CN113770670A - PCD end mill and machining method thereof - Google Patents
PCD end mill and machining method thereof Download PDFInfo
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- CN113770670A CN113770670A CN202111130907.6A CN202111130907A CN113770670A CN 113770670 A CN113770670 A CN 113770670A CN 202111130907 A CN202111130907 A CN 202111130907A CN 113770670 A CN113770670 A CN 113770670A
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- 238000003754 machining Methods 0.000 title claims description 85
- 238000000034 method Methods 0.000 title claims description 21
- 238000005520 cutting process Methods 0.000 claims abstract description 33
- 238000010892 electric spark Methods 0.000 claims abstract description 20
- 239000000956 alloy Substances 0.000 claims abstract description 13
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 239000011265 semifinished product Substances 0.000 claims abstract description 6
- 238000003466 welding Methods 0.000 claims abstract description 6
- 239000000047 product Substances 0.000 claims abstract description 3
- 230000008569 process Effects 0.000 claims description 8
- 238000000227 grinding Methods 0.000 abstract description 12
- 238000003672 processing method Methods 0.000 abstract description 11
- 229910003460 diamond Inorganic materials 0.000 abstract description 9
- 239000010432 diamond Substances 0.000 abstract description 9
- 230000007547 defect Effects 0.000 abstract description 5
- 238000005516 engineering process Methods 0.000 abstract description 4
- 230000002093 peripheral effect Effects 0.000 description 13
- 239000000463 material Substances 0.000 description 6
- 238000005219 brazing Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000006557 surface reaction Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- YWJQGSHYTRHJJH-UHFFFAOYSA-N [Co].[Ti].[W] Chemical compound [Co].[Ti].[W] YWJQGSHYTRHJJH-UHFFFAOYSA-N 0.000 description 1
- ZTJWUVMPZRLXAB-UHFFFAOYSA-N [Ta].[Ti].[W] Chemical compound [Ta].[Ti].[W] ZTJWUVMPZRLXAB-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- JPNWDVUTVSTKMV-UHFFFAOYSA-N cobalt tungsten Chemical compound [Co].[W] JPNWDVUTVSTKMV-UHFFFAOYSA-N 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000009760 electrical discharge machining Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
- B23P15/34—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools milling cutters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/16—Milling-cutters characterised by physical features other than shape
- B23C5/18—Milling-cutters characterised by physical features other than shape with permanently-fixed cutter-bits or teeth
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2226/00—Materials of tools or workpieces not comprising a metal
- B23C2226/31—Diamond
- B23C2226/315—Diamond polycrystalline [PCD]
Abstract
The invention relates to a PCD end mill and a processing method thereof. The processing method comprises the following steps: step S1, welding the PCD blank on one end of the hard alloy bar to obtain a cutter blank; step S2, processing the end face and the outer circle of the cutter blank in an electric spark cutting mode to obtain a semi-finished cutter; and step S3, performing laser processing on the PCD blank on the semi-finished product of the cutter according to the shape of the required cutter to obtain the finished product of the PCD end mill. According to the processing method of the PCD end mill, by adopting the combination technology of electric spark cutting and laser processing, the tool blank is firstly subjected to reducing processing by utilizing electric sparks, and then the PCD blank is processed in a laser processing mode according to the design requirement of the tool appearance, so that the advantages of rapidness in cutting and high laser processing precision are fully utilized, the defects that the processing time is long and a grinding wheel is easy to wear in a diamond grinding processing mode in the prior art are overcome, the processing efficiency is greatly improved, and the production cost is reduced.
Description
Technical Field
The invention belongs to the technical field of cutter processing, and particularly relates to a PCD end mill and a processing method thereof.
Background
With the continuous development of science and technology, the precision manufacturing industry puts higher demands on cutters, especially micro cutters, and the traditional hard alloy coating cutters cannot guarantee continuous and efficient machining of micro structures of high-hardness and difficult-to-machine materials.
Polycrystalline Diamond (PDC) belongs to a novel functional material, is formed by sintering diamond micropowder and a hard alloy substrate under the condition of ultrahigh pressure and high temperature, has the high hardness, high wear resistance and thermal conductivity of diamond and the strength and impact toughness of hard alloy, and is an ideal material for manufacturing cutting tools, drilling bits and other wear-resistant tools. The PCD cutter can overcome the defects of the hard alloy cutter, and is widely applied to the processing of hard and brittle materials at present, such as: ceramics, glass, graphite, and cemented carbides, and the like. However, PCD belongs to the category of difficult-to-machine materials, tool grinding machines are mainly used for manufacturing PCD cutters at present, and grinding is mainly carried out by using diamond grinding wheels, and the loss of the diamond grinding wheels in the process of grinding PCD is large, so that the machining mode is low in efficiency and high in cost.
Disclosure of Invention
The invention aims to solve the defects in the prior art at least to a certain extent and provides a PCD end mill and a processing method thereof.
In order to achieve the above object, the present invention provides a method for machining a PCD end mill, comprising:
step S1, welding the PCD blank on one end of the hard alloy bar to obtain a cutter blank;
step S2, processing the end face and the outer circle of the cutter blank in an electric spark cutting mode to obtain a semi-finished cutter;
and step S3, performing laser processing on the PCD blank on the semi-finished product of the cutter according to the shape of the required cutter to obtain the finished product of the PCD end mill.
Optionally, in step S1, the PCD compact is cut by means of spark erosion cutting to form the PCD blank.
Optionally, the PCD blank is a cylindrical structure with the diameter being 1-2 mm larger than the diameter of the cutter shape.
Optionally, in step S2, the tool blank is mounted on a rotating shaft, and electric spark cutting processing is performed by using 0.1mm galvanized wire, the rotating speed of the rotating shaft is set to 80-120 rpm, and the cutting speed is set to 1-3 mm/min.
Optionally, the electric spark cutting comprises rough machining, semi-finishing machining and finishing machining, wherein the machining voltage of the rough machining is 50-60V, the voltage of the semi-finishing machining is 30-40V, and the voltage of the finishing machining is 20-30V.
Optionally, in step S3, the laser processing of the PCD blank includes laser thinning, rake face processing and flank face processing.
Optionally, in the laser thinning process, the laser processing parameters are set as follows: the laser power is 80-100W, the scanning speed is 1-2 mm/s, the scanning depth is 0.01-0.02 mm, and the laser point spacing is 0.02 mm.
Optionally, the processes of the front tool face machining and the rear tool face machining both include laser rough machining and laser finish machining, the laser power adopted by the laser rough machining is greater than the laser power adopted by the laser finish machining, and the machining allowance of the laser rough machining is greater than the machining allowance of the laser finish machining.
Optionally, the laser power of the laser rough machining is 60-80W, the laser finish machining power is 30-40W, and the scanning depth of each layer is 0.01 mm.
The invention also provides a PCD end mill which is prepared by the processing method.
According to the processing method of the PCD end mill, by adopting the combination technology of electric spark cutting and laser processing, the tool blank is firstly subjected to reducing processing by utilizing electric sparks, and then the PCD blank is processed in a laser processing mode according to the design requirement of the tool appearance, so that the advantages of rapidness in cutting and high laser processing precision are fully utilized, the defects that the processing time is long and a grinding wheel is easy to wear in a diamond grinding processing mode in the prior art are overcome, the processing efficiency is greatly improved, and the production cost is reduced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of a method of machining a PCD end mill in accordance with the present invention;
FIG. 2 is a schematic structural view of a PCD end mill produced by the processing method of the present invention;
FIG. 3 is a schematic view of the welding of a PCD blank to a cemented carbide bar in step S1 of the present invention;
FIG. 4 is a schematic diagram illustrating the cutting of the tool blank by electric spark in step S2 according to the present invention;
FIG. 5 is a schematic diagram of the laser thinning process in step S3 according to the present invention;
fig. 6 is a schematic view of the rake face machining process in step S3 according to the present invention;
fig. 7 is a schematic view of another rake face machining flow in step S3 according to the present invention;
fig. 8 is a schematic machining view of the flank face machining flow in step S3 of the present invention.
Reference numerals:
10a, PCD blank; 10b, a PCD bit; 20. hard alloy bar stock; 30. brazing;
11. an evacuation section; 12. a rake face; 13. a knife bottom; 14. an end edge first relief surface; 15. a peripheral edge first relief surface; 16. an end blade second relief surface; 17. a peripheral edge second relief surface; 18. an end blade; 19. a peripheral edge.
Detailed Description
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "circumferential," "radial," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the present invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be construed as limiting the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.
Referring to fig. 1 and 2, an embodiment of the present invention provides a PCD end mill and a processing method thereof, where the processing method of the PCD end mill specifically includes:
step S1, welding the PCD blank 10a to one end of the cemented carbide bar 20 to obtain a tool blank.
The PCD blank 10a is cut from a PCD composite sheet by means of electric spark cutting, one PCD composite sheet can be cut to obtain a plurality of PCD blanks 10a, and the diameter of the PCD blank 10a in this embodiment is 2 mm; the hard alloy bar 20 is made of tungsten-cobalt hard alloy, tungsten-titanium-cobalt hard alloy or tungsten-titanium-tantalum hard alloy; as shown in fig. 3, a PCD blank 10a is selected, brazing 30 is arranged between the PCD blank 10a and the cemented carbide bar 20, and then the PCD blank 10a and the cemented carbide bar 20 are welded together through high temperature, heat preservation, temperature reduction and other processes in a vacuum welding machine, so that a tool blank is formed. Preferably, the PCD blank 10a is a cylindrical structure with a diameter 1 to 2mm larger than the diameter of the tool shape.
And step S2, processing the end face and the excircle of the cutter blank in an electric spark cutting mode to obtain a semi-finished cutter.
The purpose of this step is to reduce the removal amount of laser processing, improve the processing efficiency and reduce the processing cost, so the welded cutter blank is pretreated by means of electric spark cutting. Specifically, as shown in fig. 4, a tool blank is mounted on a rotating shaft of a wire electric discharge machine, and electric discharge cutting machining is performed by using a 0.1mm galvanized wire, wherein the rotating speed of the rotating shaft is set to 80-120 rpm, and the cutting speed is set to 1-3 mm/min, so that the electric discharge cutting wire cuts the tool blank along a line shown in fig. 4.
Because the surface reaction layer is generated when the PCD material is cut by the electric spark, in order to reduce the surface reaction layer, rough machining, semi-finishing machining and finish machining are included when the PCD blank 10a is cut by the electric spark, the machining voltage of the rough machining is 50-60V, the voltage of the semi-finishing machining is 30-40V, the voltage of the finish machining is 20-30V, and the machining speed is set to be 2 mm/min.
In this embodiment, the handle portion (i.e. the cemented carbide bar 20 portion) of the final PCD end mill is taken as an example of a taper neck structure, the shape structure of the tool blank after the electric spark cutting process is shown in fig. 5, and the obtained tool semi-finished parameters are: the PCD blank 10a part has a cylindrical diameter of 1.1mm and a thickness of 0.35mm, the diameter of the neck part connecting the hard alloy bar 20 and the PCD blank 10a is 0.9mm, and the effective blade length is 2 mm.
And step S3, carrying out laser processing on the PCD blank 10a on the semi-finished cutter according to the required cutter shape to obtain the finished PCD end mill.
Specifically, in the present embodiment, the PCD blank 10a is laser processed by a laser processing device, and the laser processing device may adopt a nanosecond, picosecond, or femtosecond laser device according to actual requirements.
By adopting the processing method, the combined technology of electric spark cutting and laser processing is adopted, the diameter of the tool blank is reduced by utilizing electric sparks firstly, then the PCD blank 10a is processed by the laser processing mode according to the design requirement of the tool shape, the advantages of high speed of electric spark cutting and high laser processing precision are fully utilized, the defects of long processing time and easy abrasion of a grinding wheel in the diamond grinding processing mode adopted in the prior art are overcome, the processing efficiency is greatly improved, and the production cost is reduced.
It should be noted that the present invention is exemplified by the number of cutting edges of the finished PCD end mill being 2, and as shown in fig. 2, in other embodiments, 3 or 4 cutting edges may be used; specifically, the laser processing of the PCD blank 10a includes laser thinning, rake face 12 processing, and flank face processing.
As shown in fig. 5, in the laser thinning process of the tool, the PCD blank 10a is machined by a laser beam so as to remove portions of the PCD blank 10a that may interfere with each blade in the actual cutting process, and a clearance 11 is formed behind each blade with respect to the rake face 12 so as to ensure smooth cutting of the PCD end mill. Since the clearance 11 does not participate in the cutting action of the tool, the efficiency is the main factor when the clearance 11 is machined by the laser, and the laser machining parameters may be set as follows: the laser power is 80-100W, the scanning speed is 1-2 mm/s, the scanning depth is 0.01-0.02 mm, and the laser point spacing is 0.02mm, so that the machining efficiency in cutter production is further improved.
As shown in fig. 6 and 7, in order to implement the machining process of the rake face 12 of the tool, a laser beam generated by a laser machining device is directed vertically downward along the Z axis, the central axis of the tool blank coincides with the rotation axis of the laser machining device, the tool blank is adjusted to have its central axis at a predetermined angle (45 ° in this embodiment) with respect to the Z axis, and the laser beam moves from the outer edge of the PCD blank 10a to the central axis of the tool along the X axis direction and then moves away from the PCD blank 10a along the Y axis direction (i.e., moves along the dashed-line path shown in fig. 7); this rake face 12 processing flow is repeated to form two oppositely facing rake faces 12 on the PCD blank 10a, with each rake face 12 connecting a rake bottom 13 that is beveled at 45 °.
As shown in fig. 8, in the flank processing flow of the tool, the tool semi-finished product is adjusted to be in a horizontal position, the rotating shaft is rotated to make the included angle between the rake face 12 of the tool semi-finished product and the XY-axis plane be 10 °, meanwhile, the rotating shaft is adjusted to make the central axis of the tool semi-finished product and the X-axis plane be 10 °, so that the laser beam starts from the top center of the PCD blank 10a to perform cutting processing along the edge thereof, thereby forming the end edge first flank 14 and the peripheral edge first flank 15, the end edge first flank 14 and the peripheral edge first flank 15 are in arc transition, the fillet radius is 0.1mm, and the included angles between the rake face 12 and the end edge first flank 14 and the peripheral edge first flank 15 are both 80 °; then, the rotation axis is rotated to make the included angle between the rake face 12 of the semi-finished tool with respect to the XY-axis plane 30 °, the rotation axis is adjusted to make the central axis of the semi-finished tool with respect to the X-axis plane preferably 30 °, the laser beam is cut along the edge of the PCD blank 10a from the top center thereof again, thereby forming an end edge second flank face 16 connected to the end edge first flank face 14 and a peripheral edge second flank face 17 connected to the peripheral edge first flank face 15, the end edge second flank face 16 and the peripheral edge second flank face 17 are also in arc transition, and the included angles between the rake face 12 and the end edge second flank face 16 and the peripheral edge second flank face 17 are both 60 °.
In this manner, the PCD tip 10b having a desired shape can be machined from the PCD blank 10a by the laser thinning, rake face 12 machining, and flank face machining flow of step S3, thereby completing a finished PCD end mill having a diameter of 1mm, in which the end edge 18 is formed between the rake face 12 and the end edge first flank 14, the peripheral edge 19 is formed between the rake face 12 and the peripheral edge first flank 15, and the PCD end mill is actually chipped by the end edge 18 and the peripheral edge 19, as shown in fig. 2; the PCD end mill structure in the embodiment of the invention can be conveniently manufactured by utilizing electric spark cutting and laser processing, thereby greatly improving the processing efficiency of the cutter and simultaneously reducing the manufacturing cost of the cutter.
It should be noted that since the surface quality of the rake face 12 has a great influence on the tool performance, in order to obtain better surface quality, the rake face 12 needs to be processed with smaller laser processing parameters after the processing is completed, and the laser power is generally less than 20W. Of course, in other embodiments, the rake face 12 may be ground or repaired by a diamond grinding wheel.
Preferably, the processes of machining the front cutter face 12 and the rear cutter face both comprise laser rough machining and laser finish machining, the laser power adopted by the laser rough machining is larger than that adopted by the laser finish machining, the machining allowance of the laser rough machining is larger than that of the laser finish machining, the laser power of the laser rough machining ranges from 60W to 80W, the power of the laser finish machining ranges from 30W to 40W, and the scanning depth of each layer ranges from 0.01 mm.
In the above embodiments, the descriptions of the respective embodiments have respective emphasis, and for parts that are not described in detail in a certain embodiment, reference may be made to related descriptions of other embodiments.
In view of the above description of the technical solutions provided by the present invention, those skilled in the art will recognize that there may be variations in the technical solutions and the application ranges according to the concepts of the embodiments of the present invention, and in summary, the content of the present specification should not be construed as limiting the present invention.
Claims (10)
1. A method of machining a PCD end mill, comprising:
step S1, welding the PCD blank on one end of the hard alloy bar to obtain a cutter blank;
step S2, processing the end face and the outer circle of the cutter blank in an electric spark cutting mode to obtain a semi-finished cutter;
and step S3, performing laser processing on the PCD blank on the semi-finished product of the cutter according to the shape of the required cutter to obtain the finished product of the PCD end mill.
2. The method of machining a PCD end mill according to claim 1, wherein in step S1, the PCD compact is cut by means of electric discharge cutting to form the PCD blank.
3. The method of manufacturing a PCD end mill according to claim 2, wherein the PCD blank is a cylindrical structure having a diameter 1 to 2mm larger than the tool shape diameter.
4. The method of machining a PCD end mill according to claim 1, wherein in step S2, the tool blank is attached to a rotating shaft, and spark cutting machining is performed using a 0.1mm galvanized wire, the rotating shaft being set to rotate at 80 to 120rpm and the cutting speed being set to 1 to 3 mm/min.
5. The method for machining a PCD end mill according to claim 4, wherein the electric discharge cutting includes rough machining, semi-finish machining, and a machining voltage for the rough machining is 50 to 60V, a voltage for the semi-finish machining is 30 to 40V, and a voltage for the finish machining is 20 to 30V.
6. The method of machining a PCD end mill according to claim 1, wherein in step S3, the laser machining of the PCD blank includes laser thinning, rake face machining, and flank face machining.
7. The method of machining a PCD end mill according to claim 6, wherein in the laser thinning process, the laser machining parameters are set to: the laser power is 80-100W, the scanning speed is 1-2 mm/s, the scanning depth is 0.01-0.02 mm, and the laser point spacing is 0.02 mm.
8. The method of machining a PCD end mill according to claim 6, wherein the machining processes of the rake face and the flank face each include laser rough machining and laser finish machining, the laser power used for the laser rough machining is larger than the laser power used for the laser finish machining, and the machining allowance for the laser rough machining is larger than the machining allowance for the laser finish machining.
9. The method of machining a PCD end mill according to claim 8, wherein the laser power for the laser rough machining is 60 to 80W, the power for the laser finish machining is 30 to 40W, and the scan depth per layer is 0.01 mm.
10. A PCD end mill, produced by the method of manufacture of any one of claims 1 to 9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111130907.6A CN113770670A (en) | 2021-09-26 | 2021-09-26 | PCD end mill and machining method thereof |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111130907.6A CN113770670A (en) | 2021-09-26 | 2021-09-26 | PCD end mill and machining method thereof |
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| CN113770670A true CN113770670A (en) | 2021-12-10 |
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| CN202111130907.6A Pending CN113770670A (en) | 2021-09-26 | 2021-09-26 | PCD end mill and machining method thereof |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114932258A (en) * | 2022-06-09 | 2022-08-23 | 南京航空航天大学 | Micro milling cutter and picosecond laser preparation method thereof |
| CN115041926A (en) * | 2022-06-29 | 2022-09-13 | 中国工程物理研究院激光聚变研究中心 | Method for manufacturing capacitor coil target |
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