An ultrasonic disc knife for processing honeycomb core material

Abstract

The utility model relates to ultrasonic cutter technical field especially relates to a kind of ultrasonic wave disc cutter for processing honeycomb core material, including disc cutter body, the disc cutter body includes installation end and blade part, the installation end of the disc cutter body is optical axis structure, is installed on ultrasonic wave cutter handle by SK type structure or ER type structure or heat shrink clamping structure or other forms of jacket, the installation end of the disc cutter body adjustable, the installation end of the disc cutter body is reduced setting, the installation end diameter of the disc cutter body is not greater than the diameter of the convex portion of traditional disc cutter third, the blade part of the disc cutter body is equipped with abrasive structure, the abrasive structure includes the blade edge plane of 2mm axial length. This ultrasonic wave disc cutter not only can effectively protect workpiece, improve processing quality, and improve processing adaptability and range, ensure high-precision machining, also prolongs tool life, reduces use cost.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic cutting tool technology, and in particular to an ultrasonic disc cutter for processing honeycomb core materials. Background Technology

[0002] Due to its lightweight and high strength, honeycomb core materials are widely used in sandwich structure components in aerospace, rail transportation, and other fields. These components often require the machining of connecting holes and weight-reducing grooves during manufacturing. However, honeycomb cores are characterized by thin walls, high porosity, and easy deformation, making them prone to defects such as burrs, tears, and delamination when machined using traditional milling and drilling methods. Therefore, the industry has gradually adopted ultrasonic machining technology. This technology uses high-frequency mechanical vibration of the cutting tool to perform micro-impact material removal, offering advantages such as low cutting force and no thermal damage, making it particularly suitable for machining honeycomb core materials.

[0003] Currently, as shown in the attached document Figure 4 As shown, disc cutters used in ultrasonic machining are typically mounted on ultrasonic tool holders using a threaded connection and a positioning step. However, this traditional disc cutter structure has the following inherent drawbacks: First, the cutter's extension length is fixed and cannot be adjusted, making it difficult to adapt to the machining needs of cavities of different depths, severely limiting its deep cavity machining capabilities; second, the large size of the protrusion at the tool holder makes it prone to squeezing and pulling the honeycomb core workpiece during machining, leading to deformation or damage; third, the threaded connection and positioning step cannot guarantee high coaxiality, resulting in large blade runout after installation, severely affecting machining accuracy and surface quality; finally, after the cutter wears out, due to the lack of a repairable design, it usually has to be scrapped entirely and cannot be reused through grinding, resulting in high tool usage costs and poor economic efficiency.

[0004] Therefore, the existing ultrasonic disc cutters need improvement in terms of processing adaptability, workpiece protection, processing accuracy, and economy. Summary of the Invention

[0005] The main objective of this invention is to overcome the shortcomings of the existing technology and provide an ultrasonic disc cutter for processing honeycomb core materials.

[0006] The technical solution adopted by this utility model to achieve its technical purpose is: an ultrasonic disc cutter for processing honeycomb core materials, including a disc cutter body, wherein the disc cutter body includes a mounting end and a cutting edge; The mounting end of the disc cutter body is an optical axis structure, which is mounted on the ultrasonic tool holder through an SK-type structure, an ER-type structure, a heat-shrink clamping structure, or other forms of clamping. The extension length of the mounting end of the disc cutter body is adjustable. The SK-type or ER-type clamping is connected to the mounting end of the disc cutter body, so that the extension length of the mounting end of the disc cutter body can be adjusted as needed to adapt to the processing requirements of cavities of different depths and ensure that ultrasonic vibration energy is effectively transmitted to the processing area.

[0007] The mounting end of the disc cutter body is reduced in size, and the diameter of the mounting end of the disc cutter body is no more than one-third of the diameter of the protrusion of a traditional disc cutter.

[0008] The blade of the disc cutter body is provided with a grindable structure, which includes a cutting edge plane with an axial length of 2mm.

[0009] Preferably, the mounting end of the disc cutter body is fixed to the ultrasonic tool holder by a clamp and a nut. The mounting end is fixed to the ultrasonic tool holder by the clamp and the nut, which avoids the threaded connection structure and positioning step structure of traditional disc cutters, improves the coaxiality of the cutter and the ultrasonic tool holder, ensures stable transmission of ultrasonic vibration energy, and guarantees machining accuracy.

[0010] Preferably, the coaxiality error between the mounting end of the disc cutter body and the ultrasonic cutter holder after assembly is ≤0.005mm.

[0011] Preferably, the grindable structure of the blade portion of the disc cutter body can restore its cutting edge performance by grinding after wear.

[0012] Preferably, the runout of the cutting edge of the disc cutter body is ≤0.005mm.

[0013] Preferably, the cutting edge of the disc cutter body is recessed, with a recess depth of 1mm to 10mm. The cutting edge is recessed from the cutting edge plane towards the middle. The deeper the recess, the greater the ultrasonic vibration amplitude at the cutting edge plane. Therefore, the recess depth needs to be set within a certain range to actually meet the usage requirements.

[0014] Compared with the prior art, the beneficial effects of this utility model are: This ultrasonic disc cutter for processing honeycomb core materials improves processing adaptability and range. Due to the optical axis design at the mounting end and the clamping of universal clamping sets such as SK and ER, the extension length of the disc cutter body can be freely and conveniently adjusted according to the depth of the processing cavity. This completely solves the technical problem that existing fixed-length cutters cannot perform deep cavity processing, and greatly expands the processing application range of this cutter.

[0015] This ultrasonic disc cutter for processing honeycomb core materials effectively protects the workpiece and improves processing quality. By reducing the size of the protruding part at the mounting end to less than one-third of that in traditional structures, it significantly reduces the risk of interference, compression, and pulling between this part and the honeycomb core workpiece during processing. Structurally, it effectively avoids workpiece deformation and damage, ensuring the structural integrity of the workpiece and the final processing accuracy.

[0016] This ultrasonic disc cutter for processing honeycomb core materials has higher processing accuracy. By abandoning the traditional threaded connection and positioning step structure, it adopts a jacket-type positioning clamping, which greatly improves the coaxiality between the cutter and the ultrasonic cutter holder. This allows the runout of the cutting edge to be stably controlled within a high-precision range of ≤0.005mm, thereby ensuring excellent surface quality and dimensional accuracy.

[0017] This ultrasonic disc cutter for processing honeycomb core materials extends tool life and reduces operating costs. It features a grindable surface of a specific length (2mm) on the cutting edge, allowing the tool to regain its edge sharpness and cutting performance through conventional grinding processes after wear. This enables the tool to be reused multiple times, significantly extending its service life, reducing long-term operating costs for users, and minimizing resource waste.

[0018] This ultrasonic disc cutter for processing honeycomb core materials has a simpler overall structure. No special tools are required for installing and replacing the cutter. The operation process is the same as that of conventional CNC cutters, which simplifies the operation steps, saves tool change time, and improves processing efficiency. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of an ultrasonic disc cutter used for processing honeycomb core materials.

[0020] Figure 2 This is a front view schematic diagram of an ultrasonic disc cutter used for processing honeycomb core materials.

[0021] Figure 3 This is a three-dimensional structural diagram of an ultrasonic disc cutter used for processing honeycomb core materials, viewed from the bottom.

[0022] Figure 4 This is a schematic diagram of the front view structure of an existing (traditional) disc cutter.

[0023] in: 1-Disc cutter body; 101-Mounting end; 102-Cutting edge; 1022-Cutting edge plane; 2-Traditional disc cutter; 201-Protrusion; 202-Threaded connection structure; 203-Positioning step structure. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit its scope. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the present utility model.

[0025] In the description of this utility model, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to or indirectly connected to the other element.

[0026] In the description of this utility model, it should be noted that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not 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 utility model. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "multiple" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0027] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances. Example 1

[0028] Please see Figures 1-4 An ultrasonic disc cutter for processing honeycomb core materials includes a disc cutter body 1, which includes a mounting end 101 and a cutting edge 102.

[0029] The mounting end 101 of the disc cutter body 1 is an optical axis structure. It is mounted on the ultrasonic tool holder through an SK-type structure, an ER-type structure, a heat-shrink clamping structure, or other forms of clamping. The mounting end 101 of the disc cutter body 1 is fixed to the ultrasonic tool holder by the clamping and nut. The mounting end 101 is fixed to the ultrasonic tool holder by the clamping and nut, which avoids the setting of the threaded connection structure 201 and the positioning step structure 203 of the traditional disc cutter 2. It improves the coaxiality between the tool and the ultrasonic tool holder, so that the coaxiality error of the mounting end 101 of the disc cutter body 1 and the ultrasonic tool holder after assembly is ≤0.005mm, ensuring stable transmission of ultrasonic vibration energy and guaranteeing machining accuracy.

[0030] The extension length of the mounting end 101 of the disc cutter body 1 is adjustable. It is connected to the mounting end 101 of the disc cutter body 1 through a SK-type or ER-type structure jacket, so that the extension length of the mounting end 101 of the disc cutter body 1 can be adjusted as needed to adapt to the processing requirements of cavities of different depths and ensure that ultrasonic vibration energy is effectively transmitted to the processing area.

[0031] The mounting end 101 of the disc cutter body 1 is reduced in size, and the diameter of the mounting end 101 of the disc cutter body 1 is no more than one-third of the diameter of the protrusion 201 of the conventional disc cutter 2.

[0032] It should be noted that the optical axis structure dimensions of the disc cutter body 1 can be designed according to the model of the tool holder collet. For example, the optical axis structure dimensions corresponding to tool holder collet models such as ER11, ER16, ER20, and ER32 are all different.

[0033] Furthermore, the length of the optical axis structure of the disc cutter body 1 can also be designed according to the depth of the machining cavity. When the machining depth is greater, the length of the optical axis structure is also designed to be longer, so that the overall tool can machine to a greater depth.

[0034] The blade portion 102 of the disc cutter body 1 is provided with a grindable structure, which restores the cutting edge performance after wear by grinding. The grindable structure includes a cutting edge plane 1022 with an axial length of 2mm. The blade portion 102 is generally designed as a trumpet structure, with a concave structure in the middle and a cutting edge structure at the edge. The grindable structure is provided on the outer ring of the cutting edge structure, and the grindable structure is the cutting edge plane 1022 with an axial length of 2mm.

[0035] The blade portion 102 of the disc cutter body 1 has a runout of ≤0.005mm, and the blade portion 102 is concave with a depth of 1mm to 10mm. The blade portion 102 is concave from the cutting edge plane 1022 towards the middle. The deeper the concavity, the greater the ultrasonic vibration amplitude at the cutting edge plane 1022. Therefore, the concavity depth needs to be set within a certain range to actually meet the usage requirements.

[0036] It should be noted that the cutting edge 102 can also be designed in various sizes as needed, such as 30mm and 50mm in diameter. Its size is mainly designed according to the processing requirements. If a larger cavity or structure is being processed, or if a larger amount of material needs to be removed, a larger disc cutting tool is used. Conversely, a smaller disc cutting tool can be used, thus making it easier to meet the processing requirements of parts of various sizes.

[0037] The working principle and specific usage process of the ultrasonic disc cutter used for processing honeycomb core materials: The mounting end 101 of the disc cutter body 1 is an optical axis structure, which is installed on the ultrasonic cutter handle through SK type or ER type clamps and nuts. During installation, the extension length of the mounting end 101 is adjusted to adapt to the processing requirements of cavities of different depths. During the machining process, the high-frequency vibration generated by the ultrasonic tool holder is transmitted to the cutting edge 102 through the mounting end 101. The cutting edge plane 1022 at the end of the tool is used to perform high-frequency micro-impact cutting on the honeycomb core material. Since the diameter of the mounting end 101 is significantly reduced and a jacketed connection is adopted, interference and runout caused by the traditional protrusion 201, threaded connection structure 202, and positioning step structure 203 are avoided, thereby ensuring stable transmission of vibration energy and achieving low-stress, high-precision machining. When the cutting edge 102 is worn, the cutting edge plane 1022 can be ground to restore its cutting performance and extend the tool life.

[0038] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection for this utility model. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of this utility model, or equivalent structural, procedural, or functional transformations made using the content of this utility model's specification and drawings, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of protection of this utility model patent.

Claims

1. An ultrasonic disc cutter for processing honeycomb core materials, characterized in that: It includes a disc cutter body (1), which includes a mounting end (101) and a cutting edge (102). The mounting end (101) of the disc cutter body (1) is an optical axis structure, which is mounted on the ultrasonic cutter holder through a SK type structure, ER type structure or heat shrink clamping structure. The extension length of the mounting end (101) of the disc cutter body (1) is adjustable. The mounting end (101) of the disc cutter body (1) is reduced in size; The blade portion (102) of the disc cutter body (1) is provided with a grindable structure, which includes a cutting edge plane (1022) with an axial length of 2 mm.

2. The ultrasonic disc cutter for processing honeycomb core materials according to claim 1, characterized in that: The mounting end (101) of the disc cutter body (1) is fixed to the ultrasonic cutter handle by a clamp and a nut.

3. The ultrasonic disc cutter for processing honeycomb core materials according to claim 1, characterized in that: The coaxiality error between the mounting end (101) of the disc cutter body (1) and the ultrasonic cutter holder after assembly is ≤0.005mm.

4. The ultrasonic disc cutter for processing honeycomb core materials according to claim 1, characterized in that: The grindable structure of the blade part (102) of the disc cutter body (1) can restore the cutting edge performance by grinding after wear.

5. The ultrasonic disc cutter for processing honeycomb core materials according to claim 1, characterized in that: The runout of the blade part (102) of the disc cutter body (1) is ≤0.005mm.

6. The ultrasonic disc cutter for processing honeycomb core materials according to claim 1, characterized in that: The blade portion (102) of the disc cutter body (1) is recessed, with a recess depth of 1mm to 10mm.

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