JP2009113120A - Cutting tool, and cutting method using the same - Google Patents

Cutting tool, and cutting method using the same Download PDF

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JP2009113120A
JP2009113120A JP2006047635A JP2006047635A JP2009113120A JP 2009113120 A JP2009113120 A JP 2009113120A JP 2006047635 A JP2006047635 A JP 2006047635A JP 2006047635 A JP2006047635 A JP 2006047635A JP 2009113120 A JP2009113120 A JP 2009113120A
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Prior art keywords
cutting
cutting tool
tool according
rake face
grooves
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Toshiyuki Enomoto
俊之 榎本
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Osaka University NUC
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Osaka University NUC
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Priority to JP2006047635A priority Critical patent/JP2009113120A/en
Priority to PCT/JP2007/052719 priority patent/WO2007099777A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C5/00Milling-cutters
    • B23C5/02Milling-cutters characterised by the shape of the cutter
    • B23C5/06Face-milling cutters, i.e. having only or primarily a substantially flat cutting surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C5/00Milling-cutters
    • B23C5/16Milling-cutters characterised by physical features other than shape
    • B23C5/20Milling-cutters characterised by physical features other than shape with removable cutter bits or teeth or cutting inserts
    • B23C5/202Plate-like cutting inserts with special form
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C5/00Milling-cutters
    • B23C5/28Features relating to lubricating or cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C2200/00Details of milling cutting inserts
    • B23C2200/08Rake or top surfaces
    • B23C2200/086Rake or top surfaces with one or more grooves
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C2250/00Compensating adverse effects during milling
    • B23C2250/12Cooling and lubrication

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cutting tool, capable of providing high lubricity to the surface of a cutting blade even with less cutting fluid, and achieving a longer service life than conventional. <P>SOLUTION: The cutting tool includes a number of grid-shaped grooves 2 on a cutting face 1 of the cutting blade to form an ultra-fine segment structure. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、フライス盤等の工作機械に用いる切削工具、並びにこれを用いた切削方法に関するものである。   The present invention relates to a cutting tool used for a machine tool such as a milling machine and a cutting method using the same.

切削工具においては、その長寿命化を実現するために、被削材との摩擦を抑制することによって切削抵抗を低減する技術が検討されている。
例えば、切れ刃表面にくぼみを設けることにより、切りくずを短く破断して、切削抵抗を減少させる技術が知られている(特許文献1)。
In the cutting tool, in order to realize the long life, a technique for reducing the cutting resistance by suppressing the friction with the work material has been studied.
For example, a technique is known in which a dent is provided on the surface of the cutting edge to break the chip short and reduce the cutting resistance (Patent Document 1).

又、工具本体の外周にねじれた切り刃を有するエンドミルにおいて、切れ刃を形成する逃げ面及び/又はすくい面に刃先稜線に対して略平行に幅0.3mm以下の溝を少なくとも1本以上設けて、該溝に切削液を溜めることにより、切れ刃の保油性を良好なものとし、切削抵抗を低減する技術が提案されている(特許文献2)。   Further, in an end mill having a twisted cutting edge on the outer periphery of the tool body, at least one groove having a width of 0.3 mm or less is provided on the flank and / or rake face forming the cutting edge substantially parallel to the edge line of the cutting edge. Thus, a technique has been proposed in which cutting fluid is stored in the groove to improve the oil retaining property of the cutting edge and reduce cutting resistance (Patent Document 2).

更に、切削工具の耐摩耗性の向上を図るために、工具表面にダイヤモンド状炭素(DLC:Diamond-Like Carbon)等の硬質膜をコーティングする技術や、切れ刃表面の平滑度を上げることによって被削材との摩擦を低減させる技術が検討されている(非特許文献1)。   Furthermore, in order to improve the wear resistance of the cutting tool, the tool surface is coated with a hard film such as diamond-like carbon (DLC), and the smoothness of the cutting edge surface is increased. A technique for reducing friction with the cutting material has been studied (Non-Patent Document 1).

一方、ベアリング等の各種の摺動部材において、基材の表面に多数のセグメントに分割されたDLC保護膜を形成することにより、耐摩耗性の向上を図ると共に、保護膜の剥離を防止する技術が提案されている(特許文献3)。
特開2004−216510号公報 特開平7−80718号公報 特開2003−147525号公報 “トライボロジスト”第49巻 第6号 (2004) pp509-517
On the other hand, in various sliding members such as bearings, by forming a DLC protective film divided into a number of segments on the surface of the substrate, it is possible to improve wear resistance and prevent the protective film from peeling off Has been proposed (Patent Document 3).
Japanese Patent Laid-Open No. 2004-216510 Japanese Patent Laid-Open No. 7-80718 JP 2003-147525 A “Tribologist” Vol. 49, No. 6 (2004) pp509-517

しかしながら、従来の技術では、更なる工具の長寿命化に対する要求に応えることが困難となってきている。また近年は、環境負荷低減を目的に切削液を極少量のみ使用する加工方法が採用されるようになり、従来のように大量の切削液による潤滑効果が得られ難くなっており、切れ刃表面の一層の高潤滑性が求められている。   However, according to the conventional technology, it has become difficult to meet the demand for further extending the tool life. In recent years, machining methods that use only a very small amount of cutting fluid have been adopted for the purpose of reducing environmental impact, and it has become difficult to obtain a lubricating effect with a large amount of cutting fluid as in the past. Further higher lubricity is required.

本発明の目的は、少量の切削液によっても切れ刃表面に高い潤滑性が得られ、従来よりも長寿命化を図ることが出来る切削工具を提供することである。   An object of the present invention is to provide a cutting tool which can obtain a high lubricity on the surface of the cutting edge even with a small amount of cutting fluid and can have a longer life than conventional ones.

そこで本発明者は、切削工具の切れ刃表面に高潤滑性を得るべく鋭意研究を重ね、その結果、従来は摺動部材において耐摩耗性の向上と剥離防止に有効と考えられていたセグメント構造の保護膜が、切削工具の切れ刃において高い潤滑性を発揮することを見出し、本発明の完成に至った。   Therefore, the present inventor has intensively studied to obtain high lubricity on the cutting edge surface of the cutting tool, and as a result, a segment structure that has been conventionally considered effective for improving wear resistance and preventing peeling in a sliding member. It has been found that this protective film exhibits high lubricity in the cutting edge of the cutting tool, and the present invention has been completed.

本発明に係る切削工具は、少なくとも切れ刃のすくい面に多数の溝を凹設することにより、多数のセグメントの配列からなる規則的な微細三次元セグメント構造を付与したものである。
そして、本発明に係る切削方法は、前記本発明の切削工具を用いて、少なくともすくい面に対して切削液を供給しつつ切削加工を行なうものである。
The cutting tool according to the present invention is provided with a regular fine three-dimensional segment structure composed of a large number of segments by providing a large number of grooves on at least the rake face of the cutting edge.
And the cutting method which concerns on this invention cuts, supplying a cutting fluid with respect to a rake face at least using the cutting tool of the said this invention.

従来、切削工具においては、切れ刃表面を平滑に仕上げることによって、切削抵抗の低減を図っていたが、本発明においては、これとは逆の着想に基づき、切れ刃のすくい面に凹凸形状(規則的な極微細三次元構造)を付与することで、従来よりも高い潤滑性を実現した。   Conventionally, cutting tools have been designed to reduce the cutting resistance by finishing the surface of the cutting edge smoothly.In the present invention, however, the rake face of the cutting edge has an irregular shape ( By providing a regular ultra-fine three-dimensional structure), higher lubricity was achieved than before.

即ち、本発明に係る切削工具において、加工時に供給される切削液は、切削工具と被削材又は切りくずとの間に介在することにより潤滑性を発揮し、切削抵抗の低減や工具摩耗の抑制といった効果をもたらすが、切れ刃表面に形成されている極微細三次元構造が切削液を溜めるマイクロプールとしての役割を発揮し、外部から切削液が到達し難い切削点に対しても適切量の切削液が安定して供給され、更により長い時間切れ刃表面に滞留・保持され、これらの結果、従来よりも高い潤滑性が得られる。   That is, in the cutting tool according to the present invention, the cutting fluid supplied at the time of machining exhibits lubricity by being interposed between the cutting tool and the work material or chips, thereby reducing cutting resistance and tool wear. Although it has an effect such as suppression, the ultra-fine three-dimensional structure formed on the surface of the cutting edge plays a role as a micropool that collects the cutting fluid, and it is suitable for the cutting point where the cutting fluid is difficult to reach from the outside. The cutting fluid is stably supplied, and is retained and held on the surface of the cutting edge for a longer time, and as a result, higher lubricity than conventional is obtained.

具体的には、切れ刃のすくい面を覆うDLC等の硬質膜に前記多数の溝を凹設した構成や、切れ刃を構成する基材の表面に直接に前記多数の溝を凹設した構成を採ることが出来る。   Specifically, a configuration in which the multiple grooves are provided in a hard film such as DLC that covers the rake face of the cutting edge, or a configuration in which the multiple grooves are provided directly on the surface of the base material forming the cutting edge. Can be taken.

尚、前記多数の溝の凹設によってすくい面に形成される多数のセグメントがそれぞれ、1辺が10〜500μmの矩形状を呈し、且つセグメントの間隔が3〜200μmである場合に特に高い効果が得られる。   A particularly high effect is obtained when a large number of segments formed on the rake face due to the recesses of the large number of grooves each have a rectangular shape with one side of 10 to 500 μm and the interval between the segments is 3 to 200 μm. can get.

前記多数の溝は、切れ刃のすくい面のみならず、逃げ面にも凹設することが可能であり、これによって更に高い効果が得られる。   The plurality of grooves can be recessed not only on the rake face of the cutting edge but also on the flank face, thereby obtaining a higher effect.

本発明に係る切削工具及びこれを用いた切削方法によれば、切れ刃と被削材又は切りくずとの間に切削液が常に介在するようになり、これによって切削抵抗が低減され、工具摩耗を抑制することが出来、この結果、工具寿命が大幅に延びることになる。また、微少量の切削液を用いた切削加工においても、切れ刃表面での切削液の保持性に優れるため、大量の切削液を用いた切削加工と同等の加工性が得られる。   According to the cutting tool and the cutting method using the same according to the present invention, the cutting fluid always intervenes between the cutting edge and the work material or chip, thereby reducing cutting resistance and tool wear. As a result, the tool life is greatly extended. Further, even in a cutting process using a very small amount of cutting fluid, since the cutting fluid retainability on the surface of the cutting edge is excellent, workability equivalent to a cutting process using a large amount of cutting fluid can be obtained.

以下、本発明の実施の形態につき、図面に沿って具体的に説明する。
本発明に係る切削工具は、図1に示す如く、切れ刃のすくい面(1)に多数の溝(2)を格子状に凹設したものであり、具体的には、DLCの膜を複数の多数のセグメント(3)に分割して、極微細三次元セグメント構造を付与したものである。
ここで、各セグメント(3)は、1辺の長さAが150μmの矩形状であり、セグメント(3)の間隔(溝幅)Bは80μm、膜厚は0.8μmである。
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIG. 1, the cutting tool according to the present invention has a large number of grooves (2) formed in a grid shape on a rake face (1) of a cutting edge. Specifically, a plurality of DLC films are formed. Are divided into a number of segments (3) to give an ultrafine three-dimensional segment structure.
Here, each segment (3) has a rectangular shape with a side length A of 150 μm, the interval (groove width) B of the segments (3) is 80 μm, and the film thickness is 0.8 μm.

本発明に係る切削工具の効果を確認するべく、すくい面に上記セグメント構造を有するDLC膜を形成した本発明の切削工具と、すくい面の全面に連続的なDLC膜を形成した従来の切削工具とを用意し、切削加工実験を行なった。   In order to confirm the effect of the cutting tool according to the present invention, the cutting tool of the present invention in which the DLC film having the segment structure is formed on the rake face, and the conventional cutting tool in which the continuous DLC film is formed on the entire surface of the rake face. And prepared cutting experiments.

本発明の切削工具と従来の切削工具の作製において、DLC膜の合成はプラズマCVD法により行なった。本発明の切削工具の作製においては、先ずすくい面の全面にDLCを成膜した後、メッシュ状の電極を用いることにより、サイズ150×150μm、間隔80μm、膜厚0.8μmのセグメント構造を有するDLC膜を形成した。   In the production of the cutting tool of the present invention and the conventional cutting tool, the DLC film was synthesized by the plasma CVD method. In the production of the cutting tool of the present invention, a DLC film is first formed on the entire rake face, and then a mesh-like electrode is used to have a segment structure with a size of 150 × 150 μm, an interval of 80 μm, and a film thickness of 0.8 μm. A DLC film was formed.

切削加工実験においては、工作機械として、立形マシニングセンタ(ヤマザキマザック(株)製AJV−18)を用い、図2に示す如く、カッタ(3)に1つの切削工具(4)を取り付け、被削材(5)の下には動力計(6)(KISTLER製9257B)を設置し、切削抵抗を測定した。
切削工具(4)の基材としては、超硬合金を材料とした住友電工ハードメタル(株)製の「SEKN
42M」を用いた。被削材(5)にはアルミニウム合金「A5052」を用い、1枚刃にて中心削りで正面フライス切削を行なった。
In the cutting experiment, a vertical machining center (AJV-18 manufactured by Yamazaki Mazak Co., Ltd.) was used as a machine tool, and as shown in FIG. 2, one cutting tool (4) was attached to the cutter (3) and the workpiece was cut. A dynamometer (6) (9257B manufactured by KISTLER) was installed under the material (5), and cutting resistance was measured.
As a base material for the cutting tool (4), “SEKN” manufactured by Sumitomo Electric Hard Metal Co., Ltd., made of cemented carbide.
42M "was used. An aluminum alloy “A5052” was used as the work material (5), and face milling was performed by center cutting with a single blade.

加工条件としては、加工速度を380m/分、加工深さを3mm、送り速度を0.12mm/回転、切削液の供給量を12.6L/分に設定した。
そして、カッタ1回転中の切削抵抗と切りくずの厚さの変化を評価し、断続切削時における工具すくい面の潤滑状態の変化を検討した。
As processing conditions, the processing speed was set to 380 m / min, the processing depth was set to 3 mm, the feed rate was set to 0.12 mm / rotation, and the supply amount of the cutting fluid was set to 12.6 L / min.
Then, changes in cutting resistance and chip thickness during one rotation of the cutter were evaluated, and changes in the lubrication state of the tool rake face during intermittent cutting were studied.

図3は、カッタ1回転中の切削抵抗(サンプリング周波数2225Hz)を示している。尚、この切削抵抗の値は25回転分の測定値を平均したものである。
図3から分かるように、本発明の切削工具ではY方向で5%程度、Z方向で15%程度、切削抵抗が減少している。又、切削開始はカッタが20°回転、終了は160°回転したところであるが、Y、Zいずれの方向ともカッタが60°回転した付近からセグメント構造化による減少率が徐々に大きくなっている。
FIG. 3 shows the cutting resistance (sampling frequency 2225 Hz) during one rotation of the cutter. The value of this cutting resistance is the average of the measured values for 25 revolutions.
As can be seen from FIG. 3, in the cutting tool of the present invention, the cutting resistance is reduced by about 5% in the Y direction and by about 15% in the Z direction. In addition, the cutter starts at 20 ° and ends at 160 °, but the decrease rate due to the segment structure gradually increases from the vicinity where the cutter has rotated 60 ° in both the Y and Z directions.

一般にせん断角が大きくなるとせん断面積が減少し、切削抵抗は減少するため、次にせん断角を評価した。
図4は、切りくずの厚さを2mm間隔で測定し、2次元切削に近似してせん断角を算出した結果を表わしている。この切りくずの厚さは、10個の切りくずの測定値を平均したものである。従来の切削工具においては、カッタが60°回転した付近からせん断角が小さくなるが、本発明に係る切削工具ではせん断角の低下が抑制されていることが分かる。
In general, as the shear angle increases, the shear area decreases and the cutting resistance decreases. Therefore, the shear angle was evaluated next.
FIG. 4 shows the result of measuring the thickness of the chip at intervals of 2 mm and calculating the shear angle by approximating two-dimensional cutting. The chip thickness is an average of the measured values of ten chips. In the conventional cutting tool, the shear angle decreases from the vicinity of the cutter rotated by 60 °, but it is understood that the decrease in the shear angle is suppressed in the cutting tool according to the present invention.

この結果から、従来の切削工具では、カッタが60°回転した付近からすくい面における切削液の潤滑効果が失われ、これによって摩擦係数が高まり、せん断角が小さくなって、切削抵抗も大きくなったものと考えられる。
これに対し本発明の切削工具では、すくい面のセグメント構造により潤滑効果の減少が抑制され、この結果、せん断角の減少も抑制されて、切削抵抗が小さくなったものと考えられる。
From this result, in the conventional cutting tool, the lubricating effect of the cutting fluid on the rake face is lost from the vicinity where the cutter is rotated by 60 °, which increases the friction coefficient, reduces the shear angle, and increases the cutting resistance. It is considered a thing.
On the other hand, in the cutting tool of the present invention, it is considered that the reduction of the lubrication effect is suppressed by the segment structure of the rake face, and as a result, the reduction of the shear angle is also suppressed and the cutting resistance is reduced.

上述の如く、本発明に係る切削工具によれば、切削抵抗が低減され、工具摩耗を抑制することが出来るので、工具寿命が大幅に延びることになる。また、1時間当たり10mLという微少量の切削液を用いた切削加工においても、切れ刃表面での切削液の保持性に優れるため、優れた加工性が得られる。   As described above, according to the cutting tool of the present invention, the cutting resistance is reduced and the tool wear can be suppressed, so that the tool life is greatly extended. Further, even in cutting using a very small amount of cutting fluid of 10 mL per hour, excellent workability is obtained because of excellent retention of the cutting fluid on the surface of the cutting edge.

尚、本発明の各部構成は上記実施の形態に限らず、特許請求の範囲に記載の技術的範囲内で種々の変形が可能である。例えば、上記実施形態では、DLC膜にセグメント構造を形成しているが、切れ刃を構成する基材の表面にマスクエッチングやレーザ加工を施すことにより溝を凹設して、基材自体にセグメント構造を形成することも可能である。又、セグメント構造は、切れ刃のすくい面のみならず、逃げ面にも形成することが可能である。
セグメント構造を付与すべき膜としては、DLCに限らず、ダイヤモンド、TiC、TiN、TiAlN、TiCN、TiSiN、TiBON等、種々の硬質膜を採用することが出来る。又、切削工具の基材としては、超硬合金、高速度鋼、セラミックス(Al系、Si系、Al-TiC系、Ti(C,N)系等)、ダイヤモンド、CBN等を用いることが出来る。
In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, in the above embodiment, the segment structure is formed on the DLC film, but the groove is formed by performing mask etching or laser processing on the surface of the base material constituting the cutting edge, and the segment is formed on the base material itself. It is also possible to form a structure. The segment structure can be formed not only on the rake face of the cutting edge but also on the flank face.
The film to be provided with the segment structure is not limited to DLC, and various hard films such as diamond, TiC, TiN, TiAlN, TiCN, TiSiN, and TiBON can be employed. Moreover, as the base material of the cutting tool, cemented carbide, high speed steel, ceramics (Al 2 O 3 system, Si 3 N 4 system, Al 2 O 3 —TiC system, Ti (C, N) system, etc.), Diamond, CBN, etc. can be used.

本発明に係る切削工具の構造を示す一部拡大斜視図である。It is a partially expanded perspective view which shows the structure of the cutting tool which concerns on this invention. 切削加工実験の装置構成を示す斜視図である。It is a perspective view which shows the apparatus structure of a cutting experiment. 本発明の切削工具と従来の切削工具の切削抵抗の変化を示すグラフである。It is a graph which shows the change of the cutting resistance of the cutting tool of this invention, and the conventional cutting tool. 本発明の切削工具と従来の切削工具のせん断角の変化を示すグラフである。It is a graph which shows the change of the shear angle of the cutting tool of this invention, and the conventional cutting tool.

符号の説明Explanation of symbols

(1) すくい面
(2) 溝
(3) セグメント
(1) Rake face
(2) Groove
(3) Segment

Claims (11)

少なくとも切れ刃のすくい面に多数の溝を凹設してなる切削工具。   A cutting tool in which a large number of grooves are provided in at least the rake face of the cutting edge. 前記多数の溝の凹設によって多数のセグメントの配列からなる微細セグメント構造が形成されている請求項1に記載の切削工具。   The cutting tool according to claim 1, wherein a fine segment structure composed of an array of a plurality of segments is formed by recessing the plurality of grooves. 前記多数のセグメントは、その表面が平滑に仕上げられている請求項2に記載の切削工具。   The cutting tool according to claim 2, wherein the plurality of segments have a smooth surface. 前記セグメントの表面粗さは、最大高さ3μmRy以下である請求項3に記載の切削工具。   The cutting tool according to claim 3, wherein the surface roughness of the segment is a maximum height of 3 μm Ry or less. 前記多数のセグメントはそれぞれ、正方形、長方形、その他の多角形、円、若しくは楕円の平面形状を有している請求項2乃至請求項4の何れかに記載の切削工具。   The cutting tool according to any one of claims 2 to 4, wherein each of the plurality of segments has a planar shape of a square, a rectangle, another polygon, a circle, or an ellipse. 切れ刃のすくい面は硬質の膜によって覆われており、該膜に前記多数の溝が凹設されている請求項1乃至請求項5の何れかに記載の切削工具。   The cutting tool according to any one of claims 1 to 5, wherein the rake face of the cutting edge is covered with a hard film, and the plurality of grooves are provided in the film. 前記膜は、ダイヤモンド、ダイヤモンド状炭素、TiC、TiN、TiAlN、TiCN、TiSiN、TiBONから選択される材料から形成されている請求項6に記載の切削工具。   The cutting tool according to claim 6, wherein the film is formed of a material selected from diamond, diamond-like carbon, TiC, TiN, TiAlN, TiCN, TiSiN, and TiBON. 切れ刃を構成する基材の表面に直接に前記多数の溝が凹設されている請求項1乃至請求項5の何れかに記載の切削工具。   The cutting tool according to any one of claims 1 to 5, wherein the plurality of grooves are directly provided in a surface of a base material constituting the cutting edge. 前記多数の溝の凹設によってすくい面に形成される多数のセグメントはそれぞれ、1辺が10〜500μmの矩形状を呈し、セグメントの間隔は3〜200μmである請求項1乃至請求項8の何れかに記載の切削工具。   9. The multiple segments formed on the rake face by the recesses of the multiple grooves each have a rectangular shape with a side of 10 to 500 [mu] m, and the interval between the segments is 3 to 200 [mu] m. The cutting tool according to Crab. 前記多数の溝は、切れ刃のすくい面及び逃げ面に凹設されている請求項1乃至請求項9の何れかに記載の切削工具。   The cutting tool according to any one of claims 1 to 9, wherein the plurality of grooves are recessed in a rake face and a flank face of a cutting edge. 少なくとも切れ刃のすくい面に多数の溝を凹設して多数のセグメントの配列からなる微細セグメント構造を形成した切削工具を用い、少なくとも該すくい面に対して切削液を連続的に或いは間欠的に供給しつつ切削加工を行なうことを特徴とする切削方法。   Using a cutting tool in which a large number of grooves are formed at least on the rake face of the cutting edge to form a fine segment structure consisting of an array of multiple segments, at least the cutting fluid is continuously or intermittently applied to the rake face. A cutting method characterized by performing cutting while supplying.
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