A method for manufacturing an ultra-small-diameter superhard micro-cutter

Abstract

This invention discloses a method for preparing ultra-small diameter superhard micro-tools, relating to the field of tool preparation technology. The method includes the following steps: cutting a superhard material block from a superhard material composite sheet using laser cutting; welding the laser-cut superhard material block to a tool holder using high-frequency induction welding to form a superhard tool bar; reducing the diameter of the superhard tool bar using laser processing; and precision grinding the reduced-diameter superhard tool bar to form an ultra-small diameter superhard micro-tool. The precision grinding includes sequential end-face grinding, cylindrical grinding, spiral groove grinding, bottom groove grinding, and second clearance angle grinding of the new bottom edge using a grinding wheel. This invention improves the efficiency and quality of ultra-small diameter superhard micro-tool preparation.

Description

Technical Field

[0001] This invention relates to the field of cutting tool manufacturing technology, and in particular to a method for manufacturing ultra-small diameter, ultra-hard micro-cutting tools. Background Technology

[0002] Ultra-small diameter, ultra-hard micro-tools are crucial in the milling of high-precision micro-parts; therefore, tool design and fabrication are prerequisites and foundations for achieving high-precision machining of micro-parts. The fabrication of ultra-hard milling tools mainly includes methods such as electrical discharge machining (EDM), laser machining, ion beam machining, and precision grinding. EDM is not limited by material hardness and has high processing efficiency, but it leaves a recast layer and a modified layer on the machined surface, reducing the cutting edge strength. Laser machining has high efficiency and small processing deformation, but it limits tool roughness and the presence of a modified layer degrades tool performance. Ion beam machining produces good surface quality, but has a low material removal rate and is expensive, making mass production difficult. Precision grinding technology, with its superior precision, excellent surface quality, high processing efficiency, and ability to machine complex shapes, has become the main technical method for fabricating ultra-small diameter, ultra-hard micro-tools.

[0003] The fabrication quality of ultra-small diameter, ultrahard micro-tools directly affects their performance. Ultrahard materials such as polycrystalline diamond (PCD) are characterized by their high hardness, which makes the fabrication of ultra-small diameter, ultrahard micro-tools quite challenging.

[0004] In view of the problems existing in the above-mentioned prior art, those skilled in the art urgently need a method for preparing ultra-small diameter ultrahard micro-tools. Summary of the Invention

[0005] The purpose of this invention is to provide a method for preparing ultra-small diameter, ultra-hard micro-tools, in order to solve the problems existing in the prior art and improve the efficiency and quality of preparing ultra-small diameter, ultra-hard micro-tools.

[0006] To achieve the above objectives, the present invention provides the following solution: This invention provides a method for preparing ultra-small diameter superhard micro-tools, comprising the following steps: cutting a superhard material block from a superhard material composite sheet using laser cutting; welding the laser-cut superhard material block to a tool holder using brazing filler metal via high-frequency induction welding to form a superhard tool bar; reducing the diameter of the superhard tool bar using laser processing; and performing precision grinding on the reduced-diameter superhard tool bar to form an ultra-small diameter superhard micro-tool, wherein the precision grinding includes sequential end face grinding, cylindrical grinding, spiral groove grinding, tool bottom groove grinding, and second clearance angle grinding of the new bottom edge on the superhard tool bar using a grinding wheel.

[0007] In some embodiments, the method further includes: error compensation for errors present in the precision grinding process.

[0008] In some embodiments, the end face grinding step includes: before performing the end face grinding, the axis of the superhard tool bar is in a position parallel to the axis of the parallel grinding wheel; during the end face grinding, the end face of the parallel grinding wheel is used to perform the end face grinding on the superhard tool bar.

[0009] In some embodiments, the cylindrical grinding step includes: before performing the cylindrical grinding, the axis of the superhard tool bar is positioned parallel to the axis of the parallel grinding wheel; during the cylindrical grinding, the outer cylindrical surface of the parallel grinding wheel is used to perform the cylindrical grinding on the superhard tool bar.

[0010] In some embodiments, the spiral groove grinding step includes: before performing the spiral groove grinding, the axis of the superhard tool bar is set at a certain angle to the axis of the single-bevel grinding wheel; during the spiral groove grinding, the superhard tool bar is controlled to rotate around its own axis and the spiral groove grinding is performed on the superhard tool bar using the single-bevel grinding wheel.

[0011] In some embodiments, the bottom groove grinding step includes: before grinding the bottom groove, the axis of the superhard tool bar is set at a certain angle to the axis of the parallel grinding wheel; during the bottom groove grinding, the outer cylindrical surface of the parallel grinding wheel is used to grind the bottom groove of the superhard tool bar.

[0012] In some embodiments, the step of grinding the second back angle of the new bottom edge includes: before grinding the second back angle of the new bottom edge, the axis of the superhard tool bar is set at a certain angle with the axis of the parallel grinding wheel; during the grinding of the second back angle of the new bottom edge, the end face of the parallel grinding wheel is used to grind the second back angle of the new bottom edge on the superhard tool bar.

[0013] In some embodiments, the step of "compensating for errors in the precision grinding process" includes: achieving precision grinding by compensating for errors in one or more of the X-axis, Y-axis, Z-axis and A-axis of the CNC tool grinder.

[0014] In some embodiments, the ultra-small diameter ultra-hard micro-cutting tool is a double-edged micro-end mill, a single-edged fan-shaped micro-end mill, or a single-edged D-shaped micro-end mill.

[0015] In some embodiments, the superhard material composite sheet is mainly made of PCD material or PCBN material.

[0016] The present invention achieves the following technical effects compared to the prior art: The present invention provides a method for preparing ultra-small diameter, ultra-hard micro-tools that combines laser cutting, high-frequency induction brazing, laser diameter reduction, and precision grinding. The precision grinding process includes sequential end-face grinding, cylindrical grinding, spiral groove grinding, bottom groove grinding, and grinding of the second clearance angle of the new bottom edge. Specifically, the present invention employs a method for preparing ultra-small diameter, ultra-hard micro-end mills that combines laser cutting, high-frequency induction brazing, laser diameter reduction, and precision grinding. The processing steps in the precision grinding process are rationally designed. First, end-face grinding removes surface defects caused during the preparation of the bar stock. Then, cylindrical grinding removes surface oxides formed during the preparation of the bar stock, with precise control of the tool dimensions to ensure processing accuracy. Next, spiral groove grinding forms a spiral groove. Then, bottom groove grinding forms the end-edge rake face and / or bottom groove. Finally, grinding of the second clearance angle of the new bottom edge forms the end-edge clearance face or the second clearance face. Thus, precision grinding enables the preparation of ultra-small diameter, ultra-hard micro-tools, improving tool preparation efficiency and quality. 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 embodiments 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 the overall fabrication process of ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 2 This is a process flow diagram of grinding ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 3 This is a three-dimensional structural diagram of a double-edged micro end mill in some embodiments of the present invention; Figure 4 This is a three-dimensional structural diagram of a single-flute fan-shaped micro end mill in some embodiments of the present invention; Figure 5 This is a three-dimensional structural diagram of a single-flute D-shaped micro end mill in some embodiments of the present invention; Figure 6 This is one of the processing principle diagrams for end face grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 7 This is the second schematic diagram illustrating the machining principle of end face grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention. Figure 8This is one of the machining principle diagrams for cylindrical grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 9 This is the second schematic diagram illustrating the machining principle of cylindrical grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention. Figure 10 This is one of the machining principle diagrams for spiral groove grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 11 This is the second schematic diagram illustrating the machining principle of spiral groove grinding using ultra-small diameter ultrahard micro-tools in some embodiments of the present invention. Figure 12 This is one of the machining principle diagrams for grinding the bottom groove of ultra-small diameter ultrahard micro-tools in some embodiments of the present invention; Figure 13 This is the second schematic diagram illustrating the machining principle of grinding the bottom groove of an ultra-small diameter ultra-hard micro-tool in some embodiments of the present invention. Figure 14 This is one of the machining principle diagrams for grinding the second back angle of the new bottom edge of an ultra-small diameter ultrahard micro-tool in some embodiments of the present invention; Figure 15 This is the second schematic diagram of the machining principle for grinding the second back angle of the new bottom edge of an ultra-small diameter ultra-hard micro-tool in some embodiments of the present invention; Figure 16 This is a schematic diagram of the grinding results of a double-edged micro end mill in some embodiments of the present invention; Figure 17 This is a schematic diagram of the grinding results of a single-flute fan-shaped micro end mill in some embodiments of the present invention; Figure 18 This is a schematic diagram of the grinding results of a single-edged D-shaped micro end mill in some embodiments of the present invention; In the diagram: 1-Helical groove; 2-Circular cutting edge; 3-End cutting edge rake face; 4-End cutting edge; 5-Circular cutting edge flank face; 6-End cutting edge flank face; 7-Tool bottom groove; 8-First flank face; 9-Second flank face; 10-Superhard tool bar stock; 11-Parallel grinding wheel; 12-Single bevel grinding wheel; 13-Outer cylindrical surface; 14-End face; 101-PCD composite sheet; 102-PCD block; 103-Carbide tool holder; 104-Silver copper brazing filler metal; 105-Laser; 106-Diamond grinding wheel. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0020] The purpose of this invention is to provide a method for preparing ultra-small diameter, ultra-hard micro-tools, in order to solve the problems existing in the prior art and improve the efficiency and quality of preparing ultra-small diameter, ultra-hard micro-tools.

[0021] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] This invention provides a method for preparing ultra-small diameter, ultrahard micro-tools, such as... Figures 1 to 18 As shown, it includes the following steps: Step S1: Use laser cutting to cut out superhard material blocks from the superhard material composite sheet; Step S2: High-frequency induction welding is used to weld the laser-cut superhard material block to the tool holder together with brazing filler metal to form a superhard tool bar. Step S3: Use laser processing to reduce the diameter of the superhard tool bar; Step S4: The reduced-diameter superhard tool bar is precision ground to form an ultra-small diameter superhard micro-tool, such as... Figure 2 As shown, precision grinding includes end face grinding, cylindrical grinding, spiral groove grinding, tool bottom groove grinding, and second clearance angle grinding of the new bottom edge on the superhard tool bar through a grinding wheel.

[0023] It should be noted that the material used in the superhard material composite sheet of the present invention can be diamond material (such as PCD, single crystal diamond) or polycrystalline cubic boron nitride PCBN. Figure 1 The diagram in (a) shows a PCD block 102 being laser-cut from a PCD composite sheet 101. Figure 1 Figure (b) shows a schematic diagram of the PCD block 102 and the carbide tool holder 103 being welded together by high-frequency induction brazing using silver-copper brazing filler metal 104. Figure 1 Figure (c) shows a schematic diagram of reducing the diameter of PCD bar stock using a laser 105. For example, the diameter of the welded PCD bar stock is greater than 1 mm, while the diameter of the final ultra-small diameter superhard milling tool is 0.1 mm. Therefore, laser processing is used to reduce the diameter of the PCD bar stock efficiently and with high quality. Figure 1 The diagram shown in (d) illustrates the precision grinding of PCD bars using a diamond grinding wheel 106. Figure 2 Image (e) shows the end face grinding of the superhard tool bar 10. Figure 2 Image (f) shows the cylindrical grinding of the superhard tool bar 10. Figure 2 Image (g) shows the helical groove grinding of the superhard tool bar 10. Figure 2The image in (h) shows the bottom groove grinding of the superhard tool bar 10. Figure 2 The image in (j) shows the grinding of the second back angle of the new bottom edge of the superhard tool bar 10.

[0024] In some embodiments, step S4 above further includes: error compensation for errors present in the precision grinding process.

[0025] In some embodiments, the step of "compensating for errors present in the precision grinding process" includes: Errors present in the precision grinding process are compensated for by one or more of the X-axis, Y-axis, Z-axis and A-axis of the CNC tool grinder.

[0026] This invention can be achieved using a Makino CNC tool grinder, which can realize five-axis (X, Y, Z, A, W axes) linkage, has high flexibility, and the presence of the U axis ensures the positioning accuracy of tool grinding.

[0027] In some embodiments, such as Figure 6 and Figure 7 As shown, the steps of end face grinding include: Before end face grinding, the axis of the superhard tool bar 10 is in a position parallel to the axis of the parallel grinding wheel 11; During end face grinding, the end face 14 of the parallel grinding wheel 11 is used to grind the end face of the superhard tool bar 10.

[0028] It should be noted that the end face grinding of the present invention is completed through the end face 14 of the parallel grinding wheel 11. First, the grinding machine positions the superhard tool bar 10 and the parallel grinding wheel 11 to the grinding position through the linkage of the W-axis and Y-axis. Then, the end face grinding is completed by moving the Z-axis. This end face grinding is used to grind the axial end face of the superhard tool bar 10. In a specific embodiment, before performing end face grinding, the superhard tool bar 10 is controlled to rotate in the negative direction of the W-axis until the axis of the superhard tool bar 10 is aligned with the parallel grinding wheel 11. The end face 14 is positioned vertically, and the superhard tool bar 10 and the parallel grinding wheel 11 are controlled to move relative to each other along the Y-axis to the end face grinding position; during end face grinding, the parallel grinding wheel 11 is controlled to move along the negative direction of the Z-axis and the end face 14 of the parallel grinding wheel 11 is used to perform end face grinding on the superhard tool bar; wherein, the Z-axis is the vertical movement axis, the Y-axis is the first horizontal movement axis, and the W-axis is the rotation axis that rotates around the vertical direction; the error existing in the end face grinding process is achieved by error compensation along the Y-axis and Z-axis to achieve precision grinding.

[0029] In some embodiments, such as Figure 8 and Figure 9 As shown, the steps of cylindrical grinding include: Before cylindrical grinding, the axis of the superhard tool bar 10 is parallel to the axis of the parallel grinding wheel 11. During cylindrical grinding, the outer cylindrical surface 13 of the parallel grinding wheel 11 is used to perform cylindrical grinding on the superhard tool bar 10.

[0030] It should be noted that the cylindrical grinding of the present invention is completed through the outer cylindrical surface 13 of the parallel grinding wheel 11. First, the grinding machine positions the superhard tool bar 10 and the parallel grinding wheel 11 to the grinding position by moving along the X-axis. Then, the cylindrical grinding is completed by the linkage of the A-axis and Y-axis. This cylindrical grinding is used to grind the outer circumferential surface of the superhard tool bar 10. In a specific embodiment, before performing cylindrical grinding, the superhard tool bar 10 and the parallel grinding wheel 11 are controlled to move relative to each other along the X-axis to the position of cylindrical grinding. In cylindrical grinding, the superhard tool bar 10 is controlled to rotate in the positive direction of the A-axis, and the superhard tool bar 10 and the parallel grinding wheel 11 are controlled to move relative to each other along the Y-axis. The outer cylindrical surface 13 of the parallel grinding wheel 11 is used to perform cylindrical grinding on the superhard tool bar 10. Here, the A-axis is the rotation axis that rotates around the axis of the superhard tool bar 10, the X-axis is the second horizontal movement axis, and the X-axis is perpendicular to the Y-axis. The errors existing in the cylindrical grinding process are compensated for along the X-axis and Y-axis to achieve precision grinding.

[0031] In some embodiments, such as Figure 10 and Figure 11 As shown, the steps of spiral groove grinding include: Before spiral groove grinding, the axis of the superhard tool bar 10 is set at a certain angle with the axis of the single-bevel grinding wheel 12; During spiral groove grinding, the superhard tool bar 10 is controlled to rotate around its own axis and the spiral groove is ground by the single-bevel grinding wheel 12.

[0032] It should be noted that the spiral groove grinding of the present invention is completed by a single-bevel grinding wheel 12. First, the grinding machine positions the superhard tool bar 10 and the single-bevel grinding wheel 12 to the grinding position through the linkage of the W-axis, X-axis, Y-axis and Z-axis. Then, the spiral groove grinding is completed through the linkage of the X-axis, Y-axis and A-axis. This spiral groove grinding process is to form the spiral groove 1. In a specific embodiment, before performing spiral groove grinding, the superhard tool bar 10 is controlled to rotate 45° in the negative direction of the W-axis, and the superhard tool bar 10 and the single-bevel grinding wheel 12 are controlled to move relative to each other along the Y-axis to the processing position. The single-bevel grinding wheel 12 is controlled to rotate. The wheel 12 moves along the negative directions of the X and Z axes to the position for helical groove grinding; during helical groove grinding, the superhard tool bar 10 and the single-bevel grinding wheel 12 are controlled to move relative to each other along the X and Y axes, and the superhard tool bar 10 is controlled to rotate along the negative direction of the A axis to perform helical groove grinding on the superhard tool bar 10; wherein, the error existing in the helical groove grinding process is adjusted by adjusting the helix angle through error compensation along the X and Y axes and by adjusting the core diameter ratio of the helical groove through error compensation along the Z axis to achieve precision grinding; and the axis of the single-bevel grinding wheel 12 of the present invention is located on the same straight line as the axis of the parallel grinding wheel 11.

[0033] In some embodiments, such as Figure 12 and Figure 13 As shown, the steps for grinding the tool bottom groove include: Before grinding the tool bottom groove, the axis of the superhard tool bar 10 is set at a certain angle with the axis of the parallel grinding wheel 11; During the bottom groove grinding, the outer cylindrical surface 13 of the parallel grinding wheel 11 is used to grind the bottom groove of the superhard tool bar 10.

[0034] It should be noted that the bottom groove grinding of the present invention is completed through the outer cylindrical surface 13 of the parallel grinding wheel 11. First, the grinding machine positions the superhard tool bar 10 and the parallel grinding wheel 11 to the grinding position through the linkage of the W-axis and Y-axis. Then, the bottom groove grinding is completed through the linkage of the X-axis and Z-axis. The bottom groove grinding process is mainly to form the end face 3 and / or the bottom groove 7. In a specific embodiment, before the bottom groove grinding, the superhard tool bar 10 is controlled to rotate in the negative direction of the W-axis, and the superhard tool bar 10 and the parallel grinding wheel 11 are controlled to move relative to each other along the Y-axis to the bottom groove grinding position. During the bottom groove grinding, the parallel grinding wheel 11 is controlled to move in the negative direction of the X-axis and the negative direction of the Z-axis to grind the bottom groove of the superhard tool bar 10. Among them, the error existing in the bottom groove grinding process is adjusted by the error compensation along the Y-axis and Z-axis to adjust the offset of the bottom angle and the grinding length of the bottom angle to achieve precision grinding.

[0035] In some embodiments, such as Figure 14 and Figure 15 As shown, the grinding steps for the second clearance angle of the new bottom cutting edge include: Before grinding the second clearance angle of the new bottom edge, the axis of the superhard tool bar 10 is set at a certain angle with the axis of the parallel grinding wheel 11. When grinding the second back angle of the new bottom edge, the end face 14 of the parallel grinding wheel 11 is used to grind the second back angle of the new bottom edge of the superhard tool bar 10.

[0036] It should be noted that the grinding of the second clearance angle of the new bottom edge of the present invention is completed through the end face of the parallel grinding wheel 11. First, the grinding machine positions the superhard tool bar 10 and the parallel grinding wheel 11 to the grinding position through the linkage of the X and Y axes. Then, the grinding of the second clearance angle of the new bottom edge is completed through the linkage of the W and Z axes. This grinding of the second clearance angle of the new bottom edge is to form the end edge clearance face 6 or the second clearance face 9. In a specific embodiment, before performing the grinding of the second clearance angle of the new bottom edge, the superhard tool bar 10 and the parallel grinding wheel are controlled to... 11. Move relative to each other along the X and Y axes to the machining position; during the grinding of the second clearance angle of the new bottom edge, control the superhard tool bar 10 to rotate along the W axis, and control the superhard tool bar 10 and the parallel grinding wheel 11 to move relative to each other along the Z axis to grind the second clearance angle of the new bottom edge of the superhard tool bar; wherein, the error existing in the grinding of the second clearance angle of the new bottom edge is achieved by error compensation of the Y axis, Z axis and A axis to achieve precision grinding. Here, the error compensation of the A axis is used to control the angle of the superhard tool bar 10 in the circumferential direction.

[0037] The grinding wheel structure of the present invention includes: a first grinding wheel is a parallel grinding wheel 11, which is cylindrical and includes an outer cylindrical surface 13 and an end face 14; and a second grinding wheel is a single-bevel grinding wheel 12.

[0038] In some embodiments, such as Figures 3 to 5 As shown, the ultra-small diameter ultra-hard micro-cutting tools are double-flute micro-end mills, single-flute fan-shaped micro-end mills, or single-flute D-shaped micro-end mills.

[0039] Figure 3 The structure of a medium double-edged micro end mill includes a spiral groove 1, a circumferential cutting edge 2, a front face of the end cutting edge 3, an end cutting edge 4, a rear face of the circumferential cutting edge 5, a rear face of the end cutting edge 6, and a bottom groove 7. Figure 4 The structure of a single-flute fan-shaped micro end mill includes a spiral groove 1, a circumferential cutting edge 2, a front cutting edge 3, a front cutting edge 4, a flank cutting edge 5, a first flank cutting edge 8, and a second flank cutting edge 9. Figure 5 The single-flute D-shaped micro end mill includes a spiral groove 1, a circumferential cutting edge 2, an end-cutting rake face 3, an end-cutting edge 4, a circumferential cutting edge flank face 5, and an end-cutting flank face 6.

[0040] This invention proposes an overall preparation scheme for ultra-small diameter superhard milling cutters, which adopts a method for preparing ultra-small diameter superhard micro milling cutters by combining laser cutting, high-frequency induction brazing, laser diameter reduction and precision grinding processes, thereby improving the efficiency and quality of tool preparation.

[0041] The grinding process employs a multi-axis linkage method, and different micro-compensation strategies are designed for different tool structures, enabling the precision fabrication of ultra-small diameter PCD micro-milling tools with a diameter of less than 100μm.

[0042] Figures 16 to 18 The results show the grinding results of three different structures of ultra-small diameter PCD micro-milling tools. No significant grinding damage was observed on the tool surface.

[0043] The ultra-small diameter, ultra-hard micro-cutting tools of this invention are milling tools, generally made of polycrystalline diamond (PCD) or similar material. Due to their high strength, high rigidity, and high hardness, the diamond grinding wheel 106 is prone to wear during grinding, making it difficult to guarantee the tool's geometric accuracy and resulting in low machining efficiency. Secondly, unreasonable grinding process parameters can lead to edge chipping and breakage of the ultra-small diameter, ultra-hard micro-cutting tools, thus affecting tool quality. Finally, the precision of the grinding machine and dimensional measurement errors often pose challenges to the dimensional accuracy of the tool. This invention proposes a method for manufacturing ultra-small diameter, ultra-hard micro-milling tools, proposes corresponding grinding methods for different tool structures, and combines multi-axis linkage and precision compensation control methods to improve the grinding quality of ultra-small diameter, ultra-hard micro-cutting tools.

[0044] This invention targets the grinding of ultra-small diameter, ultra-hard micro-tools. It employs a multi-axis linkage method to precisely grind each part of the tool, compensating for errors through slight axis offsets. Different slight compensation strategies are designed for different tool structures, achieving precise fabrication of ultra-small diameter, ultra-hard micro-tools with diameters below 100μm: end face grinding errors are compensated using the Y and Z axes; cylindrical grinding errors are compensated using the X and Y axes; helix angle errors can be compensated using the X and Y axes; the core diameter ratio of the helix groove is compensated using the Z axis; groove bottom angle offset and groove bottom angle grinding length errors are compensated using the Y and Z axes; and the second clearance angle grinding error of the new bottom cutting edge is compensated using the Y, Z, and A axes.

[0045] This invention addresses the problem of difficulty in controlling grinding precision during the sharpening process. It designs an overall fabrication process for ultra-small diameter, ultra-hard micro-tools and proposes a precision sharpening method for these tools, improving grinding quality. This results in the fabrication of three designed ultra-small diameter, ultra-hard micro-tools: a double-flute micro-end mill, a single-flute fan-shaped micro-end mill, and a single-flute D-shaped micro-end mill. Following the above process, the end face, cylindrical surface, helical groove 1, tool bottom groove 7, and the second clearance angle of the new bottom cutting edge are ground respectively. Here, the second clearance angle of the new bottom cutting edge refers to… Figure 3 The end face of a medium double-flute micro end mill is 6. Figure 4 The second flank face 9 of the single-flute fan-shaped micro end mill Figure 5 The end face of a single-flute D-shaped micro end mill is 6.

[0046] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method for producing an ultrasmall-diameter superhard microcutter, characterized by, Includes the following steps: Laser cutting method is used to cut superhard material blocks from superhard material composite sheets; The superhard material block cut by laser cutting is welded to the tool holder by brazing with brazing filler metal to form a superhard tool bar. The diameter of the superhard tool bar is reduced by laser processing. The reduced diameter superhard tool bar is precision ground to form an ultra-small diameter superhard micro tool. The precision grinding process includes end face grinding, cylindrical grinding, spiral groove grinding, tool bottom groove grinding and second clearance angle grinding of the new bottom edge on the superhard tool bar in sequence by a grinding wheel.

2. The method of claim 1, wherein the super-small-diameter super-hard micro-cutter is prepared by the steps of: The method further includes: ​ Error compensation is performed to address the errors present in the precision grinding process.

3. The method of claim 1, wherein the super-small-diameter super-hard micro-cutter is prepared by the steps of: The end face grinding step includes: ​ Before the end face grinding is performed, the axis of the superhard tool bar is in a position parallel to the axis of the parallel grinding wheel; During the end face grinding, the end face of the parallel grinding wheel is used to grind the end face of the superhard tool bar.

4. The method of producing a super-small-diameter super-hard microcutter according to claim 3, wherein The cylindrical grinding steps include: Before the cylindrical grinding is performed, the axis of the superhard tool bar is in a position parallel to the axis of the parallel grinding wheel; During the cylindrical grinding, the outer cylindrical surface of the parallel grinding wheel is used to perform the cylindrical grinding on the superhard tool bar.

5. The method of claim 4, wherein the super-small-diameter super-hard micro-cutter is prepared by the steps of: The steps of the spiral groove grinding include: ​ Before performing the spiral groove grinding, the axis of the superhard tool bar is set at a certain angle to the axis of the single-bevel grinding wheel; During the spiral groove grinding, the superhard tool bar is controlled to rotate around its own axis and the spiral groove grinding is performed on the superhard tool bar using the single-bevel grinding wheel.

6. The method of producing a super-small-diameter ultrahard microcutter according to claim 5, wherein The grinding steps for the tool bottom groove include: Before grinding the tool bottom groove, the axis of the superhard tool bar is set at a certain angle to the axis of the parallel grinding wheel; During the grinding of the tool bottom groove, the outer cylindrical surface of the parallel grinding wheel is used to grind the tool bottom groove of the superhard tool bar.

7. The method of producing a super-small-diameter ultrahard microcutter according to claim 6, wherein The steps for grinding the second clearance angle of the new bottom cutting edge include: Before grinding the second clearance angle of the new bottom edge, the axis of the superhard tool bar is set at a certain angle to the axis of the parallel grinding wheel; When grinding the second back angle of the new bottom edge, the end face of the parallel grinding wheel is used to grind the second back angle of the new bottom edge of the superhard tool bar.

8. The method of producing a super-small-diameter ultrahard microcutter according to claim 2, wherein The steps of "compensating for errors present in the precision grinding process" include: The errors present in the precision grinding process are compensated by one or more of the X-axis, Y-axis, Z-axis and A-axis of the CNC tool grinder to achieve precision grinding.

9. The method of producing a micro-superhard cutter of ultra-small diameter according to claim 1, wherein The ultra-small diameter ultra-hard micro-cutting tool is a double-edged micro-end mill, a single-edged fan-shaped micro-end mill, or a single-edged D-shaped micro-end mill.

10. The method of producing a micro-superhard cutter of ultra-small diameter according to claim 1, wherein The superhard material composite sheet is mainly made of PCD or PCBN material.

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