High-feed blade and high-feed milling cutter
By designing high-feed inserts and controlling the main cutting edge angle between 0.5 and 5 degrees, combined with PCBN and alloy layers, the problem of high feed for milling cutters is solved, achieving efficient and high-precision machining results.
Patent Information
- Application Number
- CN202520086377.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-14
- Publication Date
- 2026-01-06
- Estimated Expiration
- 2035-01-14
AI Technical Summary
The large lead angle of existing milling cutters makes it difficult to achieve high feed rates, affecting machining efficiency and cutting tool life.
A high-feed insert is designed by precisely controlling the angle between the edge line and the circumscribed square formed by passing through the midpoint of the adjacent rounded edge to be between 0.5 and 5 degrees. By combining PCBN layer and alloy layer materials, the insert structure and installation method are optimized to ensure a small principal cutting edge angle and a sharp cutting edge, thereby enhancing wear resistance and stability.
It enables high-feed machining, improves machining efficiency and economy, extends tool life, and meets the demands of modern machining for high efficiency and high precision.
Smart Images
Figure CN223762224U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of milling cutter technology, and in particular to a high-feed insert and a high-feed milling cutter. Background Technology
[0002] Cutting is an important component of modern manufacturing, widely used in aerospace, automotive manufacturing, mold making, and other fields. With the development of industrial technology, the requirements for processing efficiency and precision are becoming increasingly stringent. As a key component in cutting, the performance of cutting tools directly affects processing quality and production efficiency.
[0003] In milling, the cutting edge of the milling cutter cuts the surface of the workpiece, and the reaction force of the workpiece on the cutter forms the cutting force. The angle between the cutting edge and the horizontal plane during the cutting process is the principal cutting edge angle. The smaller the principal cutting edge angle of the milling cutter, the more the radial cutting force will be distributed to the axial direction of the cutter shank, reducing the radial component of the cutter shank and improving the operational stability of small-diameter cutter shanks. At the same time, when using a milling cutter with a small principal cutting edge angle, thinner chips can be obtained through its chip thinning effect, and face milling can be performed with a very high feed per tooth. Although the depth of cut is less limited, the extremely high feed makes it a highly efficient milling method. Utility Model Content
[0004] This application provides a high-feed insert to solve the problem that the large principal cutting edge angle of current end mill inserts makes it difficult to achieve high-feed machining.
[0005] A high-feed insert, comprising:
[0006] The blade body has a positioning hole. The blade body has a rake face, a bottom positioning face, and four side faces. A main cutting edge and a rounded edge are provided between the rake face and each side face. The edge line where the bottom positioning face and the side face intersect on adjacent sides is perpendicular. The angle between the circumscribed square formed by the midpoints of two adjacent rounded edges and the edge line is α, and α is in the range of 0.5 degrees to 5 degrees.
[0007] By adopting the above technical solution, and by precisely controlling the angle (0.5 degrees - 5 degrees) between the edge line and the circumscribed square formed by passing through the midpoint of the adjacent rounded edge, the principal cutting edge angle is made smaller during the cutting process, resulting in thinner chips. At the same time, the cutting speed of the insert can be increased, enabling face milling with a very high feed per tooth, achieving high feed machining, and improving machining efficiency and economy. In addition, at the same depth of cut, the principal cutting edge is longer, which can effectively reduce the stress on the insert, reduce wear, and significantly extend the service life of the insert.
[0008] In one embodiment, each of the sides includes a flank face, a first positioning surface, and a rounded flank face, the main cutting edge is disposed between the rake face and the flank face, the rounded edge is disposed between the rake face and the rounded flank face, and the first positioning surface is disposed on the lower side of the flank face and the rounded flank face.
[0009] By adopting the above technical solution, the main cutting edge is located between the rake face and the flank face, which clarifies the main cutting area. The flank face can provide certain support and guidance for the machined surface during the cutting process. The rounded edge is located between the rake face and the rounded flank face, which further enhances the transition performance of the insert during cutting and reduces stress concentration. The first positioning surface is located on the lower side of the flank face and the rounded flank face, which provides additional positioning reference for the insert during installation and operation, and helps to improve the accuracy of insert installation and the stability during operation.
[0010] In one embodiment, a finishing edge is provided between the rake face and each of the flank faces, the finishing edge on the same side is cocurved with the main cutting edge, and a rounded edge is provided between the finishing edge and the main cutting edge on different sides.
[0011] By adopting the above technical solution, this design can further finish the workpiece surface after the main cutting edge has cut. During the cutting process, the finishing edge can effectively reduce the roughness of the workpiece surface, making the processed surface smoother.
[0012] In one embodiment, the blade body includes a PCBN layer and an alloy layer, the PCBN layer is fixed to the alloy layer, the rake face, the flank face and the rounded flank face are all disposed on the PCBN layer, and the first positioning surface and the bottom positioning surface are both disposed on the alloy layer.
[0013] By adopting the above technical solution, the PCBN layer is used to set the rake face, flank face, and rounded flank face. The PCBN material has high hardness, high wear resistance, and good thermal stability, which can withstand the high temperature and high cutting force generated during high-speed cutting, effectively resist wear, and ensure the sharpness and service life of the cutting edge. The alloy layer is used to set the first positioning surface and the bottom positioning surface. The alloy material can provide good strength and toughness, ensuring the structural stability of the insert during installation and operation, while also helping to reduce production costs.
[0014] This application also provides a high-feed end mill, including a high-feed insert and a tool holder, wherein the high-feed insert is disposed at one end of the tool holder and both sides of the high-feed insert are exposed.
[0015] By adopting the above technical solution, the main cutting edge angle of the insert remains small during the cutting process, which extends the service life of the tool holder and enables the milling cutter to quickly remove workpiece material under high feed conditions, thereby improving machining efficiency. At the same time, due to the excellent performance of the insert, the machining quality can also be guaranteed, meeting the needs of modern machining for high-efficiency and high-precision machining, and adapting to fast feed milling for hard milling on small machine tools.
[0016] In one embodiment, one end of the tool holder is provided with a plurality of blade slots, and the blade slots are provided with threaded holes. The threaded holes correspond to the positioning holes of the high-feed blades, and bolts are passed through the positioning holes and the threaded holes to fix the high-feed blades to the tool holder.
[0017] By adopting the above technical solution, this fixing method is simple and reliable, ensuring the stability of the cutting tool during high-speed rotation and high-feed cutting. Precise positioning and firm fixing effectively prevent the cutting tool from loosening or shifting during cutting, ensuring cutting accuracy and safety, while also facilitating the installation and replacement of the cutting tool and reducing maintenance costs.
[0018] In one embodiment, the tool holder is provided with a side clearance surface and a tip clearance surface, the side clearance surface and the tip clearance surface are connected, and both the side clearance surface and the tip clearance surface are spaced apart from the high feed cutting tool.
[0019] By adopting the above technical solutions, the presence of the side clearance surface and the tool tip clearance surface creates favorable spatial conditions for the cutting process, which is conducive to the smooth discharge of chips and the effective spraying of cutting fluid. They can guide chips away from the tool holder and inserts, preventing chips from accumulating around the tool and affecting cutting performance. At the same time, they also provide better flow channels for the cutting fluid, helping to cool and lubricate the tool, improving cutting efficiency and tool life.
[0020] In one embodiment, the tool holder further includes a second positioning surface, which is located at the upper end of the side clearance surface and connected to the side clearance surface. The second positioning surface is capable of positioning the high-feed insert in the insert groove.
[0021] By adopting the above technical solution, the second positioning surface can ensure the accuracy of the installation angle and position of the insert on the tool holder, thereby improving cutting accuracy and tool life.
[0022] In one embodiment, the tool holder is further provided with cooling holes along its length, the cooling holes facing the blade groove.
[0023] By adopting the above technical solution, the cooling hole can accurately spray coolant onto the working area of the blade, remove heat, and reduce the temperature of the blade and workpiece, thereby improving the service life of the blade and the machining quality.
[0024] In one embodiment, the tool holder is further provided with a chip removal groove, which is located at the upper end of the blade groove and extends toward the middle of the tool holder.
[0025] By adopting the above technical solution, the chip removal groove on the tool holder is located at the upper end of the blade groove and extends towards the middle of the tool holder. This design can guide the chips to be discharged in a specific direction, prevent the chips from accumulating in the cutting area, ensure the smooth progress of the cutting process, and improve the processing efficiency and quality.
[0026] In summary, this application includes at least one beneficial effect:
[0027] 1. By precisely controlling the angle (0.5 degrees - 5 degrees) between the edge line and the circumscribed square formed by passing through the midpoint of the adjacent rounded edge, the principal cutting edge angle is kept relatively small during the cutting process, resulting in thinner chips. At the same time, the cutting speed of the insert can be increased, enabling face milling with a very high feed per tooth, achieving high feed machining, and improving machining efficiency and economy. In addition, at the same depth of cut, the principal cutting edge is longer, which can effectively reduce the stress on the insert, reduce wear, and significantly extend the service life of the insert.
[0028] 2. The PCBN layer is used to set the rake face, flank face, and fillet flank face. PCBN material has high hardness, high wear resistance, and good thermal stability, which can withstand the high temperature and high cutting force generated during high-speed cutting, effectively resisting wear and ensuring the sharpness and service life of the cutting edge. The alloy layer is used to set the first positioning surface and the bottom positioning surface. The alloy material can provide good strength and toughness, ensuring the structural stability of the insert during installation and operation, while also helping to reduce production costs.
[0029] 3. During the cutting process, the cutting edge angle remains small, enabling the milling cutter to perform efficient cutting at high feed rates, quickly removing workpiece material and improving machining efficiency. At the same time, due to the excellent performance of the cutting edge, the machining quality is guaranteed, meeting the needs of modern machining for efficient and high-precision machining, and suitable for fast feed milling in hard milling on small machine tools. Attached Figure Description
[0030] Figure 1 This is a front structural diagram of a high-feed cutting tool provided in an embodiment of this application;
[0031] Figure 2 This is a schematic diagram of the reverse structure of a high-feed cutting tool provided in an embodiment of this application;
[0032] Figure 3 This is a bottom view of a high-feed cutting tool provided in an embodiment of this application;
[0033] Figure 4 This is a schematic diagram of the structure of a high-feed milling cutter provided in an embodiment of this application;
[0034] Figure 5 This is a schematic diagram of a tool holder provided in an embodiment of this application;
[0035] Figure 6 yes Figure 5 A magnified view of part A in the middle.
[0036] Explanation of reference numerals in the attached drawings: 1. High feed insert; 11. Insert body; 111. Locating hole; 112. Rake face; 113. Bottom locating surface; 114. Side face; 1141. Flank face; 1142. First locating surface; 1143. Rounded flank face; 115. Main cutting edge; 116. Rounded edge; 117. Finishing edge; 118. Chamfered surface; 12. PCBN layer; 13. Alloy layer; 2. High feed end mill; 21. Tool holder; 211. Insert groove; 2111. Threaded hole; 2112. Third locating surface; 212. Side clearance surface; 213. Tip clearance surface; 214. Chip groove; 2141. Side of chip groove; 2142. Bottom of chip groove; 215. Cooling hole; 216. Second locating surface; 217. Bolt. Detailed Implementation
[0037] The following is in conjunction with the appendix Figure 1-6 The high-feed insert provided in this application will be described in further detail.
[0038] Example 1
[0039] Please see Figure 1-6 The high-feed cutting tool 1 provided in this application embodiment includes a cutting tool body 11.
[0040] like Figures 1 to 3 As shown, a positioning hole 111 is provided in the middle of the blade body 11. The blade body 11 has a rake face 112, a bottom positioning face 113 and four side faces 114. A main cutting edge 115 and a rounded edge 116 are provided between the rake face 112 and each side face 114. The edges of the bottom positioning face 113 and the side face 114 on adjacent sides are perpendicular. The angle between the circumscribed square formed by the midpoint of two adjacent rounded edges 116 and the edge is α, and α is in the range of 0.5 degrees to 5 degrees.
[0041] Specifically, the insert body 11 is rotationally symmetrical along the axis of the positioning hole 111. The insert body 11 may include a PCBN layer 12 and an alloy layer 13. The combination of these two materials can improve the wear resistance and heat resistance of the insert while ensuring high strength. The PCBN layer 12 is usually prepared by sintering process and has extremely high hardness and wear resistance, making it suitable for high-feed cutting. The alloy layer 13 can be made of tungsten carbide or other high-performance alloy materials to enhance the overall strength and toughness of the insert.
[0042] The area of the rake face 112 is larger than the area of the bottom locating face 113. The bottom locating face 113 is typically used to mate with the third locating face 2112 on the tool holder 21 to ensure the accuracy of the insert during installation. The side face 114 can be designed in various ways to optimize the heat dissipation performance and cutting stability of the insert. For example, the side face 114 can be designed with a structure with heat dissipation grooves to increase the heat dissipation area and reduce thermal deformation of the insert caused by high temperature. In addition, the side face 114 can also be designed with a structure with reinforcing ribs to enhance the overall rigidity of the insert and reduce vibration during cutting.
[0043] Furthermore, each side 114 may include a rake face 1141, a first positioning surface 1142, and a rounded rake face 1143. The main cutting edge 115 is located between the rake face 112 and the rake face 1141, and the rounded edge 116 is located between the rake face 112 and the rounded rake face 1143. The first positioning surface 1142 is located on the lower side of the rake face 1141 and the rounded rake face 1143. Along the feed direction of the insert, the rounded edge 116 is located at the front end of the main cutting edge 115. The design of the main cutting edge 115 is crucial, as it determines the cutting performance of the insert.
[0044] A finishing edge 117 can be added between the rake face 112 and each flank face 1141. The finishing edge 117 on the same side is cocurved with the main cutting edge 115, and a rounded edge 116 is provided between the finishing edge 117 on different sides and the main cutting edge 115. The finishing edge 117 is located behind the main cutting edge 115 in the forward direction of the insert, and can perform secondary processing on the machined surface during the cutting process to remove burrs and minor defects, thereby improving the surface smoothness.
[0045] A chamfered surface 118 may also be included between the rake face 112 and the flank face 1141. The main cutting edge 115 and the finishing edge 117 are both located between the chamfered surface 118 and the flank face 1141. The design of the chamfered surface 118 helps to improve heat transfer and cutting force distribution during the cutting process, reduce stress concentration on the cutting edge, and improve the durability of the insert. The width and angle of the chamfered surface 118 can be adjusted according to the cutting conditions and workpiece material to achieve the best cutting effect.
[0046] The first positioning surface 1142 is designed to ensure precise positioning of the cutting tool when mounted on the tool holder 21. The shape and position of the first positioning surface 1142 need to be precisely controlled to avoid cutting instability caused by inaccurate positioning. In addition, the first positioning surface 1142 can also be designed with a guide structure to reduce the wobble of the cutting tool during installation and improve installation accuracy.
[0047] The design of the included angle α is one of the core aspects of this embodiment. By controlling the range of the included angle between the edge line and the circumscribed square formed by the midpoints of adjacent rounded cutting edges 116, the main cutting edge 115 can always maintain a small principal cutting edge angle at different cutting depths. The advantage of this design is that even under deep cutting conditions, the main cutting edge 115 can maintain a longer effective cutting length, thereby reducing the force per unit cutting length, reducing the wear rate, and extending the tool life.
[0048] like Figures 4 to 6 As shown, this embodiment also provides a high feed end mill 2, including a high feed insert 1 and a tool holder 21. The high feed insert 1 is disposed at one end of the tool holder 21, and the main cutting edge 115, finishing edge 117 and rounded edge 116 on both sides of the high feed insert 1 are exposed.
[0049] Specifically, the tool holder 21 is typically made of high-strength alloy steel or stainless steel to ensure sufficient strength and rigidity. Furthermore, the surface treatment of the tool holder 21 is also crucial. Coating technologies such as TiN, TiAlN, and DLC can be used to improve the surface hardness and lubricity of the tool holder 21, thereby reducing friction and wear during the cutting process.
[0050] One end of the tool holder 21 is provided with multiple rotationally symmetrical blade grooves 211 along the axis of the tool holder 21. Each blade groove 211 has a third positioning surface 2112, through which a threaded hole 2111 passes. The threaded hole 2111 corresponds to the positioning hole 111 of the high-feed blade 1. The bottom positioning surface 113 of the high-feed blade 1 is aligned with the third positioning surface 2112. A bolt 217 passes through the positioning hole 111 and the threaded hole 2111 to fix the high-feed blade 1 to the tool holder 21. The advantage of this design is that it makes the installation and removal of the blade very convenient, while ensuring the precise positioning of the blade during installation. In addition, the shape and position of the blade groove 211 need to be determined according to the shape and size of the blade to ensure the stability and reliability of the blade during installation.
[0051] The tool holder 21 has a side clearance surface 212 and a tool tip clearance surface 213, both located at the edge of the third positioning surface 2112. When the high-feed insert 1 is placed in the insert groove 211, the side clearance surface 212 and the tool tip clearance surface 213 are spaced apart from the high-feed insert 1. The main purpose of this design is to avoid interference between the tool holder 21 and the workpiece during cutting, which would affect the cutting effect. The design of the side clearance surface 212 and the tool tip clearance surface 213 needs to be determined according to the cutting conditions and the workpiece material to achieve the best clearance effect.
[0052] The tool holder 21 is also provided with a chip removal groove 214, which is located at the upper end of the insert groove 211 and extends towards the middle of the tool holder 21. The function of the chip removal groove 214 is to help chips be discharged smoothly and prevent chips from accumulating around the insert, which would affect cutting efficiency and insert life. In this embodiment, the chip removal groove 214 includes a chip removal groove side surface 2141 and a chip removal groove bottom surface 2142. Both the chip removal groove side surface 2141 and the chip removal groove bottom surface 2142 are arc-shaped, which can achieve higher tool holder rigidity and chip removal effect.
[0053] The tool holder 21 is also provided with cooling holes 215 along its length. The cooling holes 215 are located at the upper end of the tool tip clearance surface 213 and face the tool groove 211. The function of the cooling holes 215 is to remove the heat generated by the tool during cutting by circulating coolant, preventing the tool temperature from becoming too high and affecting cutting performance. The design of the cooling holes 215 needs to take into account the smoothness of liquid flow and the uniformity of cooling effect.
[0054] The tool holder 21 also includes a second positioning surface 216, which is located at the upper end of the side clearance surface 212 and connected to it. The second positioning surface 216 abuts against the first positioning surface 1142. The main purpose of this design is to ensure accurate positioning of the tool during installation and avoid unstable cutting due to inaccurate positioning. The shape and position of the second positioning surface 216 need to be precisely controlled to ensure a good fit with the first positioning surface 1142.
[0055] The implementation principle of this embodiment is as follows: When the milling cutter is cutting, the tool holder 21 moves towards the workpiece and drives the high-feed insert 1 to rotate along the axis of the tool holder 21, so that the high-feed insert 1 contacts the workpiece. As the cutting depth increases until the main cutting edge 115 is in complete contact with the workpiece, the projection of the main cutting edge 115 on the workpiece surface increases continuously. Since the included angle α is small, the range of the angle between the main cutting edge 115 and the horizontal direction, i.e., the principal cutting edge angle, is always small, which can obtain a better chip thinning effect and obtain thinner chips. Therefore, at the same cutting depth, a longer main cutting edge 115 can be ensured to participate in the cutting work, reducing the single-point force on the main cutting edge 115, thus it can withstand a faster cutting speed, realizing high-feed machining and improving efficiency. The reduction of single-point force reduces the wear on the high-feed insert 1 and extends its service life.
[0056] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A high-feed insert, characterized by, The utility model relates to a high feed blade (1) and a tool bar (21) comprising the same. The utility model discloses a high feed blade (1) comprising: a blade body (11) provided with a positioning hole (111), the blade body (11) is equipped with a rake face (112), a bottom positioning surface (113) and four side faces (114), a main cutting edge (115) and a fillet edge (116) are arranged between the rake face (112) and each side face (114), the intersection edge line of the bottom positioning surface (113) and the side face (114) of adjacent two sides is perpendicular, and the included angle between the circumscribed square formed by passing through the midpoints of the adjacent two fillet edges (116) and the edge line is a, and a is in the range of 0.5 degrees to 5 degrees.
2. A high feed insert according to claim 1 wherein, Each side face (114) comprises a relief face (1141), a first positioning surface (1142) and a fillet relief face (1143), the main cutting edge (115) is arranged between the rake face (112) and the relief face (1141), the fillet edge (116) is arranged between the rake face (112) and the fillet relief face (1143), and the first positioning surface (1142) is arranged on the lower side of the relief face (1141) and the fillet relief face (1143).
3. A high feed insert according to claim 2, wherein A light polishing edge (117) is further arranged between the rake face (112) and each relief face (1141), the light polishing edges (117) on the same side are co-curved with the main cutting edge (115), and the light polishing edges (117) on different sides are provided with a fillet edge (116) between the main cutting edge (115).
4. A high feed insert according to claim 3, wherein The blade body (11) comprises a PCBN layer (12) and an alloy layer (13), the PCBN layer (12) is fixed with the alloy layer (13), the rake face (112), the relief face (1141) and the fillet relief face (1143) are arranged on the PCBN layer (12), and the first positioning surface (1142) and the bottom positioning surface (113) are arranged on the alloy layer (13).
5. A high-feed milling cutter, characterized by The utility model discloses a high feed blade (1) and a tool bar (21) comprising the same.
6. A high feed cutter according to claim 5 wherein, One end of the tool bar (21) is provided with a plurality of blade grooves (211), the blade grooves (211) are provided with threaded holes (2111), the threaded holes (2111) correspond to the positioning holes (111) of the high feed blade (1), and bolts (217) pass through the positioning holes (111) and the threaded holes (2111) to fix the high feed blade (1) on the tool bar (21).
7. A high feed cutter according to claim 6 wherein, The tool bar (21) is provided with a side clearance surface (212) and a tool tip clearance surface (213), the side clearance surface (212) and the tool tip clearance surface (213) are connected, and the side clearance surface (212) and the tool tip clearance surface (213) are both arranged at intervals from the high feed blade (1).
8. A high feed cutter according to claim 7, wherein The tool bar (21) further comprises a second positioning surface (216) arranged at the upper end of the side clearance surface (212) and connected with the side clearance surface (212), and the second positioning surface (216) can position the high-feed blade (1) in the blade groove (211).
9. A high feed cutter according to claim 6 wherein, The tool bar (21) is further provided with a cooling hole (215) along the length direction thereof, and the cooling hole (215) faces the blade groove (211).
10. A high feed cutter according to claim 6 wherein, The tool bar (21) is further provided with a chip groove (214) arranged at the upper end of the blade groove (211) and extending towards the middle part of the tool bar (21).