Three-tooth wave-edge aluminum machining milling cutter

Abstract

The utility model relates to the technical field of milling cutters, and provides a three-tooth wave-edge aluminum machining milling cutter which comprises a milling cutter body, the thickness of a cutter core of the milling cutter body is d, and d is larger than or equal to 0.53 D and smaller than or equal to 0.55 D; the milling cutter is provided with a chip pocket, the chip pocket is provided with a groove back, the groove back is arc-shaped, the radius of the groove back is r, and r is larger than or equal to 0.75 D and smaller than or equal to 0.85 D; wherein D is the diameter of the blade part of the milling cutter. By means of the technical scheme, the technical problems that in the prior art, a large number of aluminum scraps are accumulated in the scrap containing groove, machining efficiency is reduced, machining quality is affected, the service life of a tool is shortened, and even workpieces are damaged are solved.

Description

Technical Field

[0001] The embodiments disclosed herein relate to the field of milling cutter technology, and more specifically, to a three-tooth wave-edge aluminum machining milling cutter. Background Technology

[0002] In the current aluminum processing field, wave-shaped end mills for aluminum are widely used. However, in the crucial chip removal stage, even with a wave-shaped groove design, the high plasticity of aluminum chips makes them easily adhere to the tool and workpiece during cutting. This makes it difficult for existing end mills to achieve ideal chip removal performance, resulting in a large accumulation of aluminum chips in the chip grooves. This severely hinders normal cutting operations, reducing processing efficiency, affecting machining quality, shortening tool life, and even damaging the workpiece. Utility Model Content

[0003] To overcome the above-mentioned defects, the embodiments of this disclosure provide a three-tooth wave-edge aluminum machining end mill, which solves the technical problem in the prior art that aluminum chips accumulate in large quantities in the chip groove, which not only reduces machining efficiency, but also affects machining quality, reduces tool life, and even damages the workpiece.

[0004] According to one aspect, at least one embodiment of this disclosure provides a three-tooth wave-edge aluminum machining end mill, comprising: an end mill, wherein the core thickness of the end mill is d, 0.53D≤d≤0.55D;

[0005] The milling cutter has a chip groove, the chip groove has a back groove, the back groove is arc-shaped and its radius is r, the radius of the back groove of the chip groove is r, 0.75D≤r≤0.85D;

[0006] Where D is the diameter of the cutting edge of the milling cutter.

[0007] For example, in a three-tooth wave-edge aluminum milling cutter provided in at least one embodiment of this disclosure, the circumferential rake angle of the milling cutter is α, where 17°≤α≤20°.

[0008] For example, in a three-tooth wave-edge aluminum milling cutter provided in at least one embodiment of this disclosure, the circumferential cutting edge width of the milling cutter is F, where 0.16D≤F≤0.19D.

[0009] For example, in a three-tooth corrugated aluminum milling cutter provided in at least one embodiment of this disclosure, the milling cutter has a circumferential cutting edge face, the circumferential cutting edge face is corrugated, and its pitch is t, where t is a constant value.

[0010] For example, in a three-tooth corrugated aluminum milling cutter provided in at least one embodiment of this disclosure, the corrugation includes a convex portion and a concave portion, wherein the radius of the convex portion is equal to the radius of the concave portion.

[0011] For example, in a three-tooth corrugated aluminum milling cutter provided in at least one embodiment of this disclosure, the corrugated shape also has a tooth depth h, 0.4mm≤h≤0.9mm.

[0012] The beneficial effects of the embodiments disclosed herein are as follows:

[0013] In this disclosure, by designing the milling cutter core thickness, circumferential rake angle, circumferential cutting edge width, circumferential cutting edge waveform, and tooth depth, the chip removal performance is improved, effectively avoiding the problem of aluminum chips adhering to the tool and workpiece, as well as accumulating in the chip groove, ensuring smooth cutting process; the cutting edge is sharper, reducing cutting force and thus improving machining efficiency; the tool life is significantly improved, reducing tool replacement frequency and machining costs. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the accompanying drawings used in the description of the embodiments of this disclosure will be briefly introduced below. Obviously, the drawings described below are merely some exemplary embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on the content of the exemplary embodiments of this disclosure and these drawings without any creative effort.

[0015] Figure 1 This is a schematic diagram of the cross-section of a traditional milling cutter;

[0016] Figure 2 This is a schematic diagram of the structure of a three-tooth wave-blade aluminum machining end mill disclosed herein;

[0017] Figure 3 for Figure 2 Schematic diagram of AA section;

[0018] Figure 4 This is a schematic diagram of the wavy shape of the circumferential cutting edge of a traditional milling cutter.

[0019] Figure 5 This is a schematic diagram of the wavy shape of the circumferential cutting edge after the improvement of this scheme.

[0020] In the figure: 1. End mill; 101. Cutting edge; 102. Circumferential cutting edge flank; 103. Chip groove; 104. Cutting core; 105. Groove back; 107. Circumferential cutting edge waveform; 108. Convex part; 109. Concave part. Detailed Implementation

[0021] The present disclosure will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present disclosure and are not intended to limit the scope of the disclosure.

[0022] To keep the drawings concise, each drawing only schematically shows the parts relevant to the disclosure; these do not represent the actual structure of the product. Furthermore, for ease of understanding, in some drawings, only one of components with the same structure or function is schematically shown, or only one is labeled. In this document, "one" not only means "only one," but can also mean "more than one," and "several" includes "two" and "more than two."

[0023] In this document, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure based on the specific circumstances.

[0024] In this disclosure, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of description and simplification of operation, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0026] Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] like Figures 1-5As shown, this invention discloses a three-tooth wave-edge aluminum machining end mill. The core 104 of a conventional aluminum machining end mill typically has a thickness of 0.6D. This structure results in a small space for the chip groove 103, causing aluminum chips to soften due to frictional heating during high-speed cutting and easily adhere to the chip groove 103. By reducing the thickness of the core 104 from 0.6D to 0.53D~0.55D, the cross-sectional area of ​​the chip groove 103 increases by approximately 15%~20%, reducing the chip filling rate within the chip groove 103 and preventing chips from sticking to the cutter due to compression, friction, and heating.

[0028] The groove radius of aluminum machining end mills has been increased from the traditional 0.4D~0.5D to an optimized 0.75D~0.85D. The increased thickness of the cutter body improves resistance to bending deformation and reduces the risk of cutting edge breakage. In summary, the synergistic optimization of core thickness and groove radius comprehensively improves the end mill's service life and further enhances machining efficiency.

[0029] In some examples, the rake angle refers to the angle formed by the line connecting the rake face of the circumferential cutting edge and the tip to the center. It is an important factor affecting the cutting performance of end mills. Traditional end mills 1 typically have a rake angle α of 15°, which provides high strength but also high cutting resistance. End mill 1, however, has a rake angle α configured to be 17°~20°. This increased rake angle makes the cutting edge sharper, reducing cutting force by approximately 15%~20% when cutting into aluminum, reducing edge wear, and lowering the cutting temperature to prevent aluminum chips from softening and sticking to the tool due to high temperatures.

[0030] In some examples, the circumferential cutting edge width F of a milling cutter refers to the width of the cutting edge in the circumferential direction of the milling cutter. When performing side milling, it determines the range of material that can be removed in a single cut. Traditionally, the circumferential cutting edge width F of a milling cutter is typically 0.22D~0.25D. In this improved design, the circumferential cutting edge width F of milling cutter 1 is configured to be 0.16D~0.19D. The contact area between the cutting edge and the workpiece is reduced by 20%~30%, the force per unit cutting edge is reduced, and the wear rate is slowed. When cutting aluminum alloys, the narrow cutting edge reduces the friction length between the cutting edge and aluminum chips, decreasing the probability of tool sticking and preventing edge breakage due to localized adhesion. The narrow cutting edge has a shorter heat conduction path, allowing cutting heat to dissipate more quickly through the tool body, reducing the cutting edge temperature by 15%~20% and delaying thermal fatigue failure of the tool material. Simultaneously, the reduced cutting force decreases the load on the machine tool spindle, allowing for a 15%~25% increase in rotational speed or a 20%~40% increase in feed rate, thus increasing the material removal rate per unit time.

[0031] In some examples, the end mill 1 has a circumferential flank face 102, which is the surface on the circumference of the end mill, opposite to the machined surface of the workpiece. The circumferential flank face 102 is corrugated, with a pitch of t, which is a constant value. A constant pitch means that the distance the chip flute 103 rises along the tool axis remains constant every 360° rotation. Each cutting edge contacts the workpiece with the same entry angle and cutting thickness, avoiding local stress concentration caused by pitch variations.

[0032] In some examples, with a fixed pitch t, ​​the circumferential cutting edge waveform 107 of a conventional milling cutter 1 has a larger radius for the protrusion 108 than for the concave portion 109. This causes the protrusion 108 of the cutting edge 101 to contact the workpiece first during actual machining, easily leading to localized stress concentration and resulting in chipping or even breakage of the cutting edge. In this solution, the radius of the protrusion 108 is optimized to be equal to the radius of the concave portion 109. A symmetrical waveform is used, ensuring consistent convex and concave undulations and uniform distribution of cutting force on the protrusion 108, reducing the cutting force per unit area. The increased radius of the concave portion 109 facilitates chip removal, reduces the impact of built-up edge on the machined surface quality, and extends fatigue life.

[0033] In traditional methods, asymmetric waveform cutting results in a large amount of residual material, while in this method, the cutting edge trajectory of symmetric waveforms is denser, thereby further reducing the residual material.

[0034] In some examples, the corrugated shape also has a tooth depth h, which refers to the vertical distance from the tooth tip (highest point of the cutting edge) to the tooth root (lowest point of the groove bottom) of the milling cutter cutting tooth, i.e., the depth dimension of a single chip groove 103. Compared to the traditional tooth depth h range of 0.34mm~0.65mm, this solution optimizes the tooth depth h to 0.4mm~0.9mm, increasing it within different ranges for milling cutters of different diameters. For example, for a milling cutter with D=6mm, the tooth depth h of the corrugated shape of a traditional milling cutter is usually 0.34mm, while this solution improves it to 0.41mm, an increase of 0.07mm. For a milling cutter with D=12mm, the tooth depth h of the corrugated shape of a traditional milling cutter is usually 0.46mm, while this solution improves it to 0.62mm, an increase of 0.16mm, representing an increase of approximately 16%~30%. As the tooth depth h increases, the chip groove 103 can better accommodate chips of different shapes and sizes. Furthermore, as the tooth depth h increases, the cross-sectional area of ​​the milling cutter body increases accordingly, enhancing its resistance to deformation. This helps reduce tool vibration and deformation during high-speed or high-feed cutting, thereby improving machining accuracy and surface quality.

[0035] Specifically, in one example of this solution, the dimensions of the milling cutter 1 are configured as follows: the core thickness is 0.54D, the circumferential cutting edge rake angle α is 18°, the groove back of the milling cutter is 0.80D, and the circumferential cutting edge width F is 0.16D. Under the same machining conditions, the chip removal effect is significantly improved, and no aluminum chip adhesion occurs during the machining process. Compared with milling cutters of traditional sizes, the machining efficiency is increased by 30%, and the tool life is extended by about 50%.

[0036] When producing aluminum alloy automotive engine cylinder blocks, traditional milling cutters required replacing the tool every 50 cylinder blocks. However, with the milling cutter 1 from this solution, the tool only needs to be replaced every 80 cylinder blocks. At the same time, the surface quality is significantly improved, and the scrap rate is reduced by 15%.

[0037] In summary, by designing the thickness of the end mill core 104, the rake angle α of the circumferential cutting edge, the width F of the circumferential cutting edge, the waveform 107 of the circumferential cutting edge, and the tooth depth h, the chip removal performance is improved, effectively preventing aluminum chips from adhering to the tool and workpiece, and from accumulating in the chip groove 103, ensuring smooth cutting. The cutting edge is sharper, reducing cutting force and thus improving machining efficiency. The tool life is significantly extended, reducing tool replacement frequency and lowering machining costs.

[0038] It should be noted that the above embodiments are only used to illustrate the technical solutions of this disclosure and are not intended to limit it. Although this disclosure has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this disclosure without departing from the spirit and scope of the technical solutions of this disclosure, and all such modifications and substitutions should be covered within the scope of the claims of this disclosure.

Claims

1. A three-tooth wave blade aluminum processing milling cutter, characterized in that, Comprise: A milling cutter (1) having a thickness of the core (104) of d, 0.53D≤d≤0.55D; The milling cutter (1) has a chip pocket (103) having a land (105), the land (105) is arc-shaped, the radius is r, 0.75D≤r≤0.85D; Wherein, D is the diameter of the blade part (101) of the milling cutter (1).

2. A three-tooth wave blade aluminum processing milling cutter according to claim 1, characterized in that, The peripheral blade rake angle of the milling cutter (1) is a, 17°≤a≤20°.

3. A three-tooth wave blade aluminum processing milling cutter according to claim 1 or 2, characterized in that, The peripheral blade width of the milling cutter (1) is F, 0.16D≤F≤0.19D.

4. A three-tooth wave blade aluminum processing cutter according to claim 3, characterized in that, The milling cutter (1) has a peripheral blade relief surface (102), the peripheral blade relief surface (102) is corrugated, the pitch is t, t is a constant value.

5. A three-tooth wave blade aluminum processing cutter according to claim 4, characterized in that, The corrugated shape includes convex parts (108) and concave parts (109), the radius of the convex part (108) is equal to the radius of the concave part (109).

6. A three-tooth wave blade aluminum processing cutter according to claim 5, characterized in that, The corrugated shape also has a tooth depth h, 0.4mm≤h≤0.9mm.

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