CN105033331A - 切削加工工具和用于制造切削加工工具的方法 - Google Patents
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Abstract
本发明涉及切削加工工具和用于制造切削加工工具的方法。对于切削加工工具(2),特别是钻承载工具,其包括在所述轴向方向上延伸的一体化基体(6),所述基体(6)至少在部分区域中具有包封在实心的外壳套(28)中的多孔的或网格状的芯结构(26)。这些措施允许使用较少的材料,同时保持良好的机械性能。所述多孔的或网格状的芯结构(26)同时被用于输送冷却剂。所述基体(6)特别是借助于3D打印方法来制造。
Description
技术领域
本发明涉及一种切削加工工具,特别是旋转刀具,诸如钻头或铣刀,该切削加工工具具有在轴向方向上延伸的一体化基体。本发明另外涉及一种用于制造这种切削加工工具的方法。
背景技术
切削加工工具,特别是钻头,通常具有在轴向方向上延伸的夹持轴,带狭槽的切削部件连接到该夹持轴,该夹持轴延伸直至前刀头,具体地讲至钻头。在此类切削加工工具(其也称为轴工具)的情况中,常常在基体的内部中形成冷却剂通道,如例如在EP0843609B1中可看到的那样。
在所谓的实心碳化物钻头中,一体化的基体形成为烧结的主体。该制造过程涉及首先通过从金属粉末压缩为烧结材料(其例如接着被烧结)而制备基体。US7,226,254B2公开了一种烧结的基体,其中为了节约烧结材料,在烧结所述基体之前,在夹持轴的区域中在基体中制作了中心凹部。由此节约的烧结材料被用于制造附加的工具。
发明内容
发明的问题
在此基础上,本发明形成用于提供切削加工工具的基础以及用于制造切削加工工具的方法,其中材料的高效利用和良好的机械性能均得以确保。
问题的解决方案
根据本发明,此问题由具有如下特征的切削加工工具来解决。该切削加工工具特别是旋转刀具,诸如钻头或铣刀。该工具包括在轴向方向上延伸的一体化基体,在该基体中,在于轴向方向上延伸的至少部分中形成非实心的芯结构,该芯结构由实心的外壳套包封。外壳套优选地以恒定的壁厚角环状地包封非实心的芯结构。由于相比实心外壳套为非实心的芯结构,基体被有意设计为不是实心的,从而不仅减轻了重量,而且节约了材料。同时,通过具有实心外壳套结构的特殊芯结构实现了足够高的机械稳定性。这样,芯结构提供了一种类型的机械支撑结构。
具体而言,本发明提供一种切削加工工具,特别是旋转刀具,诸如钻头或铣刀,所述切削加工工具具有在轴向方向上延伸的一体化基体,其特征在于,所述基体至少在部分区域中具有包封在实心的外壳套中的非实心的芯结构。
本发明还提供一种用于制造切削加工工具的方法,所述切削加工工具特别是旋转刀具,诸如钻头或铣刀,所述切削加工工具具有在轴向方向上延伸的一体化基体,其特征在于,所述基体借助于3D打印方法制造。
在这方面,尤其重要的是基体为一体化主体。该术语被理解为表示基体(即,具体地讲还有芯结构与外壳套的组合)由单个主体构成,即,由一件制成,并且不是由两个或更多个部件例如通过焊接、软钎焊、粘结或类似方式组装成。
术语“非实心的芯结构”通常被理解为表示在芯结构中形成其中不存在材料的开口区域。
芯结构优选地可选择性地为多孔的、网格状的或甚至仿生的。术语“多孔的”通常被理解为表示其中单独的孔被优选地分散(即,非结构化和全方向的)在芯结构的材料中的结构。开孔和闭孔结构两者均为可能的。在开孔结构的情况中,大体上,芯结构为可渗透气体或液体(例如冷却剂)的。
术语“网格状”被理解为表示其中不含材料的区域由通常在有序的材料结构(例如,周期性材料结构)中的隔离物(具体地讲为通道)彼此分离的结构。这些单独的通道优选地在轴向方向上延伸。
相比之下,仿生结构被理解为特别是基于来自自然的图案的这种类型的隔离物的无序的(特别是非周期性的)布置。
根据本发明,切削加工工具借助于具有如下特征的方法来制造,该方法规定基体借助于3D打印方法来制造。与此同时,3D打印方法已被用于各种各样的应用。这些方法基本上涉及利用激光逐层地处理粉状的原料,使得单独的粉末颗粒结合到彼此,例如逐层地彼此熔融或烧结成实心的刚性体。逐层的分层构造使得可以容易地形成底切和复杂的几何结构,利用此前的常规制造方法,该结构是不可能的或者需要相当多的努力和费用。在这种情况下,平均晶粒尺寸在10和50μm之间的范围内的金属粉末被用作粉末形式的原料。特别是,用于金属粉末的材料为工具钢。
相应地,使得有可能创造非常精细的结构的该具体方法在本发明中提供用于形成具体的非实心的芯结构。
切削加工工具可选择性地为具有集成到基体中的刀头的整体上考虑的一体化工具,或者备选地,其为所谓的承载工具,该工具由支撑件和施加在其上的优选地可反转地可置换的切削元件组成,支撑件由基体构成。
切削加工工具通常在其前端具有刀头,刀头自身被设计为切削元件,或者在其区域中布置有一个或多个切削元件。在本发明中,刀头由此通常被理解为表示切削加工工具的前端区域,即,切削加工工具的前表面区域。如果工具设计为模块化的承载工具,那么可置换的切削元件(切削刀片)附接到基体。根据一个优选的变体,刀头自身被设计为可置换的切削刀片。通过夹持,例如借助于诸如螺钉的紧固元件或备选地通过简单的扭转,刀头可以可反转地且可置换地附接到基体。这样,该部件特别是在基体的两个保持或夹持条之间保持被夹持。备选地,承载工具设计有用于附接(可转位的)切削刀片的刀座。在这种情况下,刀片座的区域被理解为表示刀头。在将例如主切削刃切入端面区域中的非模块化一体式工具中,具有例如在标称直径的范围内的轴向长度的前端面区域构成刀头。
钻头和铣刀工具一般被归类为旋转刀具。因此可以理解的是,在操作期间,切削加工工具绕中心轴线旋转,该中心轴线同时限定旋转轴线。
居中地形成于基体中的芯结构的另一个优点在于,它具有比实心的环形外壳套低的密度。这导致在外部区域中具有较大密度的密度分布,这导致更稳定的旋转,特别是在旋转刀具中。芯结构优选地设计为旋转对称的并且优选地为圆形的,至少具有至少两重至六重旋转几何形状的旋转对称的。
为了赋予其特别高的机械刚度,芯结构便利地设计为蜂窝结构。这构成一种特殊类型的网格状芯结构,其中单独的通道具有六边形横截面。
在例如蜂窝结构的网格状芯结构的情况中,形成多个纵向延伸的通道。在本发明中,术语“多个”被理解为特别是表示至少五个、优选地至少八个或甚至显著地更多的通道被并入。单独的通道便利地具有低于0.5mm且特别是低于0.10mm的最大通道宽度。
如果芯结构为多孔的,那么其便利地具有在5%和90%之间范围内的孔隙率。这意味着,相比实心主体,在5%和90%之间的体积由孔组成。孔优选地具有范围在15和45μm之间的平均孔尺寸。
芯结构便利地至少在轴部分中具有圆形横截面并且设计成特别是同心于环形外壳套。芯结构和外壳套因此同轴于中心轴线和特别是同轴于旋转轴线。
总体上,芯结构覆盖优选地基体的总横截面积的约5%至80%的面积。如果芯结构为圆形的,那么其芯半径优选地在基体的外半径的50%和90%之间。在芯结构上形成相对较窄的周向实心边沿,其形成优选地具有恒定的壁厚的外壳套,然而,该壁厚被充分地尺寸设计为满足所需的机械负荷,例如,在夹持基体时存在的夹持力。芯结构部分便利地在轴向方向上变化。特别是,芯结构的部分在带槽的前切削部分和后轴部分之间有所不同。相对于总横截面积(诸如排屑槽的凹部不计算在总横截面内),在前切削部分中,芯结构的部分在下限范围中,例如在5%和30%之间,而在轴部分中,芯结构的部分在上限范围中,例如在40%和80%之间。
在一个可用的实施例中,芯结构包括在轴向方向上变化的横截面积。原则上,3D打印的特殊制造方法允许创建任何所需的结构。在本发明中,该方法在以下意义上使用:在基体的不同的轴向部分中形成具体地适合于基体几何形状的芯结构几何形状。改变横截面几何形状另外允许在限定的轴向位置处适当地调整机械性能。特别是,对于高负荷部分来说,例如,通过增大在这些部分中的实心外壳套的壁厚来留出余量。
在一个尤其适宜的改进中,实心撑条在中心轴线的方向上被引入到芯结构中,从而在刚度上实现额外的改善。这种类型的撑条便利地弯曲成例如镰刀的形状,以将在切削刃处出现的增加的机械负荷传递到例如基体的内部。引入的撑条的数目便利地等于周向地分布的切削刃的数目。如果存在两个周向切削刃,那么两个撑条优选地在中心轴线中融入彼此,并且例如整体上卷绕成S的形状。撑条形成例如呈辐条和带辐条的轮子的形状的结构。撑条基本上具有显著大于网格状芯结构的正常壁厚的壁厚。例如,其壁厚比正常壁厚大许多倍。撑条的壁厚还优选地根据其径向位置变化,并且具体而言优选地连续地变化。
基体通常包括作为夹持轴的轴部分,基体利用该夹持轴夹持到切削加工工具的夹持装置中。切削加工工具的中心轴线取向成使得它与切削加工工具的旋转轴线精确地同轴。在轴向方向上连接到轴部分的前部的是前切削部分,该前切削部分通常设有排屑槽。这些排屑槽设计成或者在直线中延伸,或者螺旋地延伸。在一个适宜的设计中,芯结构进一步从轴部分出发延伸进入切削部分,从而形成连续的芯结构。在这种情况下,芯结构优选地在轴部分中具有圆形横截面几何形状,该几何形状在切削部分中过渡成改变的几何形状。
芯结构便利地设计成在带槽的切削部分的区域中为细长的并且跨入基体的中心区域中。芯结构另外在中心区域的两侧具有加宽部,赋予其横截面总体上骨头状的外观。其相对的两端区域是球形的或倒圆的,使得特别是,芯结构的径向外周同心于外壳套延伸。
在一个尤其便利的实施例中,芯结构设计成适合传导冷却剂并且从基体的后端延伸至前端面。为此,特别是,常规的标准化的冷却剂连接件便利地形成在基体的后端处。这通常包括横向凹槽,冷却剂从切削加工工具进给到该凹槽中。
在前端面处,冷却剂可选择性地离开基体或者传递到与刀头的接口,冷却剂可以进一步进给到刀头内。
整体而言,切削加工工具在一个便利的实施例中设计为具有至少一个切削元件的承载工具,该切削元件可固定到基体,特别是刀头或切削刀片。基体优选地由工具钢制造。相比之下,切削元件由诸如实心的碳化物或者还有陶瓷的较硬材料制成。该切削元件特别是作为可反转地可拆卸的刀片固定到基体。
附图说明
下面基于附图更详细地解释本发明的示例性实施例,附图中的一些为简化图示。
图1示出了设计为模块化承载工具的切削加工工具的侧视图;
图2示出了沿着截面线A-A穿过图1所示切削加工工具的剖视图;
图3示出了沿着截面线C-C穿过图1所示切削加工工具的剖视图;
图4示出了沿着截面线B-B穿过切削加工工具的剖视图;
图5示出了网格状芯结构的剖视图;
图6示出了在如图1所示的截面线A-A的区域中的仿生芯结构的剖视图;和
图7示出了在如图1所示的截面线B-B的区域中的仿生芯结构的剖视图。
具有相同作用的部件在附图中给出相同的附图标记。
具体实施方式
图1中示出的切削加工工具2设计为模块化的钻具。该钻具具有由实心的碳化物或陶瓷制成的切削元件形式的刀头4,刀头4可反转地且可拆卸地附接到基体6的前端。在本发明中,刀头通常被理解为表示切削加工工具2的前端区域,即,切削加工工具的前端面区域。在根据图1的示例性实施例中,这由可置换的刀头4形成。在具有用于附接作为切削元件的(可转位)刀片的刀片座的承载工具的情况中,刀片座的区域被理解为表示刀头。在非模块化的一体式工具中,具有例如在切削加工工具2的标称直径的范围内的轴向长度的前端区域被称为刀头。在根据图1的示例性实施例中,刀头4作为可反转的可置换刀片被夹持在基体6的两个夹持或保持腹板7之间。
切削加工工具2和因此还有基体6和刀头4均在轴向方向10上沿着中心轴线8从后端延伸至前端。同时,该中心轴线8限定旋转轴线,切削加工工具在操作期间在旋转方向D上围绕该轴线旋转。
基体6又被分成后轴部分12,切削加工工具2在操作期间利用后轴部分12在切削加工工具的张紧件中保持被夹持。设有排屑槽14的切削部分16在轴向方向10上连接到轴部分12。在示例性实施例中,排屑槽14以螺旋图案延伸。端面刀头4具有主切削刃18,每个主切削刃通常过渡到在圆周侧上的副切削刃20中。这些在切削部分16中延续。
支撑斜面24与旋转方向相对地邻接副切削刃20。
如下文基于图2至图5所述,基体6为一体化基体6,其不是由实心材料形成,而是由至少在轴向部分中具有非实心的芯结构26形成。如图2特别地所示,该芯结构被设计为轴部分12中的圆形结构,如在剖视图中所看到的那样。为此,在该轴部分12中的芯结构26优选地被设计成具有恒定的半径R1。支撑斜面24与旋转方向相对地邻接副切削刃20。该圆柱形芯结构26由外壳套28围绕,除了在外部引入的平坦部30之外,外壳套28被设计为环形圈。该外罩壳28具有半径R2。芯结构26的半径R1优选地为外半径R2的约50%至90%。芯结构26具有芯横截面积A1,并且切削加工工具2具有总横截面积A2。该面积由外壳套28所包围的区域限定,包括外壳套28的表面。
在轴部分12的后端处,轴部分12可选择性地用实心材料制成的端面板封闭,即,非实心的芯结构26仅形成于轴部分12的内部中,而从后端面不可见。冷却剂传输点便利地形成并结合到此实心端面板中。特别是,引入了具有延伸至芯结构26的通孔的横向凹槽。
在示例性实施例中,芯结构26以类似的方式同样在轴向方向10上被实心的隔离物32限制在轴部分12的端部区域中,至少一个或在示例性示例中两个切口34贯穿隔离物32。备选地,芯结构26也从轴部分12不间断地跨越到切削部分6中,并且不带有隔离物32。隔离物32具体地讲设置在没有内部冷却剂源的切削加工工具2中。然而,冷却剂源在原则上经由切削部分16中的切口34而得以实现。
在切削加工工具2的前部区域中,即,在刀头4的区域中,设置了用于冷却剂或润滑剂的至少一个出口点35。例如朝切削区域取向的多个出口部位35优选地形成于前端面中或者也周向地形成。出口部位35可以常规方式被设计为镗孔。然而,其同样优选地借助于3D打印方法形成并且是在几何上复杂的。芯结构26优选地导向至外部以形成出口部位35。在图1所示示例性实施例中,出口部位35在刀头的区域中形成于例如圆周壁36中,并且特别是形成为多孔结构。因此,出口部位35在示例性实施例中因此大体上一体化到保持腹板7中。
芯结构26延续到切削部分16自身(图4)中。由于排屑槽14和基体6的由此修改的圆周几何形状,芯结构26的横截面几何形状特别是被调适成使得它完全地由与外壳套28大致相同的壁厚包围。特别是,芯结构26被设计成在切削部分16中为细长的,并且具有在两端处过渡到加宽部38中的中心区域37。每个所述加宽部的外边缘具有准确的轮廓,以使得加宽部同心地延伸至基体6的圆周线。
芯结构26优选地在其总横截面积A1上为同质且均匀的。备选地,可以以这里不进一步示出的方式设置附加的支撑件。在图1的实施例变体中便利地不形成单独的冷却剂通道。
根据第一实施例变体,芯结构26被设计为多孔结构。相比之下,根据图5所示的第二实施例变体,芯结构26被设计为网格状结构,特别是蜂窝形结构。该结构具有在轴向方向10上延伸的多个单独的通道40。图5中示意性地示出了矩形通道。单独的通道40各自由隔离物42彼此分离。这些隔离物42优选地仅具有例如低于0.3mm且特别是低于0.15mm的小的材料厚度。单独的通道40通常具有低于0.5mm的通道宽度W。
芯结构26的另外的备选方案在图6和图7中示出。在这些实施例变体中,芯结构26设计为所谓的仿生结构,其中,相比图5中所示的网格状结构,单独的隔离物42为无序的,并且不遵循图案,至少不是反复的图案。
原则上可以将不同的结构彼此组合并且例如在剖面内彼此紧邻地形成。备选地,该结构在轴向方向10上变化。具体的制造方法允许几乎所有所需的组合和变化。特别是,在切削部分16和轴部分12中存在具体地讲具有不同的孔隙率的不同结构。因此,例如,切削部分16具有比轴部分12更大的孔隙率,反之亦然。
基体6利用被称为3D打印的方法制造。在此方法中,金属粉末被借助于激光处理连续地且因此逐层地根据每一层的所需横截面几何形状加工并且被熔融或烧结,以形成内聚的一体化子体。在此过程中,每一层的每个横截面轮廓通过激光预限定。利用此3D打印方法,可以形成几乎任何随意而复杂的并且特别是可变的横截面几何形状。特别是,由图2至图5描述且具有实心的包围外罩壳28的芯结构26利用此方法形成。整个基体6由此通过利用此制造方法形成为单件式一体化主体。如有必要,在3D打印过程之后,该主体也可经历精修加工。
基体6优选地由根据DINEN10027的工具钢制成,该材料例如具有材料编号1.2709和/或1.2344。
Claims (12)
1.一种切削加工工具(2),特别是旋转刀具,诸如钻头或铣刀,所述切削加工工具(2)具有在轴向方向(10)上延伸的一体化基体(6),其特征在于,所述基体(6)至少在部分区域中具有包封在实心的外壳套(28)中的非实心的芯结构(26)。
2.根据权利要求1所述的切削加工工具(2),其特征在于,所述芯结构(26)选择性地构造为多孔的、网格状或仿生的,或者为这些构造方式的组合。
3.根据权利要求1或2所述的切削加工工具(2),其特征在于,所述芯结构(26)设计为蜂窝状结构。
4.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,如果所述芯结构(26)为多孔的,那么其孔隙率在5%和90%之间的范围内;并且如果所述芯结构(26)为网格状的,那么其具有多个沟道,所述多个沟道在纵向方向上延伸且具有小于0.5mm、特别是小于0.10mm的沟道宽度(W)。
5.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述芯结构(26)具有圆形横截面。
6.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述芯结构(26)覆盖所述基体(6)的总横截面积(A2)的5%至80%。
7.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述芯结构(26)在轴向方向(10)上具有不同的横截面积(A1)。
8.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述基体(6)具有轴部分(12)和前切削部分(16),所述轴部分(12)和所述前切削部分(16)各自具有芯结构(26),并且所述芯结构(26)特别是从所述轴部分(12)出发延伸进入所述切削部分(16)。
9.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述切削加工工具(2)具有带槽的切削部分(16),并且所述芯结构(26)在所述切削部分(16)的区域中横向越过中心区域(36)延伸并且在所述中心区域(37)的两侧具有加宽部(38)。
10.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述芯结构(26)设计为用于传导冷却剂。
11.根据前述权利要求中的任一项所述的切削加工工具(2),其特征在于,所述切削加工工具(2)设计为承载工具,所述承载工具具有能固定到所述基体(6)上的切削元件(4),其中所述基体(6)由工具钢制造。
12.一种用于制造切削加工工具的方法,所述切削加工工具特别是旋转刀具,诸如钻头或铣刀,所述切削加工工具具有在轴向方向(10)上延伸的一体化基体(6),其特征在于,所述基体(6)借助于3D打印方法制造。
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US20180345388A1 (en) | 2018-12-06 |
US10105769B2 (en) | 2018-10-23 |
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DE102014207507B4 (de) | 2021-12-16 |
US20150298222A1 (en) | 2015-10-22 |
US10646936B2 (en) | 2020-05-12 |
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