Rotary machining tool for metal material reinforcement

Abstract

The utility model provides a rotary machining tool for strengthening a metal material, which comprises a working part and an optional connecting part used for being directly or indirectly connected with a machine tool, and is characterized in that the working part is provided with a plurality of bulges, the surface of the top of each bulge comprises a convex cambered surface or a combination of the convex cambered surfaces, so that a machining cambered surface is formed, and the machining cambered surface is used for machining the metal material. The height of the protrusions is larger than or equal to 0.05 mm and smaller than or equal to 3 mm. According to the rotary machining tool disclosed by the invention, a plurality of machining cambered surfaces formed by a plurality of bulges are ingeniously utilized, and the material can be machined in an impact and extrusion manner under the rotary driving of the machine tool main shaft, so that the impact strengthening and nanocrystallization treatment of the material are realized; due to the innovative design, the anti-fatigue performance of the material is greatly enhanced, and the corrosion resistance and the wear resistance of the material are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of metal processing tools, in particular to a metal processing tool with multiple protrusions. Background Art

[0002] Global manufacturing technology has evolved through three generations: forming, surface integrity, and fatigue-resistant manufacturing. The first generation of forming, a traditional manufacturing technique with a centuries-old heritage, centers on cutting, based on strength theory and upholding the philosophy of precision and efficiency. Its fundamental requirement is "manufacturing to the drawing," meeting designed standards for shape, position, and surface roughness. However, most current manufacturing technologies in my country remain at this stage, facing the primary challenge of fatigue stress concentration, which directly leads to three drawbacks: short product life, poor reliability, and heavy structures.

[0003] Fatigue, corrosion, and wear are recognized as the world's three major engineering challenges, with fatigue failure topping the list. This is because corrosion can be extended through repair and protection, and wear can be prevented through early warning. However, fatigue failure often occurs suddenly and without warning, resulting in catastrophic consequences. Key components of all high-end equipment face fatigue failure during dynamic service.

[0004] Producing workpieces that meet required shape, dimensional, and surface quality through the machining of metal materials is a fundamental challenge facing the manufacturing industry. Improving the tools and methods for machining and strengthening metal materials is fundamental to the transformation and upgrading of the manufacturing industry. As an advanced surface treatment technology, material strengthening technology is of great significance for enhancing material fatigue resistance, hardness, wear resistance, and corrosion resistance. Existing methods for strengthening materials, such as laser shock peening, ultrasonic shock peening, shot peening, extrusion, and rolling, all have drawbacks and are unable to meet the demand for strengthening aviation materials. In particular, existing technologies are unable to effectively strengthen the tips of aircraft blades. Summary of the Invention

[0005] The present application provides a metal processing tool with multiple protrusions, which includes the following embodiments:

[0006] Embodiment 1. A rotary processing tool for strengthening metal materials, comprising a working portion and an optional connecting portion for direct or indirect connection with a machine tool, characterized in that:

[0007] There are multiple protrusions on the working part, and the surface of the top of the protrusion includes a convex arc surface or a combination of convex arc surfaces to form a processed arc surface. The height of the protrusion is greater than or equal to 0.05 mm and less than or equal to 3 mm, and the number of the protrusions is between 5 and 20,000.

[0008] Embodiment 2. The rotary processing tool according to embodiment 1 is characterized in that the working part has a rotation axis, the working part has a working surface, the multiple protrusions are formed on the working surface, and the working surface is axisymmetric or non-axisymmetric relative to the rotation axis.

[0009] Embodiment 3. The rotary processing tool according to embodiment 2 is characterized in that the protrusion is formed integrally on the working surface of the working portion, or is formed on the working surface of the working portion by welding.

[0010] Embodiment 4. The rotary processing tool according to embodiment 1 is characterized in that the height of the protrusion is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0011] Embodiment 5. The rotary processing tool according to embodiment 1 is characterized in that the convex arc surface is selected from a circular arc surface, a cylindrical surface, an elliptical cylindrical surface, an ellipsoidal surface, a conical surface or a combination thereof.

[0012] Embodiment 6. The rotary processing tool according to embodiment 1 is characterized in that at least the protrusions are independently made of the following materials: cemented carbide, ceramic, cubic boron nitride (CBN), polycrystalline diamond (PCD), and single crystal diamond.

[0013] Embodiment 7. The rotary processing tool according to embodiment 1 is characterized in that the curvature radius of the convex arc surface is greater than or equal to 0.03 mm,

[0014] Furthermore, the curvature radius of the convex arc surface is less than or equal to 3 mm.

[0015] Embodiment 8. The rotary processing tool according to embodiment 7 is characterized in that the curvature radius of the convex arc surface is greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0016] Embodiment 9. The rotary processing tool according to embodiment 1 is characterized in that the edge of the surface of the top of the protrusion is a convex arc surface or a combination of convex arc surfaces.

[0017] Embodiment 10. The rotary processing tool according to embodiment 2 is characterized in that the shape of the working surface is selected from the circumferential surface formed by the cutting edge of various metal cutting tools during rotation.

[0018] Embodiment 11. The rotary processing tool according to embodiment 2 is characterized in that the diameter of the rotary processing tool is 2 mm to 250 mm, for example, 3 mm to 200 mm, for example, 5 mm to 50 mm, for example, 8 mm to 40 mm, 10 mm to 30 mm.

[0019] Embodiment 12. The rotary processing tool according to Embodiment 2 is characterized in that the height of the protrusion is 1% to 10% of the diameter of the rotary processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is 1% to 10% of the diameter of the rotary processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm.

[0020] Embodiment 13. The rotary processing tool according to embodiment 1 is characterized in that the roughness Ra of the processed arc surface is less than or equal to 0.3 μm.

[0021] Embodiment 14. A method for preparing the rotary machining tool of any one of embodiments 1 to 13, comprising the steps of:

[0022] Outer contour processing step: processing the outer contour of the working part and the optional connecting part on the raw material according to the shape of the rotating processing tool;

[0023] The convexity processing step is to form the convexity on the working part.

[0024] Embodiment 15. The method according to embodiment 14 is characterized in that the protrusion processing is performed using a femtosecond pulse laser processing method, and the protrusion is formed by removing excess material.

[0025] Embodiment 16. A method for machining a metal workpiece having a Rockwell hardness lower than HRC 40 using the rotary machining tool according to any one of Embodiments 1 to 13, characterized by comprising:

[0026] Micro-forging and extrusion processing steps: in a rotating state, the processing arc surface of the rotating processing tool is made to impact and extrude the surface to be processed of the metal workpiece.

[0027] Embodiment 17. The method described in Embodiment 16 is adopted, characterized in that before performing the micro-forging and extrusion processing, the metal workpiece is first cut using a metal cutting tool to obtain the surface to be processed.

[0028] Embodiment 18. The method according to embodiment 16 is characterized in that, in the micro-forging and extrusion processing step, the depth of the rotating processing tool entering the surface of the metal workpiece at a time is between 10 microns and 100 microns, and does not exceed the height of the convex arc surface.

[0029] Embodiment 19. The method according to embodiment 16 is characterized in that the micro-forging extrusion processing step is repeated multiple times to achieve an extrusion depth of between 40 microns and 500 microns on the surface of the metal workpiece.

[0030] The metal processing tool disclosed in this application, the micro-forging extrusion head, is innovative in that it has a unique structure of arranging multiple tiny protrusions (such as spheres with a diameter range of 0.1-2 mm) on the surface of the working part. With the help of the rotation of the machine tool spindle, these tiny protrusions can accurately impact the material, and the processing depth can reach 0.1 mm each time. It can completely replace traditional milling finishing and achieve deep extrusion inside the material, thereby significantly improving the material's fatigue resistance, corrosion resistance and wear resistance. In terms of strengthening the material of thin-walled parts, through multi-layer or layered strengthening processes, the metal processing tool of this application can effectively strengthen thinner workpieces, significantly reduce product deformation, and ensure processing quality. This method not only improves the precision of the product, but also achieves deeper strengthening, further improving the overall performance of the product.

[0031] Furthermore, the micro-forging extrusion head of this application demonstrates excellent control during the processing process, effectively balancing pressure and rebound force, thereby achieving higher product precision and reinforcement depth. This process feature ensures that the processed products have better mechanical properties and longer service life.

[0032] More importantly, by ensuring continuity in the processing direction, the micro-forging extrusion process in this application can achieve continuity in the metal's internal crystal structure, thereby improving the material's fatigue resistance and significantly reducing the risk of cracks. This advantage enables the product to maintain stable performance under high-stress and high-fatigue conditions, demonstrating extremely high reliability and durability.

[0033] What is more worth mentioning is that the metal processing tools and methods of this application can achieve ultra-high sound frequency strengthening processing without relying on ultrasonic machine tools and ultrasonic auxiliary equipment. This product not only achieves impact strengthening of the workpiece material, but also greatly improves the surface finish of the processed product. This feature greatly improves the flexibility and convenience of the processing process, reduces processing costs and equipment requirements. In addition, this metal processing tool integrates milling, grinding, and forging functions, fully meeting the various needs of metal material finishing, grinding, and strengthening processing, and is undoubtedly a major innovation in the field of metal material processing.

[0034] The present application also provides a metal processing tool with multiple protrusions, which includes the following solutions:

[0035] Solution 1. A metalworking tool comprising a working portion and an optional connecting portion for direct or indirect connection with a machine tool, characterized in that:

[0036] The working portion is provided with a plurality of protrusions, and the surfaces of the tops of the protrusions include a convex arc surface or a combination of convex arc surfaces, thereby forming a processed arc surface, wherein the number of the protrusions is between 5 and 20,000.

[0037] Solution 2. The metal processing tool according to Solution 1 is characterized in that the working part has a rotation axis, the working part has a working surface, the multiple protrusions are formed on the working surface, and the working surface is axisymmetric or non-axisymmetric relative to the rotation axis.

[0038] Solution 3. The metal processing tool according to Solution 2 is characterized in that the protrusion is formed integrally on the working surface of the working part, or is formed on the working surface of the working part by welding.

[0039] Solution 4. The metal processing tool according to Solution 1 is characterized in that the height of the protrusion is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0040] Solution 5. The metal processing tool according to Solution 1 is characterized in that the convex arc surface is selected from a circular arc surface, a cylindrical surface, an elliptical cylindrical surface, an ellipsoidal surface, a conical surface or a combination thereof.

[0041] Solution 6. The metal processing tool according to Solution 1 is characterized in that at least the protrusions are independently made of the following materials: cemented carbide, ceramic, cubic boron nitride (CBN), polycrystalline diamond (PCD), and single crystal diamond.

[0042] Solution 7. The metal processing tool according to Solution 1 is characterized in that the curvature radius of the convex arc surface is greater than or equal to 0.03 mm.

[0043] Furthermore, the curvature radius of the convex arc surface is less than or equal to 3 mm.

[0044] Solution 8. The metal processing tool according to Solution 7 is characterized in that the curvature radius of the convex arc surface is greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0045] Solution 9. The metal processing tool according to Solution 1 is characterized in that the edge of the surface of the top of the protrusion is a convex arc surface or a combination of convex arc surfaces.

[0046] Solution 10. The metal processing tool according to Solution 2 is characterized in that the shape of the working surface is selected from the circumferential surface formed by the cutting edge of various metal cutting tools during rotation.

[0047] Solution 11. The metal processing tool according to Solution 2 is characterized in that the diameter of the metal processing tool is 2 mm to 250 mm, for example, 3 mm to 200 mm, for example, 5 mm to 50 mm, for example, 8 mm to 40 mm, 10 mm to 30 mm.

[0048] Solution 12. The metal processing tool according to Solution 2 is characterized in that the height of the protrusion is 1% to 10% of the diameter of the metal processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is 1% to 10% of the diameter of the metal processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm.

[0049] Solution 13. The metal processing tool according to Solution 1 is characterized in that the roughness Ra of the processed arc surface is less than or equal to 0.3 μm.

[0050] Solution 14. A method for preparing the metalworking tool according to any one of Solutions 1 to 13, comprising the following steps:

[0051] Outer contour processing step: processing the outer contour of the working part and the optional connecting part on the raw material according to the shape of the metal processing tool;

[0052] The convexity processing step is to form the convexity on the working part.

[0053] Solution 15. The method according to Solution 14 is characterized in that the protrusion processing is carried out by a femtosecond pulse laser processing method, and the protrusion is formed by removing excess material.

[0054] Solution 16. A method for processing a metal workpiece using a metal processing tool according to any one of Solutions 1 to 13, characterized in that it comprises:

[0055] Micro-forging and extrusion processing steps: in a rotating state, the processing arc surface of the metal processing tool is made to impact and extrude the surface to be processed of the metal workpiece.

[0056] Solution 17. The method described in Solution 16 is characterized in that before performing the micro-forging and extrusion processing, the metal workpiece is first cut using a metal cutting tool to obtain the surface to be processed. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] In order to more clearly illustrate the technical solutions of the embodiments of the present disclosure, the drawings of the embodiments will be briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present disclosure, rather than limiting the present disclosure.

[0058] Figure 1 This is a front view of the rotary processing tool of Example 1;

[0059] Figure 2 Schematic diagram of the working part of the rotary processing tool in Example 1;

[0060] Figure 3 It is a right side view of the rotary processing tool of Example 1;

[0061] Figure 4 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 1;

[0062] Figure 5 This is a front view of the rotary processing tool of Example 2;

[0063] Figure 6 It is a right side view of the rotary processing tool of Example 2;

[0064] Figure 7 Schematic diagram of the working part of the rotary processing tool in Example 2;

[0065] Figure 8 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 2;

[0066] Figure 9 This is a schematic diagram of the overall structure of the rotary processing tool in Example 3;

[0067] Figure 10 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 3;

[0068] Figure 11 This is a front view of the rotary processing tool of Example 4;

[0069] Figure 12 A top view of the rotary processing tool of Example 4;

[0070] Figure 13 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 4;

[0071] Figure 14This is a front view of the rotary processing tool of Example 5;

[0072] Figure 15 It is a right side view of the rotary processing tool of Example 5;

[0073] Figure 16 This is a partial schematic diagram of the working portion of the rotary processing tool of Example 5;

[0074] Figure 17 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 5;

[0075] Figure 18 This is a front view of the rotary processing tool of Example 6;

[0076] Figure 19 Schematic diagram of the working portion of the rotary processing tool of Example 6;

[0077] Figure 20 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 6;

[0078] Figure 21 This is a front view of the rotary processing tool of Example 7;

[0079] Figure 22 This is a bottom view of the rotary processing tool of Example 7;

[0080] Figure 23 Schematic diagram of the working portion of the rotary processing tool of Example 7;

[0081] Figure 24 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 7;

[0082] Figure 25 This is a front view of the rotary processing tool of Example 8;

[0083] Figure 26 Schematic diagram of the working portion of the rotary processing tool of Example 8;

[0084] Figure 27 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 8;

[0085] Figure 28 This is a front view of the rotary processing tool of Example 9;

[0086] Figure 29 Schematic diagram of the working portion of the rotary processing tool of Example 9;

[0087] Figure 30 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 9;

[0088] Figure 31 This is a front view of the rotary processing tool of Example 10;

[0089] Figure 32 Schematic diagram of the working portion of the rotary processing tool according to Example 10;

[0090] Figure 33 This is a partial schematic diagram of a protrusion provided on the working surface of a rotary processing tool in Example 10;

[0091] Figure 34 This is a schematic diagram showing that the edge of the top surface is a convex arc surface.

[0092] Description of the drawings: 100-working part, 200-connecting part, 110-working surface, 10-protrusion, 11-convex arc surface. DETAILED DESCRIPTION

[0093] To make the purpose, technical solutions, and advantages of the embodiments of the present disclosure more clear, the technical solutions of the embodiments of the present disclosure will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present disclosure. Obviously, the described embodiments are part of the embodiments of the present disclosure, not all of the embodiments. Based on the described embodiments of the present disclosure, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present disclosure.

[0094] The present application discloses a rotary processing tool for strengthening metal materials, which includes a working part and an optional connecting part for directly or indirectly connecting to a machine tool, and is characterized in that the working part has multiple protrusions, and the surface of the top of the protrusion includes a convex arc surface or a combination of convex arc surfaces, thereby forming a processing arc surface, and the height of the protrusion is greater than or equal to 0.05 mm and less than or equal to 3 mm.

[0095] In the present application, the top of the protrusion refers to the area where the protrusion is squeezed with the surface of the workpiece to be processed during processing. The present application defines that this area includes an area of convex arc surface or a combination of convex arc surfaces. The area of the convex arc surface or the combination of convex arc surfaces at the top includes arc transition surfaces between planes, between arc surfaces, and between planes and arc surfaces that constitute the surface of the protrusion. Therefore, multiple processing arc surfaces can be formed by multiple tops of the area with the convex arc surface or the combination of convex arc surfaces, and the forging and extrusion processing of the workpiece can be completed by the multiple processing arc surfaces.

[0096] The rotary machining tool disclosed in this application cleverly utilizes multiple machining arcs formed by multiple protrusions. Driven by the rotation of the machine tool spindle, it can process materials through impact and extrusion, thereby achieving impact strengthening and nano-crushing of the material. This innovative design not only greatly enhances the material's fatigue resistance, but also significantly improves its corrosion and wear resistance.

[0097] The "forging and extrusion processing", "forging and extrusion process" or "micro-forging and extrusion processing" and "micro-forging and extrusion process" mentioned in this application have the same meaning, which refers to the process in which the multiple processing arc surfaces complete the processing of the workpiece surface to be processed. For example, the working part is connected to the machine tool through the connecting part, and the machine tool drives the working part to rotate through the connecting part and brings the working part close to the surface to be processed, so that the top of the protrusion contacts the workpiece surface to be processed as the working part rotates and generates a force. By locally impacting and extruding the surface to be processed, the microstructure of the surface to be processed is improved. These tiny protrusions can accurately impact the material, and the processing depth can reach 0.1 mm each time, which can completely replace traditional milling finishing. At the same time, deep extrusion is achieved inside the material, thereby significantly improving the material's fatigue resistance, corrosion resistance and wear resistance. In terms of strengthening the material of thin-walled parts, the material strengthening effect is achieved through a multi-layer or layered strengthening process. The metal processing tool of this application can effectively strengthen thinner workpieces, significantly reduce product deformation, and ensure processing quality. This method not only improves the precision of the product, but also achieves deeper strengthening, further improving the overall performance of the product.

[0098] The rotary processing tool (ie, metal processing tool) described in this application may also be referred to as a micro-forging extrusion head.

[0099] The present application has no specific restrictions on the shape of the protrusion, as long as it has a top including a convex arc surface or a combination of convex arc surfaces, so that the forging and extrusion processing of the tool can be completed through multiple processed arc surfaces. The forging and extrusion processing method of the processed arc surface can replace grinding, milling, cutting finishing, and forging, and can be widely used in the processing of planes, grooves and various types of forming grooves, inner holes, chamfers and arc chamfers, curved surfaces, cavities, etc.

[0100] The rotary machining tool of this application can completely replace traditional milling finishing. Using this rotary machining tool, replacing traditional milling finishing with a forging and extrusion process, can solve problems such as low efficiency and poor product finish during milling finishing. This innovative technology not only improves finishing efficiency and produces higher-quality products, but also solves the process challenges of difficult-to-mill materials. Specifically, the rotary machining tool and method of this application can achieve the following advantages: 1. Improved tool life: Due to the material properties of nickel-based alloys and titanium alloys, the elastic deformation and poor thermal conductivity of micro-forging extrusion heads have little impact on them, resulting in a micro-forging extrusion head that lasts 10 to 20 times longer than traditional milling tools. 2. Improved product quality: Using a micro-forging extrusion head not only increases processing speed but also achieves higher surface quality. 3. Improved processing efficiency: Due to the material properties of nickel-based alloys and titanium alloys, conventional milling cutters can only reach a linear speed of 40 meters, resulting in relatively low processing efficiency. However, micro-forging extrusion heads can achieve a linear speed of 200 meters, increasing processing efficiency by more than 5 times.

[0101] Compared with the grinding process in the prior art, the rotary processing tools and methods of the present application can obtain the following advantages: 1. Improvement of product surface quality: The micro-forging extrusion head can achieve excellent surface roughness of the product, that is, high surface finish. Compared with the grinding process, the operation is easier. 2. Advantages in processing special-shaped workpieces: Traditional grinding is usually difficult to process special-shaped workpieces because grinding requires grinding wheels of specific shapes and sizes. The forging process is not limited by the shape of the workpiece and can be applied to various special-shaped workpieces and can be processed accurately. 3. Solution to the finish problem: Problems such as low surface finish of the product, burns and grinding marks that may occur during the grinding process can be solved by the forging process. This method does not introduce these common defects and ensures the high quality of the workpiece surface. 4. Improvement of production efficiency: The forging process is usually more efficient than grinding. It reduces the need for multiple processes and saves time and resources. This helps to improve production efficiency and reduce manufacturing costs.

[0102] The present application does not impose any specific restriction on the number of the protrusions, and those skilled in the art may reasonably set them according to processing requirements, for example, according to the contact and extrusion state between the processing tool and the surface to be processed during processing. For example, when the multiple processing arc surfaces of the processing tool are in line contact or point contact with the surface to be processed, more protrusions may be set (for example, hundreds, thousands, or tens of thousands of protrusions); when the multiple processing arc surfaces of the processing tool are in surface contact with the surface to be processed, fewer protrusions may be set, for example, several or dozens of protrusions.

[0103] This application uses multiple tiny bumps on the working part, with the help of the machine tool spindle rotation, to achieve the material strengthening effect. Through the CNC machine tool program, the impact strengthening depth can be precisely controlled, and all processed surfaces can be strengthened. Laser shock peening, ultrasonic peening, and shot peening in the existing technology all achieve surface strengthening through high-frequency impact. This causes the impact force to spread around the impacted surface, resulting in discontinuous crystal structure. However, this application can change the direction of the crystal structure by using the CNC machine tool feed direction and the spindle angle with the processed surface, thereby making the reinforced material longer-lasting and more impact-resistant. The advantages of using the micro-forging extrusion head of this application to achieve material strengthening include: 1. Precise control: The forging method can achieve precise control of the strengthening area, strength, and overlap rate, providing higher customization and being suitable for a variety of complex and special-shaped workpieces. 2. Extremely high product surface finish: Compared with other methods, forging strengthening does not introduce additional surface defects, thus strengthening the material while maintaining surface finish. 3. High efficiency: The forging process is highly efficient and can significantly improve processing speed and production efficiency. 4. Wide application: Forging and extrusion head technology is not only suitable for flat surfaces, but can also process complex and special-shaped workpieces to meet different needs. 5. Improve material strength and durability: Pressure = pressure * pressure area. The greater the pressure, the greater the rebound force. The micro-forging extrusion processing surface of this application can achieve multi-layer strengthening processing to reduce the rebound force of the material caused by excessive pressure. At the same time, the multi-layer strengthening process can achieve strengthening processing for relatively thin products, reduce product deformation, and improve product accuracy and strengthening depth. 6. Reduce the risk of material fatigue and cracks: Through the continuity of the processing direction, the continuity of the crystal structure of the internal structure of the metal can be achieved. Thereby improving the fatigue strength of the material and reducing the occurrence of cracks.

[0104] By setting up multiple processing arc surfaces, this application can achieve ultrasonic machining and ultrasonic strengthening without the assistance of ultrasonic equipment. Assuming the ultrasonic equipment oscillation frequency is 50,000 times per second, 3 million local impacts on the machined surface can be completed per minute. By setting up multiple protrusions, this application can achieve higher-frequency local impact and extrusion. For example, for the same surface to be machined, if the working surface of the working part of the processing tool of this application is provided with 6,000 protrusions and has 6,000 processing arc surfaces, when the processing tool processes the same surface to be machined at a speed of 5,000 revolutions per minute, 30 million local impacts on the machined surface can be completed per minute, thereby achieving ultrasonic strengthening processing without the assistance of ultrasonic equipment. On non-ferrous metal materials, it can even reach more than 100 million times per minute. During ultra-high-frequency processing, thin blade walls can be processed without easily causing workpiece deformation. The metal processing tool and method of this application can achieve ultra-high-frequency strengthening processing without relying on ultrasonic machine tools and ultrasonic auxiliary equipment. This product not only impact-hardens the workpiece material but also significantly improves the surface finish of the processed product. This feature significantly enhances the flexibility and convenience of the processing process, reducing processing costs and equipment requirements. Furthermore, this metalworking tool integrates milling, grinding, and forging functions, fully meeting the various needs of metal finishing, grinding, and strengthening, undoubtedly a major innovation in the field of metalworking.

[0105] The rotary processing tool described in this application can be used to achieve material strengthening through a micro-forging extrusion process. It is suitable for strengthening the curved surfaces and cavity side walls of various types of metal materials, such as: planes, inner holes, chamfers, forming grooves, mold surfaces, etc., and is used in the processing of molds, aircraft blades, aircraft blade discs, casings, aircraft landing gear, aircraft titanium alloys, aluminum alloy structural parts, new energy vehicle motors and battery housings, fixtures, hydraulic valve bodies, medical bone plates, gears, etc.

[0106] This technology is particularly suitable for strengthening aviation materials, thereby improving aircraft safety and economic performance. Its significance lies in: 1. Improving material strength and durability: Aviation components often need to withstand extreme environmental conditions such as high temperature, high pressure, and high speed, requiring materials with high strength and durability to meet these challenges; 2. Reducing the risk of material fatigue and cracking: Aircraft undergo repeated stress cycles during operation, which can easily lead to fatigue and cracking. Strengthening can improve the material's fatigue resistance and extend the life of components; 3. Reducing structural weight: Strengthened materials can generally be lighter while maintaining the same strength requirements, thereby reducing the overall weight of the aircraft. This helps improve fuel efficiency and flight performance, and reduces fuel consumption. 4. Enhancing corrosion and oxidation resistance: Aircraft components are frequently exposed to harsh weather conditions such as humidity and salt spray. Strengthened materials generally have better corrosion and oxidation resistance, extending the service life of components. 5. Improving overall performance: Strengthening aviation components can improve their overall performance, including higher stiffness, better thermal conductivity, and lower thermal expansion coefficient, all of which contribute to improved aircraft flight performance and controllability.

[0107] In some embodiments, the height of the convex curved surface or the combination of convex curved surfaces accounts for more than one-third, or more than two-fifths, of the height of the protrusion. Typically, during metal processing, only a portion of the protrusion enters the workpiece surface for forging and extruding. Therefore, the convex curved surface, as a processing surface, only needs to account for a portion of the height of the protrusion.

[0108] In some embodiments, the working portion has a rotation axis, the working portion has a working surface, the plurality of protrusions are formed on the working surface, and the working surface is axisymmetric or non-axisymmetric relative to the rotation axis.

[0109] In some embodiments, the protrusion is integrally formed on the working surface of the working portion, or is formed on the working surface of the working portion by welding.

[0110] In some embodiments, the height of the protrusion is greater than or equal to 0.08 mm and less than or equal to 0.5 mm, and the radius of curvature of the convex arc surface is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0111] In some embodiments, the protrusion is a portion of a sphere, and the diameter of the sphere is in the range of 0.1-2 mm.

[0112] The term "radius of curvature of a convex surface" in this application refers to the minimum value of the radius of curvature of the curve intercepted by the plane passing through the normal line at the vertex of the convex surface. That is, there are multiple planes passing through the normal line of the vertex of the convex surface, and these planes each cut a curve on the convex surface, and there is a radius of curvature at the vertex. The minimum value of these radii of curvature is the radius of curvature of the convex surface. The vertex of the convex surface can refer to any point on the convex surface, usually referring to the point that first contacts the workpiece during processing.

[0113] In some embodiments, the convex arc surface is selected from a circular arc surface, a cylindrical surface, an elliptical cylinder surface, an ellipsoid surface, a conical surface or a combination thereof. The convex arc surface can be a hemispherical surface, a hemispherical cylinder surface with a quarter sphere at both ends, or a half-teardrop surface. In some embodiments, the entire raised surface is composed of convex arc surfaces, such as a hemispherical surface, a hemispherical cylinder surface with a partial sphere at both ends, or a half-teardrop surface. The orientation of the half-teardrop surface and the half-cylindrical surface described in the present application on the rotary processing tool is not particularly limited. In some embodiments, the half-teardrop surface includes a combination of a quarter ellipsoidal surface and a quarter hemispherical surface, so that one side of the quarter ellipsoidal surface is longer and one side of the quarter hemispherical surface is shorter, forming a teardrop shape. Optionally, the quarter ellipsoidal surface of the half-teardrop surface is oriented forward and the quarter hemispherical surface is oriented backward, so that when the rotary processing tool is in a rotary processing state, the quarter ellipsoidal surface first contacts the workpiece to be processed.

[0114] The hardness of the rotary processing tool used to make the present application should generally be higher than the hardness of the workpiece to be processed. In some embodiments, at least the protrusions are each independently made of the following materials: cemented carbide, ceramic, cubic boron nitride (CBN), polycrystalline diamond (PCD), single crystal diamond. These materials have excellent hardness and are particularly suitable for making the rotary processing tool described in the present application. The rotary processing tool of the present application is mainly used to contact with the workpiece in a rotating state to achieve the effect of forging and extrusion processing. Therefore, the hardness of the material of the rotary processing tool is an important indicator. Generally, the hardness of the rotary processing tool can be greater than or equal to 55HRC, or even greater than or equal to 60HRC.

[0115] In some embodiments, the curvature radius of the convex arc surface is greater than or equal to 0.03 mm.

[0116] In some embodiments, the curvature radius of the convex arc surface is less than or equal to 3 mm.

[0117] In some embodiments, the radius of curvature of the convex arc surface is greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

[0118] In some embodiments, the edge of the surface of the top of the protrusion is a convex curved surface or a combination of convex curved surfaces. That is, the processed curved surface can be located at the edge of the surface of the top of the protrusion, as long as the edge is a convex curved surface or a combination of convex curved surfaces. For example, Figure 34 In the embodiment, the surface of the top of the protrusion includes a plane, and the edge of the plane of the top surface is a convex arc surface. During the forging process, the convex arc surface at the edge first contacts and extrude the surface of the workpiece to be processed, thereby completing the forging process.

[0119] In some embodiments, the shape of the working surface is selected from the circumferential surface formed by the cutting edge of various metal cutting tools during rotation.

[0120] In some embodiments, the diameter of the rotary machining tool is 2 mm to 250 mm, such as 3 mm to 200 mm, such as 5 mm to 50 mm, such as 8 mm to 40 mm, 10 mm to 30 mm.

[0121] In some embodiments, the height of the protrusion is 1% to 10% of the diameter of the rotating processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is 1% to 10% of the diameter of the rotating processing tool, and is greater than or equal to 0.05 mm to less than or equal to 3 mm, or greater than or equal to 0.08 mm to less than or equal to 0.5 mm.

[0122] In some embodiments, the number of protrusions is such that the rated rotational speed of the rotary tool in revolutions per second (e.g., 50 rpm, 100 rpm) multiplied by the number of protrusions is greater than or equal to 20,000, greater than or equal to 200,000, or greater than or equal to 2,000,000. That is, the protrusions on the rotary tool process the surface to be processed at a frequency of greater than or equal to 20,000 times per second, greater than or equal to 200,000 times per second, or greater than or equal to 2,000,000 times per second, thereby achieving ultrasonic enhanced processing. The present application does not specifically limit the number of the protrusions. Those skilled in the art can reasonably set it according to processing conditions and requirements. For example, the number of protrusions can be less than or equal to 10,000, less than or equal to 8,000, less than or equal to 5,000, less than or equal to 500, less than or equal to 300, less than or equal to 100, less than or equal to 50, less than or equal to 10. For example, the number of protrusions can also be greater than or equal to 500, greater than or equal to 1,000, greater than or equal to 3,000, greater than or equal to 5,000, greater than or equal to 8,000, or even greater than or equal to 10,000.

[0123] In some embodiments, the roughness Ra of the processed arc surface is less than or equal to 0.3 μm.

[0124] The present application also discloses a method for preparing the rotary processing tool, which comprises the following steps:

[0125] Outer contour processing step: processing the outer contour of the working part and the optional connecting part on the raw material according to the shape of the rotating processing tool;

[0126] The convexity processing step is to form the convexity on the working part.

[0127] In the present application, there is no particular limitation on the processing steps of the protrusions. The protrusions may be formed by removing excess material or by adding material.

[0128] In some embodiments, the protrusion processing step is performed using a femtosecond pulse laser processing method to form the protrusion by removing excess material.

[0129] The present application also discloses a method for machining a metal workpiece having a Rockwell hardness lower than HRC 40 using the rotary machining tool, which is characterized by comprising:

[0130] Micro-forging extrusion processing step: in a rotating state, the processing arc surface of the rotating processing tool is made to impact and extrude the surface to be processed of the metal workpiece. The rotating state mentioned here means that the rotating processing tool is in a rotating state capable of mechanical processing. There is no special restriction on the specific rotating state. Those skilled in the art can adjust the linear speed of rotation according to actual needs, such as the material of the tool, the material of the workpiece, the required processing efficiency, etc. The linear speed of rotation can generally be between 10 m / s and 200 m / s, such as 40 m / s to 100 m / s, such as 60 m / s to 80 m / s. This speed refers to the linear speed of the outermost edge of the rotating processing tool. The speed of the rotating processing tool can also be described by the rotational speed, for example, the rotational speed is 1000 rpm to 10,000 rpm, such as 3000 rpm to 7000 rpm, such as 4000 rpm to 6000 rpm. Those skilled in the art can make a selection according to actual needs.

[0131] In some embodiments, the metal processing method includes using a metal cutting tool to perform cutting processing on the metal workpiece to obtain a surface to be processed before performing the micro-forging and extrusion processing.

[0132] In some embodiments, in the micro-forging and extrusion processing step, the depth to which the rotary processing tool enters the surface of the metal workpiece at a time is between 10 microns and 100 microns, and does not exceed the height of the convex arc surface. By processing the arc surface to enter the workpiece surface and extrude the workpiece surface, the depth to which the processing surface enters the surface of the metal workpiece is the extrusion thickness. This processing method can achieve the strengthening of the material surface, and is particularly suitable for strengthening thinner product workpieces such as aircraft blades, significantly reducing product deformation, and ensuring processing quality. In the existing technical system, various methods are unable to effectively strengthen the tip part of aircraft blades. The micro-forging and extrusion process of this application cleverly breaks through this technical bottleneck and provides an excellent strengthening effect for the tip part of aircraft blades.

[0133] The micro-forging extrusion process of this application has excellent processing effects, with characteristics such as large strengthening layer thickness, high strain rate and no heat-affected zone. In addition, the technical process is flexible and controllable, with a wide range of applications, adjustable process parameters, and a high degree of automation. More importantly, the material impact strengthening technology has the characteristics of environmental protection and energy saving, low energy consumption and no pollution. Therefore, this technology has been widely used in many fields such as aerospace, rail transportation, automobile manufacturing, electric power and energy, providing an effective means to improve the performance and service life of key components.

[0134] In some embodiments, the micro-forging extrusion process is repeated multiple times to achieve an extrusion depth of 40 to 500 microns on the surface of the metal workpiece. That is, the present application achieves a material strengthening effect through a multi-layer or layered strengthening process, which can increase the material density and strength in the area between 40 and 500 microns, effectively strengthening the workpiece, significantly reducing the deformation of thinner workpieces, improving the material's corrosion resistance, fatigue strength, and hardness, and ensuring processing quality. This method not only improves the precision of the product, but also achieves deeper strengthening, further improving the overall performance of the product.

[0135] The micro-forging extrusion head of the present application demonstrates excellent control capabilities during the processing process, and can effectively balance pressure and rebound force during the forging process, thereby achieving higher product precision and strengthening depth. This process feature enables the processed products to have more excellent mechanical properties and longer service life. More importantly, through the continuity of the processing direction, the micro-forging extrusion process of the present application can achieve the continuity of the crystallization of the internal structure of the metal, thereby improving the fatigue strength of the material and significantly reducing the risk of cracks. This advantage enables the product to maintain stable performance under high stress and high fatigue conditions, demonstrating extremely high reliability and durability.

[0136] As an innovative metal processing method, the micro-forging extrusion process cleverly achieves an organic combination of the three forging methods of cold forging, warm forging and hot forging by controlling the processing temperature. When processing metal materials, these three forging methods each show unique effects and application values. By comprehensively utilizing the characteristics of these three forging processes, the plasticity, hardness and toughness of the material can be effectively improved. Specifically, by staggered application of cold forging, warm forging and hot forging processes, the crystal structure of the material can be rearranged and organized, thereby significantly improving its performance. This process can achieve grain refinement, reduce defects at grain boundaries, and further improve the strength and toughness of the material, bringing new breakthroughs and progress to the field of metal material processing. This method is particularly suitable for processing metal materials with a hardness of 20HRC-40HRC, such as titanium alloys, nickel-based alloys, etc.

[0137] The rotary machining tool of this application can completely replace grinding and milling, two traditional methods of material removal, effectively resolving the problem of low finish quality while significantly improving machining efficiency, tool life, and production efficiency. It is also widely applicable to workpieces of various special shapes. Furthermore, the rotary machining tool and metalworking method of this application offer outstanding performance and flexibility in the field of aerospace material strengthening, effectively overcoming the limitations of traditional material strengthening methods and bringing new opportunities and solutions to the development of the aviation industry.

[0138] The above ranges can be used alone or in combination. The present application can be more easily understood through the following examples.

[0139] Example

[0140] Example 1

[0141] like Figures 1 to 4 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is an inner R micro-forging extrusion head, comprising a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, which is a concave arc surface with an inner R angle. The working portion 100 has a rotation axis, and the working surface is axisymmetric relative to the rotation axis. It is characterized in that a plurality of protrusions 10 are provided on the working surface 110, and the surface of the top of the protrusion includes a convex arc surface 11, which is a circular arc surface, thereby forming a plurality of processing arc surfaces. The protrusions are integrally formed on the working surface.

[0142] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the connecting part 200) is 20 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 3,000.

[0143] This rotary machining tool is used to machine the side edges of metal workpieces, or to chamfer the sides of metal workpieces. During machining, the working surface 110 of the working portion approaches the side edge of the workpiece, causing the convex curved surface 11 at the top of the protrusion to contact the side edge of the workpiece as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the side edge of the workpiece, the metal material is strengthened.

[0144] Example 2

[0145] like Figures 5 to 8 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is an inner hole chamfering micro-forging extrusion tool, which includes a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has two working surfaces 110, and the working portion 100 has a rotation axis. The working surfaces are axisymmetric relative to the rotation axis. It is characterized in that a plurality of protrusions 10 are provided on the working surface 110, and the surface of the top of the protrusion includes a convex arc surface 11, and the convex arc surface 11 is a circular arc surface, thereby forming a plurality of processing arc surfaces. The protrusions are integrally formed on the working surface.

[0146] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the connecting part 200) is 20 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 800.

[0147] This rotary machining tool is used for machining inner holes and chamfering inner holes in metals. During machining, the working surface 110 of the working portion approaches the surface to be machined, so that the convex curved surface 11 at the top of the protrusion contacts the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0148] Example 3

[0149] like Figures 9 and 10 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is an internal micro-forging extrusion tool, comprising a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, which is a cylindrical surface. It is characterized in that the working surface 110 has multiple protrusions 10, and the surface of the top of the protrusion includes a convex arc surface 11, which is a circular arc surface, thereby forming multiple processing arc surfaces. The protrusions are integrally formed on the working surface.

[0150] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the working part 100) is 20 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 40.

[0151] This rotary machining tool is used for machining inner holes and sidewalls of metal materials. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex curved surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0152] Example 4

[0153] like Figures 11 to 13 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a disc-type micro-forging extrusion disc, comprising a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, characterized in that the working surface 110 has a plurality of protrusions 10, the top surface of each protrusion including a convex arc surface 11, and the convex arc surface 11 is a circular arc surface, thereby forming a plurality of processing arc surfaces. The protrusions are integrally formed on the working surface.

[0154] The working part is made of cemented carbide, the diameter of the rotary processing tool is 250 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 10,000.

[0155] This rotary machining tool is used for machining metal gears and forming grooves. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex arc surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining arc surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0156] Example 5

[0157] like Figures 14 to 17As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a Christmas tree forming micro-forging extrusion head. It includes a working part 100 and a connecting part 200 for connecting to a machine tool. The working part has three teeth. The working part 100 has a working surface 110. It is characterized in that the working surface 110 has multiple protrusions 10. The surface of the top of the protrusion includes a convex arc surface 11. The convex arc surface 11 is a circular arc surface, thereby forming multiple processing arc surfaces. The protrusions are integrally formed on the working surface.

[0158] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the connecting part 200) is 32 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 6,000.

[0159] This rotary machining tool is used for machining blisks, blades, and various grooves. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex curved surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface, the tool achieves enhanced machining of the metal material.

[0160] Example 6

[0161] like Figures 18 to 20 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a teardrop-shaped micro-forging extrusion head, comprising a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, characterized in that the working surface 110 has a plurality of protrusions 10, each of which is teardrop-shaped. The surface of the top of each protrusion includes a convex arc surface 11, which is a combination of a circular arc surface and an elliptical arc surface, thereby forming a plurality of processing arc surfaces. The protrusions are integrally formed on the working surface.

[0162] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the connecting part 200) is 12 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 800.

[0163] This rotary machining tool is used to machine the sidewalls and straight grooves of metal workpieces. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex curved surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0164] Example 7

[0165] like Figures 21 to 24 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is an external ball head micro-forging extrusion head, which includes a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, characterized in that the working surface 110 has a plurality of protrusions 10, and the surface of the top of the protrusion includes a convex arc surface 11, which is a circular arc surface, thereby forming multiple processing arc surfaces. The protrusions are integrally formed on the working surface.

[0166] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the working part 100) is 32 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 3,000.

[0167] This rotary machining tool is used for machining curved and contoured metal surfaces. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex curved surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0168] Example 8

[0169] like Figures 25 to 27 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a tapered micro-forging extrusion head. It includes a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110. It is characterized in that the working surface 110 has a plurality of protrusions 10. The top surface of the protrusions includes a convex arc surface 11. The convex arc surface 11 is a circular arc surface, thereby forming multiple processing arc surfaces. The protrusions are integrally formed on the working surface.

[0170] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the working part 100) is 20 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 1500.

[0171] This rotary machining tool is used for machining side chamfers and tapered holes. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex curved surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining curved surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. By locally impacting and squeezing the surface to be machined, the metal material is strengthened.

[0172] Example 9

[0173] like Figures 28 to 30 As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a dovetail groove forming micro-forging extrusion head, which includes a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, characterized in that the working surface 110 has a plurality of protrusions 10, and the surface of the top of the protrusion includes a convex arc surface 11, which is a circular arc surface, thereby forming multiple processing arc surfaces. The protrusions are integrally formed on the working surface.

[0174] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the working part 100) is 25 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 1000.

[0175] This rotary machining tool is used to machine dovetail grooves. During machining, the working surface 110 of the working portion approaches the surface to be machined. The machining arc of the rotary machining tool penetrates the metal workpiece surface to a depth of between 10 and 100 microns per time. As the working portion rotates, the convex arc 11 at the top of the protrusion contacts the workpiece surface to be machined, generating a force. This localized impact and compression of the machined surface completes the strengthening of the metal material.

[0176] Example 10

[0177] like Figures 31 to 33As shown, the present application provides a rotary processing tool for strengthening metal materials, which is a cylindrical micro-forging extrusion head, comprising a working portion 100 and a connecting portion 200 for connecting to a machine tool. The working portion 100 has a working surface 110, characterized in that the working surface 110 has a plurality of protrusions 10, the top surface of each protrusion comprising a convex arc surface 11, and the convex arc surface 11 is a combination of a cylindrical surface and a circular arc surface, thereby forming a plurality of processing arc surfaces. The protrusions are integrally formed on the working surface.

[0178] The working part is made of cemented carbide, the diameter of the rotary processing tool (ie, the diameter of the working part 100) is 20 mm, the height of the protrusion is 0.15 mm, the curvature radius of the convex arc surface is 0.15 mm, and the number of the protrusions is approximately 500.

[0179] This rotary machining tool is used for machining inner holes and sidewalls. During machining, the working surface 110 of the working portion approaches the surface to be machined, causing the convex arc surface 11 at the top of the protrusion to contact the workpiece surface as the working portion rotates, generating a force. The depth of the machining arc surface of the rotary machining tool penetrating the metal workpiece surface in a single pass is between 10 and 100 microns. Through the localized impact and compression of the machined surface, the metal material is strengthened.

[0180] The rotary tool in the above embodiment is manufactured using the following method: first, the outer contour of the working portion and the connecting portion are machined onto a cemented carbide stock rod according to the shape of the rotary tool; then, a femtosecond pulse laser machining method is used to remove excess material from the outer contour of the working portion to form the protrusion, completing the protrusion machining step. The cemented carbide stock rod is YG6 tungsten-cobalt (WC-Co) cemented carbide, and the femtosecond pulse laser machining method uses a precision CNC laser machine purchased from DMG Mori Seiki Co., Ltd. under the trade name LASERTEC 50Shape.

[0181] In addition, the applicant has made similar rotary machining tools using ceramics, cubic boron nitride (CBN), polycrystalline diamond (PCD), and single crystal diamond, all of which can be purchased on the market.

[0182] The micro-forging extrusion head of the present application was used to perform micro-forging extrusion and shot peening on aluminum alloy workpieces, titanium alloy workpieces, and nickel-based alloy workpiece samples, and the surface microhardness (HV) before and after processing was tested. The results are shown in the following table:

[0183] Surface microhardness (HV) Forging and extrusion Shot peening Unprocessed aluminum alloy 268 210 160 titanium alloy 470 336 315 Nickel-based alloys 458 344 297

[0184] As can be seen from the data in the table above, after forging and extrusion, the surface microhardness of the aluminum alloy and titanium alloy was significantly improved compared to the shot peening and untreated controls. The aluminum alloy after forging and extrusion had a 67% increase in microhardness, the titanium alloy had a 49% increase, and the nickel-based alloy had a 54% increase. Tests on the yield strength and tensile strength of the aluminum alloy workpieces showed that after forging and extrusion, the yield strength increased from 412MPa before processing to 544MPa, and the tensile strength increased from 495MPa before processing to 618MPa. The surface roughness Ra of the workpiece was reduced from 2μm before processing to approximately 0.8μm.

[0185] After the aluminum alloy workpiece was immersed in 3.5% Wt sodium chloride solution for 72 hours, the corrosion rate of the untreated aluminum alloy workpiece was measured to be about 1.8×10 -2 mm / y, the corrosion rate of shot peening aluminum alloy workpiece is about 3.2×10 -3 mm / y, the corrosion rate of aluminum alloy workpiece after forging and extrusion is about 1.8×10 -4 mm / y, it can be seen that the corrosion resistance of the material is significantly improved after forging and extrusion. In addition, the fatigue life of the workpiece is increased by more than 3 times after forging and extrusion.

[0186] The applicant has also discovered that similar metalworking tools made of ceramic, cubic boron nitride (CBN), polycrystalline diamond (PCD), and single-crystal diamond can achieve similar technical effects. It should be noted that in the example using single-crystal diamond, the applicant first fabricated a working portion of cemented carbide and then welded the single-crystal diamond onto the working portion to form the protrusions.

[0187] The foregoing description is merely an exemplary embodiment of the present disclosure and is not intended to limit the scope of protection of the present disclosure. The scope of protection of the present disclosure is determined by the appended claims.

Claims

1. A rotary processing tool for strengthening metal materials, comprising a working part and an optional connecting part for direct or indirect connection with a machine tool, characterized in that: The working portion has a plurality of protrusions, the top surface of the protrusions includes a convex arc surface or a combination of convex arc surfaces, thereby forming a processed arc surface, the height of the protrusions is greater than or equal to 0.05 mm and less than or equal to 3 mm, and the number of the protrusions is between 5 and 20,000.

2. The rotary processing tool according to claim 1, wherein The working portion has a rotation axis, and the working portion has a working surface. The plurality of protrusions are formed on the working surface, and the working surface is axisymmetric or non-axisymmetric relative to the rotation axis.

3. The rotary processing tool according to claim 2, characterized in that The protrusion is formed integrally on the working surface of the working part, or is formed on the working surface of the working part by welding.

4. The rotary processing tool according to claim 1, wherein The height of the protrusion is greater than or equal to 0.08 mm and less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

5. The rotary processing tool according to claim 1, wherein The convex arc surface is selected from a circular arc surface, a cylindrical surface, an elliptical cylindrical surface, an ellipsoidal surface, a conical surface or a combination thereof.

6. The rotary processing tool according to claim 1, wherein The plurality of protrusions are independently made of one of the following materials: cemented carbide, ceramic, cubic boron nitride (CBN), polycrystalline diamond (PCD), and single crystal diamond.

7. The rotary processing tool according to claim 1, wherein: The curvature radius of the convex arc surface is greater than or equal to 0.03 mm, and the curvature radius of the convex arc surface is less than or equal to 3 mm.

8. The rotary processing tool according to claim 7, wherein: The curvature radius of the convex arc surface is greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

9. The rotary processing tool according to claim 1, wherein The edge of the surface of the top of the protrusion is a convex arc surface or a combination of convex arc surfaces.

10. The rotary processing tool according to claim 2, wherein The shape of the working surface is selected from the peripheral surface formed by the cutting edge of a metal cutting tool during rotation.

11. The rotary processing tool according to claim 2, wherein: The diameter of the rotary processing tool is 2 mm to 250 mm.

12. The rotary processing tool according to claim 2, wherein: The height of the protrusion is 1% to 10% of the diameter of the rotating processing tool, and is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm, and the curvature radius of the convex arc surface is 1% to 10% of the diameter of the rotating processing tool, and is greater than or equal to 0.05 mm and less than or equal to 3 mm, or greater than or equal to 0.08 mm and less than or equal to 0.5 mm.

13. The rotary processing tool according to claim 1, wherein The roughness Ra of the processed arc surface is less than or equal to 0.3 μm.

14. The rotary processing tool according to claim 2, wherein The diameter of the rotating processing tool is 3 mm to 200 mm.

15. The rotary processing tool according to claim 2, wherein The diameter of the rotating processing tool is 5 mm to 50 mm.

16. The rotary processing tool according to claim 2, wherein: The diameter of the rotary processing tool is 8 mm to 40 mm.

17. The rotary processing tool according to claim 2, wherein: The diameter of the rotating processing tool is 10 mm to 30 mm.

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