WO2010061933A1 - エンドミル - Google Patents
エンドミル Download PDFInfo
- Publication number
- WO2010061933A1 WO2010061933A1 PCT/JP2009/070064 JP2009070064W WO2010061933A1 WO 2010061933 A1 WO2010061933 A1 WO 2010061933A1 JP 2009070064 W JP2009070064 W JP 2009070064W WO 2010061933 A1 WO2010061933 A1 WO 2010061933A1
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- WO
- WIPO (PCT)
- Prior art keywords
- land
- nick
- lands
- end mill
- blade
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/08—Side or top views of the cutting edge
- B23C2210/088—Cutting edges with a wave form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2220/00—Details of milling processes
- B23C2220/60—Roughing
- B23C2220/605—Roughing and finishing
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- 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]
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- 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
- B23C2226/37—Fibreglass
Definitions
- the present invention is a milling cutter used for cutting a work material such as FRP resin, and particularly includes a flat (router) end mill having a flat tip, or an end mill with a drill function having a blade at the tip (radius end mill, ball end mill). )
- FRP Fiber Reinforced Resin
- GFRP glass fiber
- CFRP carbon fiber compounded resin
- AFRP aramiso fiber compounded resin
- the thermal conductivity of the FRP resin itself is extremely small compared to a metal material, for example, about one-twentieth of carbon steel. For this reason, the frictional heat generated at the time of cutting is not radiated through the chips and the workpiece, and the frictional heat tends to be trapped in the cutting blade and the workpiece. At this time, if the above-mentioned “offset” occurs, it is more difficult to dissipate heat, and particularly frictional heat tends to be trapped. When frictional heat is accumulated during cutting in this way, the FRP resin is melted and transferred to the cutting edge of the cutting blade, so-called welding state is obtained.
- the present invention suppresses the occurrence of whitening phenomenon and delamination of the cutting surface, prevents the occurrence of resin welding during cutting, enables long-time cutting by high-speed rotation of FRP resin, and has excellent durability. It is an object to provide an end mill having the same.
- the end mill of the present invention is composed of a rod-shaped body of the rotating shaft S with the distal end side as a blade portion and the proximal end side as a shank portion, A plurality of torsion grooves 1 extending while twisting the peripheral surface of the rod-shaped body from the distal end of the blade portion toward the proximal end side are formed for each predetermined phase with the rotation axis S as the center, The plurality of twisted grooves 1 are formed between the adjacent twisted grooves 1 and odd-numbered lands 2 that are also twisted and extended, At least one adjacent land group (one or plural land groups each including the first land 21 and the second land 22) among the odd number of lands 2 includes each land constituting the land group.
- a first nick 31 having a nick apex 3t having a land width extending in a predetermined first direction a1 is formed on the first land 21, and a nick apex 3t extending in a second direction a2 different from the first direction.
- a second nick 32 having Of the odd number of lands 2, finishing lands 4 are formed on the remaining lands 23 other than the land group.
- the first nick of the first land 21 and the second nick of the second land 22 constituting one set of land groups can continuously cut in different directions or discharge chips after cutting. As a result, chips are less likely to remain on the work material.
- the finishing blade 4 passes the work surface every time the end mill rotates, so that the remaining land 23 is cut each time cutting in different directions and discharging chips.
- the finishing process is performed by the finishing blade 4. This produces the same effect as the case where cutting in two directions is continued while always performing fine finishing, and the effect of constantly suppressing the increase in frictional heat due to cutting.
- the occurrence of vibration (behavior phenomenon) during high-speed rotation can be suppressed as compared with the conventional case having a plurality of twisted grooves 1 and lands. This also contributes to the formation of a beautiful finished surface, the whitening phenomenon of the work surface, and the suppression of delamination.
- the cutting process is performed.
- the process and the finishing process can be completed in one process, and the machining efficiency is improved by eliminating the need for a single cutting process.
- the first direction a1 of the nick top portion 3t of the first nick and the second direction a2 of the nick top portion 3t of the second nick are equal to each other on both sides with the rotation axis S as a boundary. It is preferable that it is inclined in axisymmetric manner.
- the nick top 3t of the first nick is formed in a first direction inclined at an inclination angle ⁇ to one side with respect to the rotation axis S, and the second direction of the nick top 3t of the second nick is relative to the rotation axis S. And formed in a second direction inclined at an inclination angle ⁇ toward the other side.
- the formation direction of the edge angle and clearance angle with respect to the work piece is the first land 21 and the second land 22. Therefore, cutting with the same efficiency is continuously performed. Thereby, generation
- finishing blade 4 of at least one remaining land 23 is a polycrystalline diamond sintered blade.
- finishing blade 4 By making the finishing blade 4 of other crystal diamond sintered blade, the finishing effect is enhanced, the occurrence of fluffing and squeezing is further suppressed, and the cutting burden on the work material is suppressed to reduce the whitening phenomenon and Generation of delamination can be suppressed.
- the finishing blade 4 of any one of the remaining lands 23 is made of a polycrystalline diamond sintered blade, so that the finishing blade 4 of a different material can be cut.
- Different finishing effects such as rough finishing and dense finishing can be obtained by contacting the objects in order.
- the first nick 31 and the second nick 32 are rotating shafts from one side end on the rear side in the rotation direction of the land width 2w toward the other side end on the front side in the rotation direction.
- the height of the nick top portion 3t from the bottom is a shape subjected to so-called second-handing processing.
- each nick has a clearance angle in the axial cross-sectional view at the nick top 3t, and the efficient discharge of chips is further suppressed and the frictional heat is further suppressed. can do.
- the plurality of torsion grooves 1 formed in any one of the end mills have the same groove width 1w, and are formed at phase positions in which the circumferential surface of the rod-like body is unequally divided around the rotation axis. It is preferable.
- each land is dispersedly arranged at a non-periodic phase position in the cross-sectional view of the axis, and the land is formed at a position slightly deviated from the equally divided position along the circumference of the rod-shaped body. Therefore, it is possible to prevent the occurrence of a co-seismic vibration due to the natural frequency of the end mill. Thereby, cutting by high-speed rotation is possible at any rotation speed.
- the land width 2w of the remaining land 23 is the land width 2w of the first land 21 and the second land 22 (first It is preferably larger than both the land width 21w and the second land width 22w).
- the contact time of the remaining land 23 that finishes the cut surface is ensured longer than the contact time with each nick that discharges cutting and chips,
- the finishing blade 4 hits the work surface at a timing shifted from the cutting timing by the second land 22. Therefore, the finished surface can be more reliably formed and the finished surface roughness can be increased.
- the land width 2w (first land width 21w, second land width 22w) of the first land 21 and the second land 22 is equal to each other as in the embodiments described later. It may be equal. Further, when there are a plurality of land groups as in Example 3 described later, the first land 21 and the second land 22 of one group are different in land width from the first land 21 and the second land 22 of the other group, respectively. It can be. If the land widths 2w of a plurality of lands are made uneven for this purpose, the cutting timing and the contact time with the workpiece become uneven, so that different cutting effects are produced for each land.
- the present invention has the above-described configuration, the first nick, the second nick, and the finishing blade 4 are sequentially contacted with the workpiece to suppress the whitening phenomenon and delamination of the cutting surface.
- a relatively elegant finish surface can be formed.
- FIGS. 1 to 4 show an end mill according to a first embodiment of the present invention.
- 3 shows a partially enlarged view of the axial cross section of Nick
- FIG. 4 shows the intermediate product before forming the cutting blade in the end mill manufacturing method of Example 1.
- FIGS. 5 and 6 show the front end structures of the end mills of Example 2 and Example 3, respectively.
- the end mill of the present invention is composed of a rod-shaped body of the rotating shaft S having a distal end side as a blade portion and a proximal end side as a shank portion, and a plurality of twisted grooves 1 are formed on the rod-shaped body. By forming, a plurality of lands are formed between the twisted grooves 1. The number of twisted grooves 1 and lands formed is an odd number of 3 or more.
- the twisted grooves 1 are formed by an odd number of 3 or more for each predetermined phase centering on the rotation axis S that extends while twisting the peripheral surface of the rod-shaped body from the distal end of the blade portion toward the proximal end side.
- the lands 2 are elongated by twisting the twisted grooves 1 between the adjacent twisted grooves 1 by the odd number of three or more odd-numbered twisted grooves 1, and only the same odd number of the twisted grooves 1 are formed.
- the odd number of lands 2 formed with a predetermined phase interval around the periphery of the rod-shaped body is composed of adjacent first lands 21 and second lands 22 and other remaining lands 23.
- first land 21 and second land 22 constitute a set of land sets.
- a first nick 31 having a nick apex 3t having a land width extending in a predetermined first direction a1 is formed.
- the first nick has a first nick top 3t that spans the land width in a predetermined first direction.
- the first direction is a direction inclined at an inclination angle ⁇ to one side with respect to the rotation axis in a side view.
- the second nick has a second nick top 3t that spans the land width in a predetermined second direction different from the first direction. It has the 2nd nick top part 3t covering the land width direction inclined in the 2nd direction opposite to said 1st direction with respect to the rotating shaft S. As shown in FIG. The first direction and the second direction are different from each other.
- the end mill of the present invention has at least one (one or a plurality of) land sets among the odd number of lands 2 formed along the periphery of the rod-shaped body, and among the odd number of lands 2, Finishing blades 4 are formed on the remaining lands 23 other than the land set.
- the end mill is inserted into a work piece made of FRP resin having a hole and rotated at a high speed.
- different two-way cutting and finishing of the cutting surface can be performed at the same time, and the conventional one-way cutting process using the one-way nick blade, the other-direction cutting process using the other-direction nick blade, and the finishing using the finishing blade 4.
- Three steps such as steps can be performed in one step.
- each configuration will be described in detail.
- FIG. 1 is a perspective view of the end mill according to the first embodiment
- FIGS. 2 and 3 are twisted grooves when viewed from the front end side of the blade (front view) and from the side (side view).
- 1 to FIG. 2 are diagrams for explaining the configuration around the land 2.
- FIG. 4 is a partial enlarged explanatory view of the first nick in the first land 21 in the twist direction
- FIG. 5 is a diamond before engraving the twist grooves 1 to 3 in the manufacturing process of the end mill of the present invention.
- the perspective view of a sintering state is shown.
- three twisted grooves 1 have a central phase interval of 120 degrees around the rotation axis (in this case, the phase interval at the central position of each groove width 1w) on the tip side.
- a total of three lands 2 consisting of a set of lands (one set of lands consisting of the first land 21 and the second land 22) and one remaining land 23 are formed.
- the first land 21 is the first land 21
- the second land 22 is the second land 22
- the third land is the remaining land 23.
- the first land 21 has a nick top 3 t in the first direction a 1.
- One nick group includes a second nick group having a nick top 3t in the second direction a2 in the second land 22, and a finishing blade 4 having a polycrystalline diamond sintered portion 43 in one remaining land 23. Is formed.
- the first direction a1 of the first nick top part 3t and the second direction a2 of the second nick top part 3t are respectively inclined at equal angles to both sides of the rotation axis S as shown in FIG. It is tilted axisymmetrically.
- the nick apex 3t of the first nick 31 is formed in a first direction inclined at an inclination angle + ⁇ to one side with respect to the rotation axis S
- the second direction of the nick apex 3t of the second nick is the rotation axis. It is formed in a second direction inclined at an inclination angle ⁇ ( ⁇ ) to the other side with respect to S.
- the formation direction of the edge angle and clearance angle with respect to the work piece is the first land 21 and the second land 22. Therefore, cutting with the same efficiency is continuously performed.
- the first nick 31 in the first land 21 is formed of a vertically elongated isosceles mountain shape that uniformly extends along the twist direction, as shown in a partially enlarged sectional view along the twist direction in FIG.
- the lower portions of the first land 21 are connected to each other and continue in the twisting direction of the first land 21.
- the second nicks in the second land 22 are also formed in the same size, shape, and pitch.
- the two hypotenuses constituting the nick's chevron are symmetrically splayed back and forth with respect to the nick's nick apex 3t, so that cutting without bias in the torsional direction, that is, in the extension direction of the first land 21 is performed. It becomes possible.
- first and second nicks are symmetrical and have the same size, so that more uniform cutting with less force bias is possible, which is applied to the finishing blade 4 that performs finishing simultaneously. The wear burden is reduced.
- each nick has a clearance angle in the cross-sectional view at the top of the nick 3t, and the efficient discharge of chips is further suppressed to further suppress the accumulation of frictional heat. Can do.
- the finishing blade 4 of the remaining land 23 formed in this embodiment is a polycrystalline diamond sintered blade having a polycrystalline diamond sintered portion 43 at the corner.
- a twisted groove 41 is formed in advance at a position where the finishing blade 4 is formed from the outer peripheral tip of the cemented carbide rod-shaped body 40 before forming to the base end side.
- a sintered body 42 (FIG. 9) in which the polycrystalline diamond sintered portion 43 is integrally formed is prepared by embedding polycrystalline diamond or ceramic powder in the twisted groove 41 and then sintering.
- the groove 1 and the nick 3 shown in FIG. 1 are formed so that the polycrystalline diamond sintered portion 43 in the sintered body 42 is disposed on the blade portion of the finishing blade 4.
- the land width 2w (first land width 21w, second land width 22w) of the first land 21 and the second land 22 of the end mill according to the first embodiment is equal to each other at each position on the rotation axis S, and is provided only by one.
- the remaining land 23 has a land width 2w (remaining land width 23w) larger than the first land 21 and the second land width 22 by a slight angle difference of 1 to 2 degrees. Finishing with the finishing blade 4 is slightly longer than the contact time with each nick 3, so that finishing is more emphasized in one cutting rotation, and it is difficult to cause spilling of each blade.
- the land width 2w (first land width 21w, second land width 22w) of the first land 21 and the second land 22 is determined at each position of the rotation axis S of the end mill. Slightly unequal widths can also be used. Even in this case, it is preferable that the land width 2w (remaining land width 23w) of the remaining land 23 is larger than the first land 21 and the second land width 22 by a slight angle difference of 1 to 2 degrees.
- the nick apex 3t is equal to each other toward the end of the end mill, and the land width 2w of the single remaining land 23 (remaining land width 23w) is the land width 2w (first land) of the first land 21 and the second land 22.
- FIG. 6 is a perspective view of the end mill of Example 2
- FIGS. 7 and 8 are twisted grooves when viewed from the front end side of the blade portion (front view) and when viewed from the side (side view).
- FIG. 1 is a diagram illustrating the configuration of a land 2.
- FIG. 9 is a perspective view of the sintered body 42 in the manufacturing process.
- five twisted grooves 1 are provided at the front end side at substantially equal intervals with a center phase interval of 70 degrees to 74 degrees (phase interval at the center position of each groove width 1w) around the rotation axis.
- a total of five lands 2 consisting of a set of lands and three remaining lands 23 are formed at unequal division positions where the adjacent intervals are slightly increased or decreased.
- the first land is the first land 21
- the second is the second land 22
- the third to fifth are the first remaining land 231, the second remaining land 232, and the third remaining land 233.
- the first land 21 has a first nick group having a nick top 3t in the first direction a1
- the second land 22 has a second nick group having a nick top 3t in the second direction a2, and three nicks.
- the first remaining land 231 and the second remaining land 232 are formed with the finishing blade 4 by polycrystalline diamond sintering.
- the finishing blades 4 of the first and second remaining lands 231 and 232 excluding the third remaining land 233 are respectively polycrystalline diamond sintered blades. .
- two torsional recesses having a phase difference of 72 degrees from the axial center are formed in advance at a position where the finishing blade 4 is formed from the outer peripheral tip to the base end side of the cemented carbide rod-shaped body 40 before molding.
- Grooves 41 are formed, and polycrystalline diamond or ceramic powder is embedded in each twisted concave groove 41 and then sintered, so that two polycrystalline diamond sintered portions 43 extending while twisting are integrally formed.
- a sintered body 42 (FIG.
- Example 2 is prepared, and in this sintered body 42, the polycrystalline diamond sintered portion 43 is arranged on the blade portion of each finishing blade 4 of the first and second remaining lands 231 and 232, respectively. As shown, the groove 1 and the nick 3 are formed.
- two of the three finishing blades 4 on the front side in the rotation direction are made of a polycrystalline diamond sintered blade having a polycrystalline diamond sintered portion 43, and two diamonds are continuously formed at the time of cutting. Finishing with a sintered blade is performed in order, followed by a cemented carbide finishing blade. As a result, the finishing blade 4 having excellent wear resistance of the finishing blade 4 and more excellent finishing effect is formed.
- the plurality of torsional grooves 1 formed in the end mill of the second embodiment have the same groove width 1w, and are formed at phase positions in which the circumferential surface of the rod-shaped body is unequally divided around the rotation axis. If this is the case, each land is dispersedly arranged at a non-periodic phase position in the cross-sectional view of the axis, and the land is formed at a position slightly deviated from the equally divided position along the circumference of the rod-shaped body. Therefore, it is possible to prevent the occurrence of a co-seismic vibration due to the natural frequency of the end mill. Thereby, cutting by high-speed rotation is possible at any rotation speed.
- the land width 2w (first land width 21w, second land width 22w) of the first land 21 and the second land 22 is equal to each other at each position of the rotation axis S of the end mill.
- the remaining three land lands 23 have the same land width 2w (remaining land width 23w).
- the land width 2w (first land width 21w, second land width 22w) of the first land 21 and the second land 22 is larger than each land width 2w (23w) of the three remaining lands 23.
- FIG. 10 shows a configuration explanatory view around the torsion grooves 1 to the lands 2 when viewed from the front end side of the blade portion.
- five twisted grooves 1 are provided at the front end side at substantially equal intervals with a center phase interval of 70 degrees to 74 degrees (phase interval at the center position of each groove width 1w) around the rotation axis.
- a total of five lands 2 composed of A and B2 land groups and one remaining land 23 are formed at unequal division positions where the adjacent intervals are slightly increased or decreased.
- the first set is the first land 21 of the first set, the second set of the second land 22 of the first set, the third set of the first land 21 of the second set, and the fourth set of the second set.
- the second land 22 and the fifth land as the remaining land 23.
- the first nick group having a nick apex 3t in the first direction a1 in the first land 21 and the second nick having a nick apex 3t in the second direction a2 in the second land 22 A group is formed.
- the finishing blade 4 by polycrystalline diamond sintering is formed in one remaining land 23.
- the land width 2w is equal to each other in the first land 21 and the second land 22 constituting each land group, and each land 2 of the A group of land groups is longer than each land 2 of the B group of land groups. It has become.
- the two-way cutting of the B group is subsequently performed, and then the finishing with the polycrystalline diamond sintered blade is performed.
- Other configurations are the same as those of the first embodiment.
- Examples 4 to 6 In the end mills of Examples 4, 5, and 6 (FIGS. 11a, b, and c), the central blade 51 or the peripheral blade 52 protrudes from the tip. As shown in FIG. 12, these second licks have a nick groove 3d having a semicircular cross section, a vertical portion 323 is formed from the front end thereof, and inclined portions 321 and 322 are formed before and after the nick top portion 3t.
- a nick groove 3d having a semicircular cross section
- a vertical portion 323 is formed from the front end thereof
- inclined portions 321 and 322 are formed before and after the nick top portion 3t.
- the end mill of the present invention is suitable for the cutting of the FRP composite material in which the FRP reinforcing fibers are combined with the above configuration, and has the following effects.
- ⁇ The first nick in the first direction and the second nick in the second direction, which are inclined symmetrically about the rotation axis, suppress the occurrence of “spotting”, “mushy”, and “burrs”, and a series of first cutting and second cutting.
- Example 1, 3 After one (Example 1, 3) or a plurality of (Example 2) cutting steps, be sure to sandwich one (Example 1, 2) or a plurality of finishing steps between the cutting step and the finishing step.
- the release of frictional heat is promoted when contacting the finishing blade 4.
- the so-called second machining process also suppresses frictional heat from being accumulated on the work piece and the end mill itself. These enable long-time cutting.
- the land of the finishing blade 4 is formed adjacent to the set of cutting lands composed of a plurality of sets of symmetrical cutting blades, the cutting edge of the work is good against the cutting lands, and high speed cutting is performed.
- FIG. 1 It is an isometric view explanatory drawing of the end mill of Example 1 of the present invention. It is front view explanatory drawing which shows arrangement
- FIG. It is side view explanatory drawing of the end mill of Example 1.
- FIG. It is an axial sectional view partial explanatory view of the 1st nick among the end mills of Example 1.
- FIG. It is a perspective explanatory view of the end mill of Example 2 of the present invention. It is front view explanatory drawing which shows arrangement
- FIG. 4 is a perspective explanatory view of an intermediate product when producing an end mill of Example 2.
- FIG. 4 is a perspective explanatory view of an intermediate product when producing an end mill of Example 2.
- FIG. It is front view explanatory drawing which shows arrangement
- FIG. 6 is an explanatory side view of end mills of Examples 4 to 6.
- FIG. 5 is a partial explanatory view of a first nick in an end section of Examples 4 to 6 in an axial cross section.
Abstract
Description
刃部の先端から基端側に向けて棒状体の周面をねじれながら伸びるねじれ溝1が、回転軸Sを中心とした所定の位相毎に複数本形成され、
この複数本のねじれ溝1によって、隣接するねじれ溝1間に、同じくねじれながら伸長する奇数本のランド2が形成されたものであって、
奇数本のランド2のうち隣り合う少なくとも一組のランド組(第一ランド21、第二ランド22からなるひと組または複数組のランド組)には、ランド組を構成する各ランドにおいて、それぞれ、ランド幅を所定の第一方向a1に亘るニック頂部3tを有した第一ニック31が第一ランド21に形成されると共に、ランド幅を前記第一方向と異なる第二方向a2に亘るニック頂部3tを有した第二ニック32が第二ランド22に形成され、
奇数本のランド2のうち、前記ランド組以外の残ランド23には、仕上げ刃4が形成されたことを特徴とする。
このようなものであれば、各ニックはそのニック頂部3tにおいて、軸横断面視の逃げ角を形成したものとなり、切り屑の効率的な排出が促されて摩擦熱がこもるのをさらに抑制することができる。
実施例1のエンドミルについて、図1に斜視図を、また図2および図3に、刃部の先端側から見たとき(正面視)、および側方から見たとき(側面視)のねじれ溝1乃至ランド2周辺の構成説明図を示す。そして図4に、第一ランド21における第一ニックのねじれ方向断面視部分拡大説明図を、そして図5に、本発明のエンドミルの製造過程における、ねじれ溝1乃至ニック3の刻設前のダイヤモンド焼結状態の斜視図を示す。
第一ランド21における第一ニック31は、図4のねじれ方向に沿った断面視部分拡大説明図のように、ねじれ方向に沿って均等に伸びる縦長の二等辺山形からなり、複数の第一ニックの下部同士が連結して、第一ランド21のねじれ方向に連続する。第二ランド22における第二ニックも同じ大きさ、同形状、同ピッチに形成される。ニックの山形を構成する両斜辺は、ニックのニック頂部3tを境にして前後へ対称に下斜方向にひろがるため、ねじれ方向前後、すなわち第一ランド21の伸長方向へ偏りを有さない切削が可能となる。例えば一つのニックの断面において、前辺あるいは後辺のいずれかが垂直近くに立設したものであると、切削時に立設側に偏向力がかかり、摩耗や欠損の原因となる。本実施例では第一、第二ニックのすべてを前後対称形状かつ同一大としているため、力の偏りが少ないより均一な切削が可能となっており、これは同時に仕上げをおこなう仕上げ刃4への摩耗負担を抑えるものとなっている。
また第一ニックおよび第二ニックは、図2に示すように、ランド幅の一側端(回転方向前側)から他側端(回転方向後側)に向かって、回転軸からのニック頂部3tの高さが低くなるように形成している。この形状は、いわゆる二番取り加工を施したものと表現される。この二番取り加工により、各ニックはそのニック頂部3tにおいて、軸横断面視の逃げ角を形成したものとなり、切り屑の効率的な排出が促されて摩擦熱がこもるのをさらに抑制することができる。
本実施例に形成される残ランド23の仕上げ刃4は多結晶ダイヤモンド焼結部43を角部に有した多結晶ダイヤモンド焼結刃となっている。これは図5に示すように、成形前の超硬合金製の棒状体40の外周の先端から基端側に向かって、仕上げ刃4が形成される位置に予めねじれ凹溝41を形成しておき、このねじれ凹溝41内に、多結晶ダイヤモンドまたはセラミック粉を埋設したのち焼結することで、多結晶ダイヤモンド焼結部43が一体形成された焼結体42(図9)を用意し、この焼結体42における多結晶ダイヤモンド焼結部43を仕上げ刃4の刃部に配するようにして図1に示す溝1およびニック3を形成したものである。仕上げ刃4を他結晶ダイヤモンド焼結刃からなるものとすることで、耐摩耗性に優れ、仕上がり面の粗度が高い仕上げ刃4が形成される。
実施例1のエンドミルの第一ランド21および第二ランド22のランド幅2w(第一ランド幅21w、第二ランド幅22w)は、回転軸S上の各位置において互いに等しく、唯一設けた一本の残ランド23のランド幅2w(残ランド幅23w)は前記第一ランド21および第二ランド幅22のいずれよりも1~2度の僅角度差だけ大きいものとなっている。仕上げ刃4による仕上げを、各ニック3による接触時間よりもわずかに多くすることで、1回の切削回転において仕上げをより重点して行い、各刃の刃こぼれが生じにくいものとしている。
(実施例2)
実施例2のエンドミルについて、図6に斜視図を、また図7および図8に、刃部の先端側から見たとき(正面視)、および側方から見たとき(側面視)のねじれ溝1・ランド2の構成説明図を示す。図9は製造過程における焼結体42の斜視図である。
本実施例に形成される三つの残ランド23のうち、第三残ランド233を除いた第一、第二残ランド231,232の仕上げ刃4は、それぞれ多結晶ダイヤモンド焼結刃となっている。これは、成形前の超硬製の棒状体40の外周の先端から基端側に向かって、仕上げ刃4が形成される位置に予め、軸中心からの位相差72度の2本のねじれ凹溝41を形成しておき、各ねじれ凹溝41内に、多結晶ダイヤモンドまたはセラミック粉を埋設したのち焼結することで、ねじれながら伸びる2本の多結晶ダイヤモンド焼結部43が一体形成された焼結体42(図9)を用意し、この焼結体42において、多結晶ダイヤモンド焼結部43が、それぞれ第一、第二残ランド231,232の各仕上げ刃4の刃部に配されるように、溝1およびニック3を形成したものである。実施例2では3つの仕上げ刃4のうち回転方向前方側のふたつを、多結晶ダイヤモンド焼結部43を有した多結晶ダイヤモンド焼結刃からなるものとし、切削時には先に連続して二つのダイヤモンド焼結刃による仕上げを順に行い、続けて超硬製の仕上げ刃を行うものとなっている。これにより仕上げ刃4の耐摩耗性に優れ、より仕上げ効果に優れた仕上げ刃4が形成される。
実施例2のエンドミルにおいて形成された複数本のねじれ溝1は、互いに等しい溝幅1wであるとともに、回転軸を中心として、棒状体の周面を不等分割した位相位置に形成される。このようなものであれば、各ランドが軸横断面視にて非周期的な位相位置に分散配置され、棒状体の周に沿って等分割した位置からわずかにずれた位置にランドが形成されることで、エンドミルの固有周波数による共震の発生を防ぐことができる。これにより、どのような回転速度においても高速回転による切削が可能となる。
その他、実施例1と異なる態様として、エンドミルの回転軸Sの各位置において、第一ランド21および第二ランド22のランド幅2w(第一ランド幅21w、第二ランド幅22w)は互いに等しく、これら以外の3本の残ランド23のランド幅2w(残ランド幅23w)は互いに等しい。前記第一ランド21および第二ランド22のランド幅2w(第一ランド幅21w、第二ランド幅22w)は3本の残ランド23の各ランド幅2w(23w)よりも大きい。このようにニックの形成されたランド幅2wと、仕上げ刃の形成されたランド幅2w(23w)とを不等とすることで、高速回転時の共振の発生を抑制し、1回転のうちに第一、第二方向の各切削よりも短時間の仕上げを多数回繰り返すことで、切削面を整えながら切削を行うことができる。これによりニックへの負担が軽減され、耐久性に優れたものとなる。その他の構成は、実施例1と同様である。
(実施例3)
実施例3のエンドミルについて、図10に、刃部の先端側から見たときのねじれ溝1乃至ランド2周辺の構成説明図を示す。
実施例4、5、6(図11a、b、c)のエンドミルは先端に中央刃51又は周刃52が突出したものである。これらの第二リックは図12に示すように、断面半円形のニック溝3dを有し、その前方側端から垂直部323が形成され、ニック頂部3tの前後に傾斜部321,322が形成される。
本発明のエンドミルは上記構成によって、FRP強化繊維を複合させたFRP複合材の切削加工に適したものとなり、下記作用効果を奏する。
・回転軸対称に傾斜した第一方向の第一ニック、第二方向の第二ニックにより、「ケバ立ち」「ムシレ」「バリ」の発生が抑制され、第一切削、第二切削という一連の切削ステップと、この切削ステップののちに行われる仕上げステップとの順次の繰り返しにより、微少ずつ仕上げながら均等に微少ずつ切削することで、仕上げFRPの樹脂の「白化現象」の発生や、多層形成されたFRPの「層間剥離」が抑制される。
・一回(実施例1,3)または複数回(実施例2)の切削ステップののちに必ず一回(実施例1、2)または複数回の仕上げステップを挟み、切削ステップと仕上げステップとを順に繰り返しながら切削を進めることで、仕上げ刃4との接触時に摩擦熱の放出が促される。また、いわゆる二番取り加工を施すことでも、被削物やエンドミル自体に摩擦熱がこもることを抑制している。これらにより長時間の切削が可能となる。
・複数組の対称形状の切削刃からなる切削用ランドの組に隣接して、仕上げ刃4のランドを形成しているため、切削用ランドへの被削物の刃当たりがよく、また高速切削加工をおこなっても第一、第二ランド22のニックの摩耗が抑えられ、耐久性に優れたものとなる。
・一部のランドを不当分割に配置する、又は一部の仕上げ用ランドを太幅に形成することで、固有振動数による共震を回避することができ、またこれと同時に、仕上げ刃4の仕上げ機能を強化し、仕上げ刃4部分を比較的摩耗しにくいものとすることができる。
・従来の第一ニックによる第一切削工程、第二ニックによる第二切削工程、仕上げ刃4による仕上げ工程といった3工程に亘る工程が不要となり、各工程用の回転刃の準備、機械のセットを含めた手順が、本発明のエンドミルによる切削・仕上げの同時工程からなる一手順で済むようになる。これにより効率的な製造が可能となる。
・製造が容易であり、複数本もの回転刃を用意する必要がないため、安価に得ることができる。
2 ランド
21 第一ランド
22 第二ランド
23 残ランド
2w ランド幅
21w 第一ランド幅
22w 第二ランド幅
23w 残ランド幅
第一残ランド231
第二残ランド232
第一方向a1
31 第一ニック
第二方向a2
32 第二ニック
ニック頂部3t
ニック溝3d
321 傾斜部
322 傾斜部
323 垂直部
α 傾斜角
4 仕上げ刃
40 棒状体
41 ねじれ凹溝
42 焼結体
43 多結晶ダイヤモンド焼結部
51 中央刃
52 周刃
S 回転軸
Claims (6)
- 先端側を刃部とし、基端側をシャンク部とした回転軸(S)の棒状体からなり、
刃部の先端から基端側に向けて棒状体の周面をねじれながら伸びるねじれ溝(1)が、回転軸(S)を中心とした所定の位相毎に奇数本形成され、この奇数本のねじれ溝(1)によって、隣接するねじれ溝(1)間に、奇数本のランド(2)が形成されたエンドミルであって、奇数本のランド(2)は、隣り合う少なくとも一組のランド組が構成され、このランド組を構成する各ランドにおいて、ランド幅を所定の第一方向(a1)に亘る頂部を有した第一ニック(31)及び、ランド幅を前記第一方向と異なる第二方向(a2)に亘る頂部を有した第二ニック(32)がそれぞれ形成され、奇数本のランド(2)のうち、前記ランド組以外の残ランド(23)には、仕上げ刃が形成されたことを特徴とするエンドミル。 - 第一ニックの頂部の第一方向(a1)、第二ニックの頂部の第二方向(a2)が、それぞれ回転軸(S)を境とした両側へ、互いに等しい傾斜角度で軸対称に傾斜してなる請求項1記載のエンドミル。
- 少なくともひとつの残ランド(23)の仕上げ刃(4)は多結晶ダイヤモンド焼結刃である請求項1または2記載のエンドミル。
- 第一ニック(31)および第二ニック(32)は、ランド幅の一側端から他側端に向かって、回転軸(S)からの頂部の高さが低くなった形状である請求項1、2または3のいずれか記載のエンドミル。
- 複数本のねじれ溝(1)は、互いに等しい溝幅(1w)であるとともに、回転軸を中心として、棒状体の周面を不等分割した位相位置に形成されてなる請求項1、2、3または4のいずれか記載のエンドミル。
- 回転軸(S)方向の各位置において、残ランド(23)のランド幅(2w)は第一ランド(21)および第二ランド(22)の各ランド幅(2w)よりも大きく形成されてなる請求項1、2、3、4または5のいずれか記載のエンドミル。
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Also Published As
Publication number | Publication date |
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JP2014148041A (ja) | 2014-08-21 |
JP5610292B2 (ja) | 2014-10-22 |
JPWO2010061933A1 (ja) | 2012-04-26 |
CA2741681A1 (en) | 2010-06-03 |
CN102227279A (zh) | 2011-10-26 |
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