to predict the remaining tool life.

[0032] The technical solution of this application will be further described below through specific embodiments.

[0033] Example 1: Automotive Parts Industry

[0034] This embodiment uses processing Figure 3 Taking the specific shaped workpiece shown as an example, the processing steps are as follows: [The text abruptly ends here, likely due to an incomplete sentence or a formatting error.] Figure 2 The tool holder connector 4 of the integrated tool shown is clamped onto the machining center spindle. Path planning is performed, and... Figure 1 The roughing trajectory shown in a is Figure 1 The finishing trajectory shown in b is merged into a continuous cutting path. Set the machining parameters: spindle speed 2800 rpm, feed rate 2000 mm / min, and depth of cut 0.2 mm. Start machining; the process can be completed in a single setup. Figure 3 All dimensions shown can be machined without tool changes throughout the entire process. Quality inspection is performed after machining is complete. Figure 3 The cross-sectional accuracy must meet the accuracy requirement of ±0.01mm.

[0035] Example 2: Machining of irregular grooves in aerospace parts

[0036] This embodiment uses an irregularly shaped groove in an aerospace component as an example. According to... Figure 3 The design features a composite cutting edge on a single-piece tool. The main cutting edge 2 handles roughing, while the auxiliary forming part 1 completes finishing. After clamping the tool, the machining parameters are set as follows: spindle speed 8000 rpm, feed rate 1500 mm / min, and depth of cut 0.5 mm. The groove machining is completed in a single clamping operation, taking only 25 minutes. Compared to the original method of machining with two tools in stages, which took 45 minutes, this embodiment improves efficiency by 44%.

[0037] Compared with existing technologies, the integrated composite cutting tool and its machining method for machining specific shapes of the present invention have the following advantages:

[0038] Efficiency improvement: Tool change time is reduced by about 60%, and the overall processing cycle is shortened by more than 40%.

[0039] Cost reduction: Tool procurement costs are reduced by 50%, and maintenance costs are reduced by 30%.

[0040] Improved precision: It avoids multiple clamping errors, and the dimensional accuracy can reach ±0.01mm.

[0041] Simplified process: Complex shapes can be machined with a single tool, making the process route simpler.

[0042] Enhanced reliability: Reduced tooling quantity lowers the probability of failure.

[0043] Structural innovation: One-piece molding design eliminates Figure 1 The multi-tool assembly error shown is improved by 60%; process innovation: Figure 1 The segmented machining paths shown are integrated into continuous cutting, improving efficiency by over 40%; Application innovation: targeting Figure 3 The complex shape shown can be processed in one clamping, avoiding repeated positioning errors.

[0044] Quantitative results: Machining time: reduced from 45 minutes to 25 minutes (efficiency increased by 44%); Tool cost: reduced from 2800 yuan to 1800 yuan (cost reduced by 36%); Machining accuracy: improved from ±0.05mm to ±0.01mm (accuracy increased by 80%); Surface quality: roughness improved from Ra1.6μm to Ra0.8μm.

[0045] This tool is particularly suitable for Figure 3 The complex shapes shown can be processed in fields such as aviation, automobiles, and medical devices. It has the advantages of simple structure, convenient use, high processing accuracy, and significant economic benefits, and has broad market application prospects.

[0046] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of this invention and to simplify the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this invention.

[0047] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0048] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A one-piece composite cutting tool for machining specific shapes, characterized in that, Includes a blade body (3), a main cutting edge (2) pre-embedded in the blade body (3), an auxiliary forming part (1) smoothly connected to the main cutting edge (2) and located on the blade body (3), and a handle connecting part (4) provided at one end of the blade body (3).

2. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The transition between the main cutting edge (2) and the auxiliary forming part (1) is a rounded corner with a radius of R2mm.

3. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The main cutting edge (2) has a front angle of 15°, a rear angle of 12°, and a helix angle of 30°.

4. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The main cutting edge (2) has a cutting length of 35 mm and a diameter of 12 mm.

5. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The forming profile tolerance of the auxiliary forming part (1) is ±0.01mm.

6. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The tool holder connection part (4) is a BT40 standard interface with a runout accuracy of ≤0.005mm.

7. The integrated composite tool for machining specific shapes according to claim 1, characterized in that, The cutter body (3) is provided with a double spiral chip removal groove.

8. The integrated composite cutting tool for machining specific shapes according to claim 7, characterized in that, The helix angles of the double helix chip removal grooves are 30° and 35°, respectively.

9. A machining method using an integrated composite tool as described in any one of claims 1 to 8 for machining a specific shape, characterized in that, Includes the following steps: The tool holder connecting part (4) of the integrated composite tool is clamped on the spindle of the machining center; The roughing trajectory of the first independent tool and the finishing trajectory of the second independent tool are combined to design a continuous cutting profile. Based on the continuous cutting profile, the integrated composite tool is controlled to clamp the workpiece in one operation to complete the machining.

10. The processing method according to claim 9, characterized in that, During the machining process, the integrated force sensor monitors the changes in cutting force in real time and automatically compensates for tool wear based on the monitored data.

11. The processing method according to claim 9, characterized in that, The cutting parameters during the machining process are: spindle speed 10000-15000rpm, feed rate 1500-2500mm / min.

12. The processing method according to claim 9, characterized in that, When machining irregular grooves in aerospace parts, a layered cutting strategy is adopted, with each layer having a cutting depth of 0.2-0.5mm.

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