Double flying knife roller surface processing device and processing method thereof

Abstract

This invention discloses a double-blade roller surface processing device and method, relating to the field of roller surface processing technology. The double-blade roller surface processing device includes a roller rotating device, a movable plate, a first blade cutting device, and a second blade cutting device. The roller rotating device clamps the roller substrate and drives it to rotate axially. The movable plate can slide relative to the roller substrate radially and axially. The first and second blade cutting devices are disposed on the movable plate. The first blade cutting device is used to perform circumferential groove processing on the surface of the roller substrate using blade technology, and the second blade cutting device is used to perform axial groove processing on the surface of the roller substrate using blade technology. The technical solution provided by this invention can effectively suppress burr generation, thereby improving the surface forming quality of the roller.

Description

Technical Field

[0001] This invention relates to the field of roller surface processing technology, and in particular to a double-flying-knife roller surface processing device and processing method. Background Technology

[0002] As a microfabrication technology, the following embossing technique is known: a micro-pyramid array structure is formed by machining the outer peripheral surface of a cylindrical or cylindrical roller substrate; the resulting roller substrate is then pressed onto a resin sheet to transfer the micro-pyramid array structure onto the roller substrate. In existing technology, the specific operation for machining a micro-pyramid array structure on the roller surface is as follows: First, the operator uses a V-shaped diamond cutting tool to machine multiple circumferential and axial grooves on the roller substrate; through the intersection of these two sets of mutually perpendicular grooves, a micro-pyramid array structure is finally formed on the surface of the roller substrate.

[0003] However, the aforementioned existing technology has the following drawbacks: the quality of the finished product is poor, and burrs and defects easily appear on the edges of the grooves. The fundamental reason is that the cutting edge of the V-shaped cutting tool used participates in cutting on both sides simultaneously, and the resulting chips are squeezed against each other. Since material flows in the direction of least resistance, the squeezed material flows towards the edge of the finished groove and accumulates, thus forming burrs that are difficult to remove. Summary of the Invention

[0004] The main objective of this invention is to provide a double-flying-knife roller surface processing device and its processing method, which aims to effectively suppress burr generation and improve the forming quality of the roller surface.

[0005] To achieve the above objectives, the present invention proposes a double-flying-knife roller surface processing device, comprising: Base; A roller rotating device is disposed on the base; the roller rotating device is used to clamp the roller substrate and drive it to rotate axially; A movable plate is slidably disposed on the base; the movable plate can slide relative to the roller substrate along its radial and axial directions. A first and a second flying knife cutting device are disposed on the movable plate; the first and second flying knife cutting devices are respectively located on opposite sides of the roller substrate; the first flying knife cutting device is used to perform circumferential groove processing on the surface of the roller substrate using flying knife technology, and the second flying knife cutting device is used to perform axial groove processing on the surface of the roller substrate using flying knife technology.

[0006] In one embodiment, both the first and second flying knife cutting devices include a rotary motor, a tool holder body, and a cutting tool. The drive end of the rotary motor is connected to one side of the tool holder body, and the other side of the tool holder body is used to clamp and fix the cutting tool so that the rotary motor drives the cutting tool to rotate. The first rotation plane of the cutting tool belonging to the first flying knife cutting device is perpendicular to the second rotation plane of the cutting tool belonging to the second flying knife cutting device.

[0007] In one embodiment, a dynamic balancing device is provided on the other side of the tool holder body, the dynamic balancing device being used to drive the center of mass of the tool holder body to coincide with its rotation axis.

[0008] In one embodiment, the dynamic balancing device includes a counterweight and a locking bolt. The tool holder body has a mounting groove on the side away from the cutting tool, and the mounting groove is arranged radially along the tool holder body. The counterweight is lockably and slidably connected to the mounting groove. The side of the mounting groove has a through threaded hole, and the locking bolt is threadedly connected to the threaded hole, with the end of the locking bolt abutting against the counterweight.

[0009] In one embodiment, the dynamic balancing device includes a first chamber with a linear structure, the first chamber being arranged radially along the blade holder body; a mass block is slidably connected inside the first chamber, and the side of the mass block near the blade holder body is connected to the inner wall of the first chamber via an elastic element.

[0010] In one embodiment, the dynamic balancing device includes a second chamber with an arc-shaped structure, the second chamber being arranged circumferentially along the tool holder body; the arc-shaped middle portions of the first chamber and the second chamber are isolated from each other by an elastic diaphragm; the second chamber is filled with a heat dissipation liquid, and both ends of the second chamber are connected to a heat dissipation device, the heat dissipation device being connected to the cutting tool; when the mass block squeezes the elastic diaphragm to drive a change in the air pressure in the second chamber, the heat dissipation liquid can flow along the second chamber to the heat dissipation device to perform heat dissipation operation on the cutting tool.

[0011] In one embodiment, the heat dissipation device has a cylindrical structure and is sleeved on the end of the cutting tool away from its cutting edge. The heat dissipation device has a first heat dissipation channel and a second heat dissipation channel with a spiral structure inside, and the first heat dissipation channel and the second heat dissipation channel are spirally intertwined with each other. The first heat dissipation channel and the second heat dissipation channel are used to allow the flow of the heat dissipation liquid. The port of the first heat dissipation channel is connected to the first end of the second chamber, and the port of the second heat dissipation channel is connected to the second end of the second chamber. The second chamber is provided with heat dissipation fins, and the other end of the heat dissipation fins extends to the outside of the tool holder body.

[0012] In one embodiment, the dual-flying-blade roller surface processing device includes a radial drive device and an axial drive device. The radial drive device is used to drive the movable plate to slide along the radial direction of the roller substrate, and the axial drive device is used to drive the movable plate to slide along the axial direction of the roller substrate. The axial drive device is mounted on the base, the radial drive device is mounted on the drive end of the axial drive device, and the movable plate is mounted on the drive end of the radial drive device. In one embodiment, the roller rotating device includes a rotating drive unit and a rotating driven unit, wherein the rotating drive unit and the rotating driven unit are respectively clamped and fixed at both ends of the roller substrate by a four-jaw chuck.

[0013] To achieve the above objectives, the present invention proposes a method for surface processing of a double-flying-cut roller, applied to the double-flying-cut roller surface processing apparatus as described in any of the preceding claims; wherein the double-flying-cut roller surface processing method includes the following steps: Circumferential groove processing steps: The roller rotating device drives the roller substrate to rotate continuously, and at the same time, the first flying knife cutting device is activated to perform circumferential groove processing on the surface of the roller substrate; the radial feed of the first flying knife cutting device is adjusted by the movable plate to process multiple circumferential grooves on the surface of the roller substrate. Axial groove machining steps: The roller rotating device remains stationary, while the second flying knife cutting device is started to machine the axial groove on the surface of the roller substrate; the rotation angle of the roller substrate is adjusted by the roller rotating device to machine multiple axial grooves on the surface of the roller substrate. The circumferential grooves intersect with the axial grooves to form a micro pyramid array structure on the surface of the roller substrate.

[0014] In one embodiment, the circumferential groove machining step includes the following step: the rotation direction of the cutting tool of the first flying knife cutting device is opposite to the rotation direction of the roller substrate; In one embodiment, the axial groove machining step includes the following step: the cutting tool of the second fly knife cutting device rotates in the opposite direction to its axial movement along the roller substrate.

[0015] The technical solution of this invention sets a first flying knife cutting device and a second flying knife cutting device on opposite sides of the roller substrate, and uses flying knife technology to process circumferential and axial grooves respectively. This fundamentally changes the formation and flow of chips. The flying knife technology uses a single-edged high-speed rotation to perform instantaneous shearing, and the chips are immediately thrown away from the workpiece surface. This completely avoids the chip squeezing phenomenon caused by the simultaneous cutting on both sides of the V-shaped cutting tool in the prior art. This prevents the processed material from accumulating at the edge of the groove, thereby effectively suppressing the generation of burrs and edge defects at the source and significantly improving the forming quality of the micro pyramid array structure on the surface of the roller substrate.

[0016] Understandably, because both sides of the cutting edge of a V-shaped cutting tool participate in cutting simultaneously, the generated chips are squeezed together at the bottom of the groove, forcing the material to flow and accumulate towards the machined edge with the least resistance, thus forming burrs. However, the high-speed rotating fly knife technology used in this invention is essentially a single-point cutting edge. Its extremely high linear velocity transforms the cutting process into instantaneous, intermittent high-speed shearing. In this process, the chips are thrown off the workpiece surface at high speed the instant they are cut, eliminating the mutual squeezing of chips from two directions and avoiding the slow plastic flow of material towards the edge. Simultaneously, the cutting speed of the fly knife often exceeds the critical value for plastic rheology, causing the material to transform from plastic cutting to brittle fracture or adiabatic shearing, with the chips being neatly sheared rather than extruded. Therefore, the fly knife technology fundamentally suppresses the conditions for burr formation from a mechanical and kinematic perspective, thereby significantly improving surface finish. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of an embodiment of the double-flying-knife roller surface processing device provided by the present invention. Figure 2 A schematic diagram of the structure of the first flying knife cutting device / second flying knife cutting device in one embodiment of the dual flying knife roller surface processing device provided by the present invention; Figure 3 A schematic diagram of the dynamic balance adjustment device in one embodiment of the double-flying-knife roller surface processing device provided by the present invention; Figure 4 for Figure 3 A magnified view of a section at point A in the middle; Figure 5 This is a flowchart illustrating the steps of an embodiment of the double-flying-knife roller surface processing method provided by the present invention.

[0019] Explanation of reference numerals in the attached figures: 10. Base; 20. Roller rotating device; 21. Rotary drive unit; 22. Rotary driven unit; 23. Four-jaw chuck; 30. Roller substrate; 40. Movable plate; 41. Radial drive device; 42. Axial drive device; 50. First flying knife cutting device; 51. Rotary motor; 52. Tool holder body; 521. Mounting groove; 522. Threaded hole; 53. Cutting tool; 60. Second flying knife cutting device; 70. Dynamic balance adjustment device; 71. Counterweight; 72. Locking bolt; 73. First chamber; 74. Mass block; 75. Elastic element; 76. Second chamber; 77. Elastic diaphragm; 78. Heat dissipation fins; 80. Heat dissipation device; 81. First heat dissipation channel; 82. Second heat dissipation channel; The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] The technical solutions of this invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a portion of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0022] Furthermore, it should be noted that the descriptions involving "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0023] As a microfabrication technology, the following embossing technique is known: a micro-pyramid array structure is formed by machining the outer peripheral surface of a cylindrical or cylindrical roller substrate; the resulting roller substrate is then pressed onto a resin sheet to transfer the micro-pyramid array structure onto the roller substrate. In existing technology, the specific operation for machining a micro-pyramid array structure on the roller surface is as follows: First, the operator uses a V-shaped diamond cutting tool to machine multiple circumferential and axial grooves on the roller substrate; through the intersection of these two sets of mutually perpendicular grooves, a micro-pyramid array structure is finally formed on the surface of the roller substrate.

[0024] However, the aforementioned existing technology has the following drawbacks: the quality of the finished product is poor, and burrs and defects easily appear on the edges of the grooves. The fundamental reason is that the cutting edge of the V-shaped cutting tool used participates in cutting on both sides simultaneously, and the resulting chips are squeezed against each other. Since material flows in the direction of least resistance, the squeezed material flows towards the edge of the finished groove and accumulates, thus forming burrs that are difficult to remove.

[0025] To address the aforementioned technical problems, this invention proposes a double-flying-knife roller surface processing device.

[0026] Please see Figure 1 In one embodiment of the present invention, the dual-blade roller surface processing device includes: Base 10; A roller rotating device 20 is disposed on the base 10; the roller rotating device 20 is used to clamp the roller substrate 30 and drive it to rotate axially. The movable plate 40 is slidably disposed on the base 10; the movable plate 40 can slide relative to the roller substrate 30 in its radial and axial directions. The first flying knife cutting device 50 and the second flying knife cutting device 60 are disposed on the movable plate 40; the first flying knife cutting device 50 and the second flying knife cutting device 60 are respectively located on opposite sides of the roller substrate 30; the first flying knife cutting device 50 is used to perform circumferential groove processing on the surface of the roller substrate 30 using flying knife technology, and the second flying knife cutting device 60 is used to perform axial groove processing on the surface of the roller substrate 30 using flying knife technology.

[0027] The technical solution of the present invention sets the first flying knife cutting device 50 and the second flying knife cutting device 60 on opposite sides of the roller substrate 30, and uses flying knife technology to process circumferential and axial grooves respectively. This fundamentally changes the formation and flow of chips. The flying knife technology uses a single-edged high-speed rotation to perform instantaneous shearing, and the chips are immediately thrown away from the workpiece surface. This completely avoids the chip squeezing phenomenon caused by the simultaneous participation of both sides of the cutting edge of the V-shaped cutting tool 53 in cutting in the prior art. This prevents the processed material from accumulating at the edge of the groove, thereby effectively suppressing the generation of burrs and edge defects at the source and significantly improving the forming quality of the micro pyramid array structure on the surface of the roller substrate 30.

[0028] Understandably, because both sides of the cutting edge of the V-shaped cutting tool 53 participate in cutting simultaneously, the generated chips are squeezed against each other at the bottom of the groove, forcing the material to flow and accumulate towards the machined edge with the least resistance, thus forming burrs. However, the high-speed rotating fly knife technology used in this invention is essentially a single-point cutting edge. Its extremely high linear velocity transforms the cutting process into instantaneous, intermittent high-speed shearing. In this process, the chips are thrown off the workpiece surface at high speed the moment they are cut, eliminating the mutual squeezing of chips from two directions and avoiding the slow plastic flow of material towards the edge. Simultaneously, the cutting speed of the fly knife often exceeds the critical value for plastic rheology, causing the material to transform from plastic cutting to brittle fracture or adiabatic shearing, with the chips being neatly sheared rather than extruded. Therefore, the fly knife technology fundamentally suppresses the conditions for burr formation from a mechanical and kinematic perspective, thereby significantly improving surface finish.

[0029] In the field of ultra-precision machining, the fly cutter technology specifically refers to a rotary single-point cutting process. Its core is to mount a single cutting tool 53 on a high-speed rotating spindle, utilizing the rotational motion of the tool tip to perform intermittent cutting on the workpiece. Unlike common milling cutters, fly cutters typically only have one insert, thus achieving extremely high surface quality. Since fly cutter technology falls within the scope of existing technology, its principles will not be elaborated upon here. In machining structures such as micro-pyramid arrays, this single-edge rotation characteristic is utilized: the tool cuts only once per revolution, and the extremely high rotational speed instantly throws away the chips, effectively suppressing burr formation.

[0030] As a preferred embodiment of the above embodiments, refer to Figure 2Both the first flying knife cutting device 50 and the second flying knife cutting device 60 include a rotary motor 51, a tool holder body 52, and a cutting tool 53. The drive end of the rotary motor 51 is connected to one side of the tool holder body 52, and the other side of the tool holder body 52 is used to clamp and fix the cutting tool 53 so that the rotary motor 51 drives the cutting tool 53 to rotate. The first rotation plane of the cutting tool 53 of the first flying knife cutting device 50 is perpendicular to the second rotation plane of the cutting tool 53 of the second flying knife cutting device 60. Specifically, the first rotation plane of the cutting tool 53 of the first flying knife cutting device 50 is perpendicular to the axis of the roller substrate 30, and the second rotation plane of the cutting tool 53 of the second flying knife cutting device 60 is parallel to the axis of the roller substrate 30. This configuration further defines both the first and second cutting devices 50 as "rotary motor 51 + tool holder body 52 + cutting tool 53," and clarifies that the rotation planes of the two cutting tools 53 are perpendicular to each other, achieving functional integration and directional decoupling of circumferential and axial groove machining. This structure allows the two cutting devices to be driven independently without interference, performing radial and axial cutting on the roller surface with optimal rotational postures, respectively, without relying on manual tool rotation or reclamping, thus significantly improving machining efficiency while ensuring machining accuracy. Simultaneously, the perpendicular arrangement of the two rotation planes ensures that the machined circumferential and axial grooves form a regular and symmetrical pyramidal microstructure profile when they intersect, providing a high-quality mold surface for subsequent embossing and transfer processes.

[0031] The first flying knife cutting device 50 and the second flying knife cutting device 60 are spaced apart to ensure that the second flying knife cutting device 60 is away from the roller substrate 30 during the flying knife cutting process of the roller substrate 30 driven by the movable plate 40 and the first flying knife cutting device 50; and vice versa, thereby avoiding mutual interference between the two.

[0032] As a preferred embodiment, a dynamic balancing device 70 is provided on the other side of the tool holder body 52. ​​The dynamic balancing device 70 is used to drive the center of mass of the tool holder body 52 to coincide with its rotation axis. This configuration, by providing the dynamic balancing device 70 on the tool holder body 52, ensures that the center of mass of the tool holder body 52 and its rotation axis tend to coincide in real time or statically, thereby effectively suppressing high-speed rotational centrifugal force vibration caused by uneven mass distribution of the tool holder body 52 and the cutting tool 53. This feature ensures that the tool tip trajectory remains highly stable under operating conditions of thousands or even tens of thousands of revolutions per minute, avoiding cutting depth fluctuations, increased burrs on groove edges, and premature tool wear caused by vibration, providing a stable dynamic basis for ultra-precision microstructure machining.

[0033] As one specific embodiment of the dynamic balancing adjustment device 70, refer to Figure 2 The dynamic balancing device 70 includes a counterweight 71 and a locking bolt 72. A mounting groove 521 is provided on the side of the tool holder body 52 away from the cutting tool 53, and the mounting groove 521 is arranged radially along the tool holder body 52. ​​The counterweight 71 is slidably and lockably connected to the mounting groove 521. A threaded hole 522 is provided through the side of the mounting groove 521, and the locking bolt 72 is threadedly connected to the threaded hole 522, with its end abutting against the counterweight 71. This configuration, by providing a mounting groove 521 extending radially along the tool holder body 52 and slidably and lockably connecting the counterweight 71 therein, along with the locking bolt 72, achieves precise adjustment and fixation of the radial position, providing a simple, low-cost, and convenient static dynamic balancing method. The operator can manually adjust the radial position of the counterweight 71 in the mounting groove 521 according to the actual imbalance of the cutting tool, thereby changing the magnitude of the compensating centrifugal force and bringing the center of mass of the tool holder body 52 closer to the axis of rotation.

[0034] As another specific embodiment of the dynamic balancing device 70, refer to Figure 3 The dynamic balancing device 70 includes a first chamber 73 with a linear structure, which is arranged radially along the blade holder body 52. ​​A mass block 74 is slidably connected inside the first chamber 73, and the side of the mass block 74 near the blade holder body 52 is connected to the inner wall of the first chamber 73 via an elastic element 75. Thus, a first chamber 73 with a linear structure extending radially is formed on the blade holder body 52, and a mass block 74 is slidably mounted inside this chamber. The side of the mass block 74 near the rotation center of the blade holder body 52 is connected to the inner wall of the first chamber 73 via an elastic element 75 (such as a spring). When the blade holder body 52 is stationary or rotating at low speed, the preload or restoring force of the elastic element 75 keeps the mass block 74 in a position close to the rotation center. When the blade holder body 52 rotates at high speed, the mass block 74 is subjected to centrifugal force, which overcomes the elastic force of the elastic element 75 and slides radially outward along the first chamber 73. In this way, the mass block 74 can automatically adjust its radial position according to the current rotational speed, thereby changing the magnitude of the compensating centrifugal force it generates. This allows the overall center of mass of the tool holder body 52 to dynamically approach the axis of rotation, achieving adaptive compensation for imbalance at different rotational speeds. When the rotational speed decreases or stops, the elastic element 75 pulls the mass block 74 back to its initial position, achieving a reset function.

[0035] Furthermore, the dynamic balancing device 70 includes a second chamber 76 with an arc-shaped structure, which is arranged circumferentially along the tool holder body 52; the first chamber 73 and the arc-shaped middle part of the second chamber 76 are isolated from each other by an elastic diaphragm 77; the second chamber 76 is filled with a heat dissipation liquid (not shown in the figure), and the two ends of the second chamber 76 are connected to a heat dissipation device 80, which is connected to the cutting tool 53; when the mass block 74 squeezes the elastic diaphragm 77 to drive a change in the air pressure in the second chamber 76, the heat dissipation liquid can flow along the second chamber 76 to the heat dissipation device 80 to dissipate heat from the cutting tool 53. With this configuration, when the tool holder body 52 rotates at high speed, the mass block 74 in the first chamber 73 slides radially outward under the action of centrifugal force. During this process, the mass block 74 will squeeze the elastic diaphragm 77 located between the first chamber 73 and the second chamber 76, causing the elastic diaphragm 77 to deform towards the second chamber 76, thereby compressing the volume of the second chamber 76 and changing its internal air pressure. This air pressure change will drive the heat dissipation liquid in the second chamber 76 to flow from the compressed area to the two ends with lower air pressure, and then enter the heat dissipation device 80 along the connecting pipe. When flowing through the heat dissipation device 80, it absorbs the heat generated by the cutting tool 53. When the rotation speed of the tool holder body 52 gradually decreases, the centrifugal force on the mass block 74 decreases accordingly. When it is insufficient to overcome the restoring force of the elastic element 75, the elastic element 75 (such as a spring) will drive the mass block 74 to retract along the first chamber 73 towards the direction closer to the rotation center of the tool holder body 52. During this retraction process, the squeezing effect of the mass block 74 on the elastic diaphragm 77 gradually weakens or even disappears. The elastic diaphragm 77 rebounds towards the first chamber 73 due to its own elastic restoring force, causing the volume of the second chamber 76 to increase and the internal air pressure to decrease. This decrease in air pressure creates a negative pressure suction effect between the second chamber 76 and the heat dissipation device 80, driving the cooling liquid that originally flowed into the heat dissipation device 80 to flow back to the second chamber 76 along the connecting pipe until the pressure is balanced. This reversible process ensures that when the processing speed decreases or the equipment stops, the cooling liquid can automatically return to the second chamber 76 for storage, avoiding the problem of insufficient heat dissipation during the next startup that may be caused by the cooling liquid remaining in the heat dissipation device 80. It also provides liquid reserves for the next heat dissipation cycle during high-speed rotation. Thus, the device achieves a complete closed-loop control: when the speed increases, the mass block 74 slides outward, driving the cooling liquid to flow towards the tool; when the speed decreases, the mass block 74 retracts, and the cooling liquid flows back to reset. It cleverly transforms the radial sliding motion of the mass block 74 into the power to drive the flow of cooling liquid, realizing the cooling of the cutting tool 53 while dynamically balancing and adjusting, effectively avoiding the problems of decreased machining accuracy and shortened life of the cutting tool 53 due to temperature rise.

[0036] Specifically, refer to Figure 4The heat dissipation device 80 has a cylindrical structure and is fitted onto the end of the cutting tool 53 furthest from its cutting edge. Inside the heat dissipation device 80 are a first heat dissipation channel 81 and a second heat dissipation channel 82 with a spiral structure, which are intertwined. The first and second heat dissipation channels 81 and 82 are used for the flow of cooling liquid. The port of the first heat dissipation channel 81 is connected to the first end of the second chamber 76, and the port of the second heat dissipation channel 82 is connected to the second end of the second chamber 76. The second chamber 76 is equipped with heat dissipation fins 78, the other end of which extends to the outside of the tool holder body 52. ​​With this configuration, the heat dissipation device 80 has an overall cylindrical structure and is tightly fitted onto the end of the cutting tool 53 furthest from its cutting edge (i.e., the tool tail), so as to absorb the heat conducted by the cutting tool 53 nearby. The heat dissipation device 80 contains a first heat dissipation channel 81 and a second heat dissipation channel 82, both of which are spirally intertwined (similar to a double helix or twisted structure) to maximize the heat dissipation path and increase the heat exchange area within a limited space. The port of the first heat dissipation channel 81 is connected to the first end of the second chamber 76, and the port of the second heat dissipation channel 82 is connected to the second end of the second chamber 76, thus forming a complete heat dissipation liquid circuit together with the second chamber 76. When the mass block 74 compresses the elastic diaphragm 77, driving the heat dissipation liquid to flow, the liquid can enter the two spirally intertwined heat dissipation channels, flow along the spiral path, and fully exchange heat with the tail of the cutter before returning to the second chamber 76. In addition, the second chamber 76 is equipped with heat dissipation fins 78. One end of the heat dissipation fin 78 is located inside the second chamber 76 or in contact with the cooling liquid inside the second chamber 76, while the other end extends to the outside of the tool holder body 52. ​​This allows the heat absorbed by the cooling liquid to be directly dissipated to the external environment through the heat dissipation fins 78, thereby further improving heat dissipation efficiency. This structural design combines efficient spiral channel heat exchange with passive fin cooling, achieving forced cooling of the cutting tool 53 within a compact space.

[0037] As a preferred embodiment of the above embodiments, refer to Figure 1The dual-flying-blade roller surface processing device includes a radial drive device 41 and an axial drive device 42. The radial drive device 41 drives the movable plate 40 to slide radially along the roller substrate 30, and the axial drive device 42 drives the movable plate 40 to slide axially along the roller substrate 30. The axial drive device 42 is mounted on the base 10, the radial drive device 41 is mounted on the drive end of the axial drive device 42, and the movable plate 40 is mounted on the drive end of the radial drive device 41. With this configuration, the axial drive device 42 is directly fixedly mounted on the base 10, serving as the bottom foundation of the entire drive system. The radial drive device 41 is mounted on the drive end of the axial drive device 42 (i.e., on the movable part of the axial drive device 42), and is driven by the axial drive device 42 to move axially. The movable plate 40 is further mounted on the drive end of the radial drive device 41 (i.e., on the movable part of the radial drive device 41), and is driven by the radial drive device 41 to move radially. Through this hierarchical installation structure, when it is necessary to adjust the position of the movable plate 40 and the double flying knife cutting device on it in space, the axial drive device 42 is responsible for large-range or precise axial positioning along the length of the roller, while the radial drive device 41 is responsible for controlling the depth of the flying knife cutting into the roller surface or the retraction action. The two are independent of each other and can move in coordination, realizing the flexible and precise positioning of the movable plate 40 in a two-dimensional plane, while having the characteristics of compact structure, short kinematic chain and fast response speed.

[0038] As a preferred embodiment of the above embodiments, refer to Figure 1 The roller rotation device 20 includes a rotation drive unit 21 and a rotation driven unit 22. The rotation drive unit 21 and the rotation driven unit 22 are respectively clamped and fixed at both axial ends of the roller substrate 30 by a four-jaw chuck 23. This configuration, by setting the roller rotation device 20 as a rotation drive unit 21 and a rotation driven unit 22, and respectively clamping and fixing the axial ends of the roller substrate 30 by a four-jaw chuck 23, achieves dual-end driving and stable support for the roller substrate 30 with a large length-to-diameter ratio. This effectively avoids torsional deformation and vibration that may occur with single-end driving, ensuring that the radial runout and axial movement of the roller surface are controlled within allowable limits during processing, and providing reliable reference conditions for high-precision machining by the dual-blade cutting device.

[0039] The present invention also discloses a method for surface processing of a double-flying-knife roller, applicable to the double-flying-knife roller surface processing apparatus as described in any of the above embodiments; specifically, refer to Figure 5 The surface processing method for double-blade rollers includes the following steps: Step S10: Circumferential groove processing step: The roller rotating device 20 drives the roller substrate 30 to rotate continuously, and at the same time, the first flying knife cutting device 50 is started to perform circumferential groove processing on the surface of the roller substrate 30; the axial position of the first flying knife cutting device 50 is adjusted by the movable plate 40 to process multiple circumferential grooves on the surface of the roller substrate 30. In the above steps, the roller rotation device 20 is started first, driving the roller substrate 30 to rotate continuously and uniformly around its own axis, setting the required rotation speed. Simultaneously, the first flying knife cutting device 50 is started, with its internal rotary motor 51 driving the tool holder body 52 to rotate at high speed. The movable plate 40 first controls the first flying knife cutting device 50 to feed radially along the roller substrate 30 via the radial drive device 41, causing the high-speed rotating cutting tool 53 to cut into the surface of the roller substrate 30 at a set cutting depth. Due to the continuous rotation of the roller substrate 30, the cutting tool 53 cuts a complete annular groove on the roller surface. After a single circumferential groove is processed, the movable plate 40 first drives the first flying knife cutting device 50 to retract radially, completely removing the flying knife from the processed surface. Then, via the axial drive device 42, the first flying knife cutting device 50 is moved to the axial position of the next groove to be processed (i.e., moved along the length of the roller by a preset groove spacing). The process of radial feed, roller rotation cutting, radial retraction, and axial displacement is repeated until a predetermined number of circumferential grooves are machined on the surface of the roller substrate 30. Throughout the machining process, the roller rotation device 20 rotates continuously, and the fly cutter of the first fly cutter cutting device 50 rotates at high speed. The positioning and switching between the grooves are achieved through the precise control of the movable plate 40, thereby efficiently and consistently completing the machining of all circumferential grooves.

[0040] Step S20: Axial groove machining step: The roller rotating device 20 remains stationary, while the second flying knife cutting device 60 is started to perform axial groove machining on the surface of the roller substrate 30; the rotation angle of the roller substrate 30 is adjusted by the roller rotating device 20 to machine multiple axial grooves on the surface of the roller substrate 30. In the above steps, the roller rotating device 20 first remains stationary, meaning the roller substrate 30 does not undergo continuous rotation around its axis but is locked at a fixed angular position. Simultaneously, the second flying knife cutting device 60 is activated, with its internal rotary motor 51 driving the knife holder body 52 to rotate at high speed. The movable plate 40 first controls the second flying knife cutting device 60 to feed radially along the roller substrate 30 via the radial drive device 41, causing the high-speed rotating cutting tool 53 to cut into the surface of the roller substrate 30 at a set cutting depth. After reaching the predetermined cutting depth, the movable plate 40 controls the second flying knife cutting device 60 to move axially along the roller substrate 30 via the axial drive device 42, during which the flying knife cuts a straight axial groove. After a single axial groove is machined, the movable plate 40 first drives the second fly cutter cutting device 60 to retract radially, completely removing the fly cutter from the machined surface. Then, the roller rotating device 20 drives the roller substrate 30 to rotate around its own axis by a preset angle (i.e., circumferential indexing angle), rotating the position of the next axial groove to be machined directly below the second fly cutter cutting device 60. The above-mentioned cyclic process of radial feed, axial movement cutting, radial retraction, and roller rotation indexing is repeated until a preset number of axial grooves are machined on the surface of the roller substrate 30. Throughout the entire machining process, the roller rotating device 20 only performs step-by-step indexing rotation after each axial groove is completed, without continuous rotation, thereby ensuring the straightness of each axial groove and the uniformity of the circumferential spacing between the grooves.

[0041] Step S30: The circumferential grooves and axial grooves intersect each other to form a micro pyramid array structure on the surface of the roller substrate 30.

[0042] In the above steps, the desired micro-pyramid array structure can be formed on the surface of the roller substrate 30 through the cross-processing of the circumferential and axial grooves. Furthermore, after processing the first roller substrate 30, the surface roughness needs to be tested. If the measured surface roughness value meets the preset process requirements, the current processing parameters are solidified and used as the standard process parameters for mass production; if the surface roughness value exceeds the preset range, the processing parameters are fine-tuned, and trial cutting is performed again until the process requirements are met.

[0043] This configuration, by clearly separating the circumferential groove machining steps from the axial groove machining steps and assigning them to the first fly-cutting device 50 and the second fly-cutting device 60 respectively, achieves time-sharing and coordinated machining of grooves in two different directions. In the circumferential groove machining step, the roller rotating device 20 drives the roller substrate 30 to rotate continuously, while the first fly-cutting device 50 performs high-speed single-point cutting using fly-cutting technology to form a circumferential groove on the surface of the roller substrate 30. In the axial groove machining step, the roller rotating device 20 remains stationary, and the second fly-cutting device 60 performs axial cutting using fly-cutting technology to form an axial groove. This method completely avoids the problems of chip compression and edge burr accumulation caused by the simultaneous cutting on both sides of the V-shaped cutting tool 53 in the prior art. This is because the high-speed rotation of the single edge of the fly knife causes the chips to be thrown away instantly, and the material cannot flow to the edge of the groove. At the same time, the micro pyramid array structure formed by the intersection of the circumferential groove and the axial groove has a regular geometric contour and high surface finish, providing a high-quality mold surface for the subsequent embossing and transfer process.

[0044] As a preferred embodiment of the above, step S10 includes the following steps: Step S11: The rotation direction of the cutting tool 53 of the first flying knife cutting device 50 is opposite to the rotation direction of the roller substrate 30; This reverse rotation design aims to optimize the relative kinematics during the cutting process. Understandably, when the fly cutter rotates in the opposite direction to the roller substrate 30, at the contact point, the tangential velocity of the fly cutter's edge and the tangential velocity of the roller surface are superimposed, resulting in a higher relative cutting speed. This higher relative speed allows for more thorough shear fracture of the material at the moment of cutting, and the chips are more quickly ejected from the workpiece surface, further reducing the time window for plastic flow of material towards the groove edge. Simultaneously, the cutting force generated by the reverse rotation is opposite to the rotational drive direction of the roller, forming a counter-shearing mechanical state that helps to counteract some of the vibration tendency during the cutting process, making the cutting process smoother. Compared to co-rotation, this reverse rotation method effectively reduces the burr height at the groove edge and improves the surface roughness at the bottom of the groove, thereby enhancing the overall machining quality of the circumferential groove.

[0045] As a preferred embodiment of the above, step S20 includes the following steps: Step S21: The rotation direction of the cutting tool 53 of the second flying knife cutting device 60 is opposite to its axial movement direction along the roller substrate 30; This reverse design aims to optimize the relative kinematics during the cutting process. Understandably, when the fly cutter rotates in the opposite direction to the axial movement, at the cutting contact point, the tangential velocity of the fly cutter's cutting edge and the axial feed velocity are superimposed, resulting in a higher relative cutting speed. This higher relative speed causes more thorough shear fracture of the material at the moment of cutting, and the chips are more quickly ejected from the workpiece surface, further reducing the time window for plastic flow of material towards the groove edge. Simultaneously, the cutting force generated by the reverse rotation is opposite to the axial feed direction, creating a counter-shearing mechanical state that helps to counteract some of the vibration tendency during cutting, making the cutting process smoother. Compared to co-rotation, this reverse rotation method effectively reduces the burr height at the edge of the axial groove and improves the surface roughness at the bottom of the groove, thereby enhancing the overall machining quality of the axial groove.

[0046] It should be noted that other aspects of the double-flying-knife roller surface processing device and processing method disclosed in this invention are prior art and will not be repeated here.

[0047] The above are merely optional embodiments of the present invention and do not limit the patent scope of the present invention. Any application of the present invention directly or indirectly in other related technical fields is included within the patent protection scope of the present invention.

Claims

1. A surface processing device for a double-flying-knife roller, characterized in that, include: Base; A roller rotating device is disposed on the base; the roller rotating device is used to clamp the roller substrate and drive it to rotate axially; A movable plate is slidably disposed on the base; the movable plate can slide relative to the roller substrate along its radial and axial directions. A first and a second flying knife cutting device are disposed on the movable plate; the first and second flying knife cutting devices are respectively located on opposite sides of the roller substrate; the first flying knife cutting device is used to perform circumferential groove processing on the surface of the roller substrate using flying knife technology, and the second flying knife cutting device is used to perform axial groove processing on the surface of the roller substrate using flying knife technology.

2. The dual-flying-knife roller surface processing device as described in claim 1, characterized in that: Both the first and second flying knife cutting devices include a rotary motor, a tool holder body, and a cutting tool. The drive end of the rotary motor is connected to one side of the tool holder body, and the other side of the tool holder body is used to clamp and fix the cutting tool so that the rotary motor drives the cutting tool to rotate. The first rotation plane of the cutting tool belonging to the first flying knife cutting device is perpendicular to the second rotation plane of the cutting tool belonging to the second flying knife cutting device.

3. The dual-flying-knife roller surface processing device as described in claim 2, characterized in that: A dynamic balance adjustment device is provided on the other side of the tool holder body. The dynamic balance adjustment device is used to drive the center of mass of the tool holder body to coincide with its rotation axis.

4. The dual-flying-knife roller surface processing device as described in claim 3, characterized in that: The dynamic balancing device includes a counterweight and a locking bolt. The tool holder body has a mounting groove on the side away from the cutting tool, and the mounting groove is arranged radially along the tool holder body. The counterweight is lockably and slidably connected to the mounting groove. The side of the mounting groove has a through threaded hole, and the locking bolt is threadedly connected to the threaded hole, and the end of the locking bolt is used to abut against the counterweight.

5. The dual-flying-knife roller surface processing device as described in claim 3, characterized in that: The dynamic balancing device includes a first chamber with a linear structure, which is arranged radially along the blade holder body; a mass block is slidably connected inside the first chamber, and the side of the mass block near the blade holder body is connected to the inner wall of the first chamber through an elastic element.

6. The dual-flying-knife roller surface processing device as described in claim 5, characterized in that: The dynamic balancing device includes a second chamber with an arc-shaped structure, which is arranged circumferentially along the tool holder body. The arc-shaped middle portions of the first chamber and the second chamber are isolated from each other by an elastic diaphragm. The second chamber is filled with a heat dissipation liquid, and heat dissipation devices are connected to both ends of the second chamber. The heat dissipation devices are connected to the cutting tool. When the mass block squeezes the elastic diaphragm to change the air pressure in the second chamber, the heat dissipation liquid can flow along the second chamber to the heat dissipation device to dissipate heat from the cutting tool.

7. The dual-flying-knife roller surface processing device as described in claim 6, characterized in that: The heat dissipation device has a cylindrical structure and is sleeved on the end of the cutting tool away from its cutting edge. The heat dissipation device has a first heat dissipation channel and a second heat dissipation channel with a spiral structure inside, and the first heat dissipation channel and the second heat dissipation channel are spirally intertwined with each other. The first heat dissipation channel and the second heat dissipation channel are used to supply the flow of the heat dissipation liquid. The port of the first heat dissipation channel is connected to the first end of the second chamber, and the port of the second heat dissipation channel is connected to the second end of the second chamber. The second chamber is provided with heat dissipation fins, and the other end of the heat dissipation fins extends to the outside of the tool holder body.

8. The dual-flying-knife roller surface processing apparatus according to any one of claims 1 to 7, characterized in that: The dual-flying-blade roller surface processing device includes a radial drive device and an axial drive device. The radial drive device is used to drive the movable plate to slide along the radial direction of the roller substrate, and the axial drive device is used to drive the movable plate to slide along the axial direction of the roller substrate. The axial drive device is mounted on the base, the radial drive device is mounted on the drive end of the axial drive device, and the movable plate is mounted on the drive end of the radial drive device. And / or, the roller rotating device includes a rotating drive unit and a rotating driven unit, wherein the rotating drive unit and the rotating driven unit are respectively clamped and fixed at both ends of the roller substrate by a four-jaw chuck.

9. A method for surface processing of a double-flying-cut roller, applied to the double-flying-cut roller surface processing apparatus as described in any one of claims 1 to 8; characterized in that: The double-flying-knife roller surface processing method includes the following steps: Circumferential groove processing steps: The roller rotating device drives the roller substrate to rotate continuously, and at the same time, the first flying knife cutting device is activated to perform circumferential groove processing on the surface of the roller substrate; the radial feed of the first flying knife cutting device is adjusted by the movable plate to process multiple circumferential grooves on the surface of the roller substrate. Axial groove machining steps: The roller rotating device remains stationary, while the second flying knife cutting device is started to machine the axial groove on the surface of the roller substrate; the rotation angle of the roller substrate is adjusted by the roller rotating device to machine multiple axial grooves on the surface of the roller substrate. The circumferential grooves intersect with the axial grooves to form a micro pyramid array structure on the surface of the roller substrate.

10. The surface processing method for a double-flying-knife roller as described in claim 9, characterized in that: The circumferential groove machining step includes the following steps: the rotation direction of the cutting tool of the first flying knife cutting device is opposite to the rotation direction of the roller substrate; The axial groove machining step includes the following step: the cutting tool of the second flying knife cutting device rotates in the opposite direction to its axial movement along the roller substrate.

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