WO2019151169A1 - エンドミルおよび加工方法 - Google Patents
エンドミルおよび加工方法 Download PDFInfo
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- WO2019151169A1 WO2019151169A1 PCT/JP2019/002632 JP2019002632W WO2019151169A1 WO 2019151169 A1 WO2019151169 A1 WO 2019151169A1 JP 2019002632 W JP2019002632 W JP 2019002632W WO 2019151169 A1 WO2019151169 A1 WO 2019151169A1
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- WIPO (PCT)
- Prior art keywords
- blade
- outer peripheral
- end mill
- blades
- peripheral blade
- Prior art date
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C9/00—Details or accessories so far as specially adapted to milling machines or cutter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2200/00—Details of milling cutting inserts
- B23C2200/04—Overall shape
- B23C2200/0422—Octagonal
- B23C2200/0427—Octagonal rounded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/04—Angles
- B23C2210/0407—Cutting angles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/04—Angles
- B23C2210/0407—Cutting angles
- B23C2210/0421—Cutting angles negative
- B23C2210/0435—Cutting angles negative radial rake angle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/20—Number of cutting edges
- B23C2210/207—Number of cutting edges eight
Definitions
- the present invention relates to an end mill and a processing method using the end mill.
- the present invention has been made in view of such circumstances, and is an end mill for use in contour processing, and is intended to provide an end mill that can reduce zero cut in finishing processing and increase processing accuracy.
- An end mill includes a cylindrical shaft portion extending along a central axis, and a blade portion positioned on a tip side of the shaft portion, and the blade portion is larger than the shaft portion.
- Eight outer peripheral blades having an outer diameter are provided along the circumferential direction, and the outer peripheral blades are spiral blades extending spirally around the central axis, and attention is paid to one of the eight outer peripheral blades.
- n (L ⁇ tan ⁇ ) / (2 ⁇ a)
- the end mill of the present invention employs a configuration in which excellent tool performance is reproduced when the depth of cut is shorter than the entire length of the outer peripheral blade. Specifically, it is configured such that particularly excellent tool performance is reproduced in contour line machining in which the depth of cut is half the total length of the outer peripheral blade.
- n represented by the above formula represents the number of outer peripheral blades that are always in contact with the work material during cutting of the work material by the end mill. According to the above-described configuration, in the lower half region of the outer peripheral blade, approximately one outer peripheral blade is always in contact with the workpiece during cutting (the number of simultaneous contact blades in the lower half region is always substantially lower). 1).
- the cutting resistance that the end mill receives from the work material increases or decreases. Thereby, there is a problem that the end mill vibrates and the machining accuracy is lowered. Since the lower half area of the outer peripheral blade has a large machining allowance, it is easy to amplify the vibration of the end mill when the number of simultaneous contact blades increases or decreases. Further, even when the number of simultaneous contact blades in the lower half region of the outer peripheral blade is always a natural number of 2 or more, the machining accuracy is lower than when the number of simultaneous contact blades is always approximately 1.
- the number of simultaneous contact blades is always approximately 1, so that tool deflection is difficult to occur during processing, and end mill vibrations are suppressed. Surface processing accuracy can be increased.
- the outer peripheral blade length can be secured long in the axial direction within a range that satisfies the above-described configuration, and a wider range can be processed in one step when performing contour line processing, resulting in a reduction in processing cost.
- eight outer peripheral blades are provided.
- the increase / decrease in cutting resistance when the peripheral blades contacting the work material are switched is suppressed. it can.
- the increase / decrease width of the cutting resistance is reduced, the vibration of the end mill during cutting can be suppressed, and as a result, the machining accuracy can be increased.
- the n may be 0.9 or more and 1.1 or less.
- n is 0.95 or more and 1.05 or less.
- M represented by the above formula represents the number of outer peripheral blades that always come into contact with the work material during the cutting of the work material by the end mill over the entire length of the outer peripheral blade.
- the machining surface is mainly formed in the lower half region of the blade length, and then the lower half region is newly formed.
- the upper half region of the blade length bends during machining of a smooth surface, and the region processed by the lower half region of the blade length can be processed again in the upper half region of the blade length.
- a minute step is generated at the boundary of the cut in the depth direction due to the deflection of the end mill.
- the region processed by the lower half of the blade length can be processed by aligning the blade length and the simultaneous contact blade using the upper half of the blade length in the next cutting.
- the surface processed first with the lower half blade length can be exposed to the number of simultaneous contact blades of approximately 1 in the upper half region of the blade length in the next cut. Therefore, the processing accuracy of the processed surface is further increased, and a step generated at the boundary portion of the cut in the depth direction can be reduced.
- the m may be 1.9 or more and 2.1 or less.
- the processing accuracy of the processing surface can be increased.
- m exceeds 2.1, or when m is less than 1.9, it is difficult to form a machined surface with sufficient machining accuracy because the vibration of the end mill during machining affects the machining accuracy. It becomes. That is, according to the above-described configuration, the processing accuracy of the processed surface can be sufficiently increased. More preferably, m is 1.95 or more and 2.05 or less.
- an outer diameter D of the outer peripheral blade is 4 mm or more.
- the outer diameter of the outer peripheral blade of the end mill of the present invention is 4 mm or more. Furthermore, the outer diameter of the outer peripheral blade is preferably 5 mm or more. Further, if the outer diameter is too large, it becomes difficult to manufacture as a solid end mill. Therefore, the outer diameter of the outer peripheral blade is preferably 30 mm or less.
- the twist angle is preferably 35 ° or more and 40 ° or less.
- the end mill having eight outer peripheral blades in which the simultaneous contact blade is always substantially 1 in the lower half region of the outer peripheral blade by setting the twist angle of the outer peripheral blade to 35 ° or more and 40 ° or less. Since the configuration of the outer peripheral blade is such that the blade length does not become too long, the rigidity of the tool is increased and the deflection of the tool is less likely to occur during machining. Thereby, the processing accuracy of the processing surface can be sufficiently increased without zero cut. Furthermore, it is preferable to set the twist angle of the outer peripheral blade to 37 ° or more and 39 ° or less.
- the outer peripheral blade may have a positive rake face.
- the outer peripheral blade since the outer peripheral blade has a positive type rake face, the outer peripheral edge is sharper than the case of having a negative type rake face. Thereby, the processing accuracy of the processing surface can be sufficiently increased without zero cut.
- the outer peripheral blade may have a two-step flank.
- the accuracy of the processed surface can be improved even when the feed amount of the end mill is increased as compared with the case where the flank has one stage. Thereby, the processing accuracy of the processing surface can be sufficiently increased without zero cut.
- the processing method according to one embodiment of the present invention is a processing method using the above-described end mill, and performs contour line processing with the depth of cut as half the blade length.
- the machining accuracy can be improved without zero cut.
- an end mill for use in contour processing which can reduce the zero cut for obtaining dimensional accuracy and can increase the processing accuracy.
- FIG. 1 is a mimetic diagram of an end mill of one embodiment.
- FIG. 2 is a front view of the blade portion of the end mill according to the embodiment.
- FIG. 3 is a plan view of a blade portion of an end mill according to an embodiment.
- FIG. 4 is an enlarged cross-sectional view of an outer peripheral blade of the end mill according to the embodiment.
- FIG. 5A is a diagram illustrating a procedure for contour processing of a wall surface using an end mill according to an embodiment, and illustrates a first step of contour processing.
- FIG. 5B is a diagram showing a procedure of contour processing of a wall surface using the end mill of one embodiment, and shows the next step of FIG. 5A.
- FIG. 5A is a diagram illustrating a procedure for contour processing of a wall surface using an end mill according to an embodiment, and illustrates a first step of contour processing.
- FIG. 5B is a diagram showing a procedure of contour processing of a wall surface using the end mill of one embodiment, and shows the next
- FIG. 5C is a diagram showing a procedure of contour processing of the wall surface using the end mill of one embodiment, and shows the next step of FIG. 5B.
- FIG. 6 is a developed schematic view of the outer peripheral blade of one embodiment developed along the circumferential direction.
- FIG. 7 shows the depth of the machined surface and the depth of the machined surface in the cutting tests of Test Example 1-1, Test Example 1-2, Test Example 1-3, Test Example 1-4, and Test Example 1-5. It is a graph which shows the relationship of the measurement result of the amount of collapse.
- FIG. 8A is a graph showing the change in cutting resistance with time in the cutting test of Test Example 2-1.
- FIG. 8B is a graph showing changes in cutting resistance with time in the cutting test of Test Example 2-2.
- FIG. 1 is a schematic diagram of an end mill 1 according to an embodiment.
- FIG. 2 is a front view of the blade portion 20 of the end mill 1.
- FIG. 3 is a plan view of the blade portion 20 of the end mill 1.
- the end mill 1 is a substantially cylindrical rod body that extends along an axial direction with an axis (center axis) O as a center.
- the end mill 1 is made of a hard material such as a cemented carbide.
- a direction parallel to the axis O of the end mill 1 is simply referred to as an axial direction.
- a direction orthogonal to the axis O is referred to as a radial direction.
- a direction around the axis O is referred to as a circumferential direction.
- the direction in which the end mill 1 rotates during cutting is referred to as the tool rotation direction T.
- a region on the tool rotation direction T side with respect to a specific part may be referred to as a rotation direction front side and a region opposite to the tool rotation direction T side may be referred to as a rotation direction rear side.
- the end mill 1 of this embodiment is a square end mill.
- the end mill 1 processes the standing wall by contour line processing.
- the work material processed by the end mill 1 is, for example, a mold nesting for resin molding.
- the end mill 1 has a shank part 12, a neck part (shaft part) 11, and a blade part 20.
- the shank portion 12, the neck portion 11, and the blade portion 20 are arranged in this order along the axis O from the proximal end side toward the distal end side.
- the shank portion 12 has a columnar shape extending along the axis O.
- the shank portion 12 is gripped by the machine tool 9.
- the end mill 1 is held by the machine tool 9 in the shank portion 12 and is rotated in the tool rotation direction T around the axis O.
- the end mill 1 is used for cutting work (cutting work) of a work material such as a metal material. Further, the end mill 1 processes the workpiece by being fed by the machine tool 9 in the direction intersecting the axis O along with the rotation around the axis O.
- the neck portion 11 has a columnar shape extending along the axis O.
- the neck portion 11 is located on the tip side of the shank portion 12.
- the outer diameter of the neck portion 11 is smaller than the outer diameter of the shank portion 12.
- the neck portion 11 is a region facing a processed surface formed by contour processing using the end mill 1.
- the blade portion 20 is located on the distal end side of the neck portion 11.
- the blade portion 20 is provided with eight outer peripheral blades 21 and eight bottom blades 22 respectively connected to the outer peripheral blade 21 on the tip (lower end) side of the outer peripheral blade 21.
- the eight outer peripheral blades 21 are arranged at equal intervals along the circumferential direction on the outer periphery of the blade portion 20. Further, the eight bottom blades 22 are arranged at equal intervals along the circumferential direction at the tip of the blade portion 20.
- the gash 26 is provided between the eight bottom blades 22, respectively.
- the eight bottom blades 22 are a center blade 22a that extends from the vicinity of the axis O toward the radially outer side, and a main bottom blade that is positioned radially outward from the center blade 22a and continues radially outward from the center blade 22a. 22b.
- a central blade second surface 23a is provided on the rear side in the rotational direction of the central blade 22a.
- a main bottom blade second surface 23b is provided on the rear side in the rotation direction of the main bottom blade 22b.
- the center blade second surface 23a and the main bottom blade second surface 23b are formed continuously in the radial direction.
- the center blade second surface 23 a and the main bottom blade second surface 23 b constitute a flank 23 of the bottom blade 22.
- the width in the circumferential direction of the main bottom blade second surface 23b gradually decreases as it goes radially inward.
- the circumferential width at the radially inner end of the main bottom blade second surface 23b is narrower than the circumferential width of the radially outer end of the central blade second surface 23a.
- the circumferential width of the center blade second surface 23a gradually decreases as it goes radially inward.
- a central groove 27 continuous with the gasche 26 is provided at the boundary between the central blade 22a and the central blade second surface 23a located on the front side in the rotational direction of the central blade 22a.
- Each central groove 27 reaches the axis O on the radially inner side. According to the present embodiment, while the central groove 27 is formed on the front side in the rotational direction of the central blade 22a, it is possible to make it difficult for fine chips existing in the gash 26 to enter the central groove 27.
- the outer peripheral blade 21 is a twisted blade that extends spirally around the axis O.
- the outer peripheral blade 21 is spirally twisted at a constant twist angle ⁇ toward the tool rotation direction T from the proximal end side of the end mill 1 toward the distal end side.
- the twist angles ⁇ of the eight outer peripheral blades 21 are the same angle. That is, the outer peripheral blade 21 of this embodiment is an equal lead.
- the outer diameter D of the outer peripheral blade 21 is smaller than the outer diameter d of the neck 11. Thereby, it is suppressed that the neck part 11 interferes with the process surface formed by the contour process.
- a chip discharge groove 24 is formed between the outer peripheral blades 21.
- the plurality of chip discharge grooves 24 are formed at equal intervals in the circumferential direction.
- the chip discharge groove 24 is helically twisted at a constant twist angle along the axial direction.
- the twist angle of the chip discharge groove 24 coincides with the twist angle ⁇ of the outer peripheral blade 21.
- the chip discharge groove 24 is rounded up to the outer periphery of the end mill 1 at the end portion on the proximal end side of the blade portion 20.
- An outer peripheral blade 21 is formed on the edge of the chip discharge groove 24 on the rear side in the rotation direction. That is, the chip discharge groove 24 is located on the front side in the rotation direction of the outer peripheral blade 21.
- the wall surface of the chip discharge groove 24 includes a bottom surface 24a and a rake surface 24b.
- the bottom surface 24 a is a surface that faces radially outward with respect to the axis O in the chip discharge groove 24.
- the rake face 24 b is a wall face facing the tool rotation direction T in the chip discharge groove 24.
- the outer peripheral blade 21 is formed on the outer peripheral surface of the blade portion 20 at the intersecting ridge line between the rake surface 24 b and the flank 25.
- the flank 25 is a surface adjacent to the chip discharge groove 24 on the rear side in the rotation direction.
- the flank 25 extends in a row in the circumferential direction from the outer peripheral blade 21 toward the chip discharge groove 24 on the rear side in the rotational direction of the outer peripheral blade 21.
- FIG. 4 is a schematic cross-sectional view schematically showing an enlarged cross section perpendicular to the axis O of the outer peripheral blade 21.
- a work material to be cut by the outer peripheral blade 21 is shown.
- the outer peripheral blade 21 of the present embodiment has two flank faces. That is, the flank 25 of the outer peripheral blade 21 has a first region 25a and a second region 25b arranged in the circumferential direction.
- the first region 25a is located on the outer peripheral blade 21 side.
- region 25b is located in the chip discharge groove 24 side.
- the first region 25 a and the second region 25 b are each configured in a circular shape that is eccentric with respect to a virtual circle centered on the axis O in the cross section of the end mill 1.
- the first region 25a and the second region 25b are configured in different circular shapes that are different from each other.
- the clearance angle ⁇ of the first region 25a is, for example, 4 °
- the clearance angle ⁇ of the second region 25b is, for example, 11 °. That is, the clearance angle ⁇ of the second region 25b is larger than the clearance angle ⁇ of the first region 25a.
- the outer peripheral blade 21 since the outer peripheral blade 21 is configured with two flank surfaces, the outer peripheral blade 21 contacts the machining surface at the minute first flank surface (first region 25a) during cutting. Then rub the processed surface of the work material. Thereby, the damage
- the clearance angle ⁇ of the first flank (first region 25a) is preferably 1 ° or more and 10 ° or less, and more preferably 4 ° ⁇ 1 °. If the angle of the first-stage flank (first region 25a) is too small, the cutting resistance increases and the processed surface may become rough. On the other hand, if the angle of the first-stage flank (first region 25a) is too large, cutting resistance can be suppressed, but the effect of rubbing the processed surface on the first-stage flank and smoothing the unevenness is reduced. . By setting the clearance angle ⁇ of the first flank (first region 25a) within the above range, the machining surface can be smoothed while cutting resistance is suppressed, and the dimensional accuracy of the machining surface is increased. Can do.
- the clearance angle of the flank is measured at a cut surface perpendicular to the axis O.
- a virtual circle connecting the tips of the outer peripheral blades is obtained, and the flank angle is obtained with respect to the tangent line of the virtual circle passing through the tips of the outer peripheral blades to be measured.
- the width w of the first flank (first region 25a) is preferably 0.01 mm or more and 0.15 mm or less, and more preferably 0.03 ⁇ 0.01 mm.
- the width w of the first flank (first region 25a) is measured at a cut surface perpendicular to the axis O.
- a virtual circle connecting the tips of the outer peripheral blades is obtained, and the length dimension of the first region 25a in the tangential direction of the virtual circle passing through the tips of the outer peripheral blades to be measured is defined as a width w.
- the outer peripheral blade 21 of the present embodiment has a positive type rake face 24b. That is, when viewed from the axial direction, the rake face 24b extends from the cutting edge of the outer peripheral blade 21 toward the opposite side of the tool rotation direction T with respect to the straight line connecting the cutting edge and the axis O. According to this embodiment, since the outer peripheral blade 21 has the positive type rake face 24b, the sharpness of the outer peripheral edge 21 is improved as compared with the case of having the negative type rake face. For this reason, the processing accuracy of the processed surface can be sufficiently increased.
- FIG. 5A, FIG. 5B and FIG. 5C are diagrams showing a procedure of contour processing of the wall surface using the end mill 1.
- FIG. 5A to 5C illustrate the steps of contour line processing. 5A to 5C, the blade length along the axial direction of the outer peripheral blade 21 is L.
- contour line processing is performed with the depth of cut as half of the blade length L.
- the outer peripheral blade 21 mainly forms a machining surface in the lower half region of the blade length L and performs machining again on the machining surface in the upper half region of the blade length L.
- the outer diameter D of the outer peripheral blade is uniform over the entire length of the outer peripheral blade. For this reason, the machining allowance in processing by the upper half region of the blade length L is very small.
- a minute step is generated at the boundary of the depth direction cut due to the deflection of the end mill.
- the machining surface formed in the lower half region of the outer peripheral blade 21 is reworked in the upper half region. For this reason, the level
- FIG. 6 is a developed schematic view of the outer peripheral blade 21 of the blade portion 20 developed along the circumferential direction.
- the blade length along the axial direction of the outer peripheral blade 21 is L
- the twist angle of the outer peripheral blade 21 is ⁇
- the lower end 21b of the outer peripheral blade 21 is A circumferential distance between the outer peripheral blade 21 and the other outer peripheral blade 21 adjacent to the rear of the outer peripheral blade 21 in the tool rotation direction is defined as a.
- the circumferential distance means an arc length extending in the circumferential direction around the axis O.
- the blade length L along the axial direction of the outer peripheral blade 21 is an effective blade length of the outer peripheral blade 21 that substantially cuts the work material. That is, the blade length L means a length along the axial direction of a region having a constant outer diameter D larger than the neck portion 11 in the outer peripheral blade 21 extending spirally along the axial direction. Further, the upper end 21 a of the outer peripheral blade 21 means the upper end of a region where the outer diameter dimension D is maintained in the outer peripheral blade 21. Similarly, the lower end 21b of the outer peripheral blade 21 means the lower end of the region in which the outer diameter D is maintained in the outer peripheral blade 21.
- the end mill 1 of this embodiment is a square end mill
- the lower end 21b of the outer peripheral blade 21 is a connection part with the bottom blade 22.
- the lower end 21b of the outer peripheral blade 21 is a connecting portion with an arc-shaped radius blade.
- the blade length L along the axial direction and the twist angle ⁇ of the outer peripheral blade 21 are equal for all the outer peripheral blades 21.
- the positions in the circumferential direction substantially coincide with each other.
- the end mill 1 rotates around the axis O to cut the workpiece at the blade portion 20.
- n represented by the above formula represents the number of outer peripheral blades 21 always in contact with the work material during cutting of the work material by the end mill 1 in the lower half region of the outer peripheral blade 21.
- n represented by the above formula represents the number of outer peripheral blades 21 always in contact with the work material during cutting of the work material by the end mill 1 in the lower half region of the outer peripheral blade 21.
- approximately one outer peripheral blade 21 always comes into contact with the work material in the lower half region of the outer peripheral blade 21 (the number of simultaneous contact blades in the lower half region is always constant). About 1).
- the end mill 1 of the present embodiment is configured such that particularly excellent tool performance is reproduced when contour cutting is performed with the depth of cut in half as long as the blade length L. Accordingly, the lower half region of the outer peripheral blade 21 has a large machining allowance, which is a dominant factor in generating vibration, and it is important to have a configuration that suppresses vibration.
- the cutting resistance that the end mill 1 receives from the work material increases or decreases. More specifically, the cutting resistance sharply decreases when the outer peripheral blade 21 is separated from the work material in the lower half region, and the cutting resistance increases rapidly when the outer peripheral blade 21 starts to contact the work material. To do. Thereby, there is a problem that the end mill vibrates and the machining accuracy is lowered. Further, even when the number of simultaneous contact blades in the lower half region is always a natural number of 2 or more, the machining accuracy is lower than when the number of simultaneous contact blades is always approximately 1.
- the number of simultaneous contact blades in the lower half region is always approximately 1, so that when one outer peripheral blade 21 is separated from the work material, the other outer peripheral blade 21 and the work material are substantially at the same time. Since it starts to contact, the vibration of the end mill 1 during processing can be suppressed, and the processing accuracy of the processed surface can be increased.
- the blade length of the outer peripheral blade 21 can be secured long in the axial direction within the range satisfying the above-described configuration, and a wider range can be processed in one step when performing contour line processing, resulting in a reduction in processing cost. .
- n represented by the above is preferably 0.9 or more and 1.1 or less.
- the processing accuracy of the processing surface can be maximized.
- n exceeds 1.1 or when n is less than 0.9, the vibration of the end mill 1 during processing affects the processing accuracy, and a processing surface with sufficient processing accuracy may be formed. It becomes difficult. That is, when n is 0.9 or more and 1.1 or less, the processing accuracy of the processed surface can be sufficiently increased.
- n is more preferably 0.95 or more and 1.05 or less. By setting n to 0.95 or more and 1.05 or less, vibration of the end mill 1 can be more effectively suppressed.
- m (L ⁇ tan ⁇ ) / a (Expression 2)
- M represented by (Expression 2) represents the number of outer peripheral blades 21 that always contact the work material during the cutting of the work material by the end mill 1 over the entire length of the outer peripheral blade 21.
- the blade length and the simultaneous contact blade are the same in the lower half and the upper half of the blade length L. Therefore, the processing accuracy of the processed surface is further increased, and a step generated at the boundary portion of the cut in the depth direction can be reduced.
- m represented by the above is preferably 1.9 or more and 2.1 or less.
- the processing accuracy of the processing surface can be increased.
- m exceeds 2.1 or when m is less than 1.9, the vibration of the end mill 1 during processing affects the processing accuracy, and a processing surface with sufficient processing accuracy may be formed. It becomes difficult. That is, according to the above-described configuration, the processing accuracy of the processed surface can be sufficiently increased.
- m is more preferably 1.95 or more and 2.05 or less. By setting n to 1.95 or more and 2.05 or less, vibration of the end mill 1 can be more effectively suppressed.
- the blade portion 20 is provided with eight outer peripheral blades 21.
- the number of simultaneous contact blades is always approximately 1, while the number of the outer peripheral blades 21 is increased so that the increase / decrease width of the cutting resistance when the outer peripheral blade 21 contacting the work material is switched is increased. Can be suppressed.
- the cutting resistance can be increased or decreased to suppress the vibration of the end mill 1 during cutting, and as a result, the machining accuracy can be increased.
- the outer diameter D of the outer peripheral blade 21 is preferably 4 mm or more.
- the outer diameter D of the outer peripheral blade 21 is preferably 4 mm or more.
- the outer diameter D of the outer peripheral blade 21 is preferably 5 mm or more.
- the outer diameter D of the outer peripheral blade 21 is preferably 30 mm or less.
- the core thickness of the end mill 1 in the cross section orthogonal to the axis O of the portion where the outer peripheral blade 21 is formed is equal to the outer diameter D of the outer peripheral blade 21 in the same cross section. It is preferably 75% or more and 85% or less.
- the blade length L of the outer peripheral blade 21 is preferably 1.5 times or less, and 1.2 times or less the outer dimension D of the outer peripheral blade 21. It is more preferable that
- the twist angle ⁇ is preferably 35 ° or more and 40 ° or less.
- Test 1-5 Under the following conditions, finish cutting tests on the standing walls of Test Example 1-1, Test Example 1-2, Test Example 1-3, Test Example 1-4, and Test Example 1-5 were performed.
- ⁇ Cover cut material DAC (H) 48HRC
- End mill Outer diameter of outer peripheral edge ⁇ 6mm, core thickness 80%
- Machine MAKINO V33 (HSK-F63)
- Test Example 1-1 As the end mill used in Test Example 1-1, an end mill having a simultaneous contact blade of approximately 1 in the lower half region of the outer peripheral blade was used. Then, contour processing was performed with the depth of cut in the depth direction being half the blade length of the outer peripheral blade. Therefore, in Test Example 1-1, the machined surface cut with the lower half of the outer cutter was reworked with the upper half of the outer cutter. That is, in Test Example 1-1, cutting was performed at each step so that the number of simultaneous contact blades in the lower half and upper half regions of the outer peripheral blades was always approximately 1.
- the end mill used in Test Example 1-1 has an outer peripheral blade length of 6 mm.
- the outer peripheral edge of the end mill used in Test Example 1-1 has a two-step flank.
- the end mill used in Test Example 1-1 has eight outer peripheral blades having an equal lead with a twist angle of 38 °.
- the end mill used in Test Example 1-1 has a positive rake angle of the outer peripheral edge.
- the blade length of the outer peripheral blade was set to half the blade length of the outer peripheral blade of the end mill used in Test Example 1-1.
- contour processing was performed with the depth of cut in the entire cutting length of the outer peripheral blade. That is, in Test Example 1-2, cutting was performed at each step so that the number of simultaneous contact blades was always approximately 1 over the entire blade length.
- the end mill used in Test Example 1-2 has a peripheral blade length of 3 mm.
- the outer peripheral edge of the end mill used in Test Example 1-2 has a two-step flank.
- the end mill used in Test Example 1-2 has eight outer peripheral blades having an equal lead with a twist angle of 38 °.
- the end mill used in Test Example 1-2 has a positive type rake angle of the outer peripheral edge.
- the blade length of the outer peripheral blade of the end mill used in Test Example 1-1 was doubled, and the number of simultaneous contact blades was approximately 2 in the lower half region of the outer peripheral blade. Then, contour processing was performed with the depth of cut in the depth direction being half the blade length of the outer peripheral blade. That is, in Test Example 1-3, each step was cut such that the number of simultaneous contact blades was always approximately 2.
- the end mill used for Test Example 1-3 has a peripheral blade length of 12 mm.
- the outer peripheral blade of the end mill used in Test Example 1-3 has a two-step flank.
- the end mill used in Test Example 1-3 has eight outer peripheral blades having an equal lead with a twist angle of 38 °.
- the end mill used in Test Example 1-3 has a positive rake angle on the outer peripheral edge.
- the end mill used in Test Example 1-4 had a configuration in which the outer peripheral blade length was shortened similarly to Test Example 1-2, and the outer peripheral blade had one flank.
- contour line machining was performed with the depth of cut as the total length of the outer peripheral edge. That is, contour processing was performed so that the number of simultaneous contact blades was approximately 1 over the entire length of the blade.
- the outer peripheral edge of the end mill used in Test Example 1-4 has a one-step flank.
- the end mill used in Test Example 1-4 has a peripheral blade length of 3 mm.
- the end mill used in Test Example 1-4 has eight outer peripheral blades having an equal lead with a twist angle of 38 °.
- the end mill used in Test Example 1-4 has a positive type with a rake angle of the outer peripheral edge.
- the end mill used in Test Example 1-5 had a twist angle different from that of the end mill used in Test Example 1-1.
- contour line machining was performed with the depth of cut as the total cutting length of the outer peripheral blade. That is, contour processing was performed so that the number of simultaneous contact blades was always approximately 1 throughout the blade length.
- the end mill used in Test Example 1-5 has a peripheral blade length of 6 mm.
- the outer peripheral edge of the end mill used in Test Example 1-5 has a two-step flank.
- the end mill used in Test Example 1-5 has eight outer peripheral blades of equal leads with a twist angle of 21 °.
- the rake angle of the outer peripheral blade has a positive type.
- FIG. 7 shows the measurement of the depth of the processed surface and the amount of tilt of the processed surface in the cutting tests of Test Example 1-1, Test Example 1-2, Test Example 1-3, Test Example 1-4, and Test Example 1-5. It is a graph which shows the relationship of a result. As shown in FIG. 7, in Test Example 1-1, it can be confirmed that the amount of collapse is sufficiently small as compared with the other test examples.
- Table 1 shows the evaluation results of the processed surfaces formed in the cutting tests of Test Example 1-1, Test Example 1-2, Test Example 1-3, Test Example 1-4, and Test Example 1-5.
- Ra is the arithmetic average roughness of the machined surface
- Rz is the maximum height of the machined surface.
- the “appearance / glossiness” is the result of visual evaluation of the processed surface.
- the “machining stripe” is a visual evaluation result of the state of equally spaced streaks formed due to each step of feeding in the depth direction.
- the “falling accuracy” is an evaluation result based on the graph shown in FIG.
- Cutting resistance is the evaluation result evaluated based on the measurement result of cutting resistance. In each item, A is the best, B is the next best, C is the next best, and D is not preferable.
- Test Example 1-1 was excellent in tilt accuracy and surface properties, and zero cut for correction was unnecessary.
- Test Examples 1-3 and 1-5 where the cutting depth is large, the tilting accuracy is poor, and an uncut amount of about 10 ⁇ m was confirmed even if zero cutting was performed 5 to 10 times as an additional step.
- the falling accuracy was 5 ⁇ m or less, but the surface properties were deteriorated as compared with Test Example 1-1.
- Test 2 showing the advantage of setting the number of outer peripheral blades to 8 will be described.
- the cutting tests of Test Example 2-1 and Test Example 2-2 are performed under the following conditions.
- ⁇ Cover cut material DAC (H) 48HRC
- End mill Outer diameter of outer peripheral edge ⁇ 6mm
- Machine MAKINO V33 (HSK-F63)
- the end mill used in Test Example 2-1 has eight outer peripheral blades of equal leads, and the twist angle of the outer peripheral blade is 38 °.
- the end mill used in Test Example 2-1 is an end mill having the same configuration as the end mill of Test Example 1-1 described above.
- the end mill used in Test Example 2-2 has two outer peripheral blades of equal leads, and the twist angle of the outer peripheral blade is 72 °.
- Other configurations of the end mill used in Test Example 2-2 are the same as those of the end mill in Test Example 2-1.
- Test Example 2-1 and Test Example 2-2 the change in cutting resistance with time in a step (that is, the step shown in FIG. 5A) in which cutting is performed using only the lower half region of the outer peripheral edge in contour processing was measured.
- FIG. 8A is a graph showing the change in cutting resistance with time in the cutting test of Test Example 2-1.
- FIG. 8B is a graph showing changes in cutting resistance with time in the cutting test of Test Example 2-2.
- the horizontal axis is time
- the vertical axis is cutting force.
- the scales on the horizontal axis are the same.
- numerals are shown at points where the outer peripheral blades arranged in the circumferential direction start to contact each other.
- the end mill vibrates due to the increase / decrease of the cutting resistance, and the machining accuracy decreases. That is, by using an end mill having eight outer peripheral blades used in Test Example 2-1, compared with an end mill using two outer peripheral blades (end mill of Test Example 2-2), the accuracy of the machining surface is improved. Can be increased.
Abstract
Description
本願は、2018年2月2日に、日本に出願された特願2018-017384号に基づき優先権を主張し、その内容をここに援用する。
n=(L×tanθ)/(2×a)
また、上述の構成を満たす範囲で、外周刃の刃長を軸方向に長く確保することができ、等高線加工を行う際の1ステップでより広範囲を加工でき、結果的に加工コストを低減できる。
加えて、上述の構成によれば、8つの外周刃が設けられる。外周刃の下半分の領域において同時接触刃数が略1となる構成としつつ、外周刃の数を増加させることで、被削材に接触する外周刃が切り替わる際の切削抵抗の増減幅を抑制できる。外周刃を8つ設けることで、切削抵抗の増減幅は低減されるようになり、切削中のエンドミルの振動を抑制し、結果的に加工精度を高めることができる。
m=(L×tanθ)/a
本明細書において、エンドミル1の軸線Oと平行な方向を単に軸線方向という。また、軸線Oに直交する方向を径方向という。また、軸線O周りに周回する方向を周方向という。周方向のうち、切削加工時にエンドミル1が回転する方向を工具回転方向Tという。また、以下の説明において、特定部位に対して工具回転方向T側の領域を回転方向前方側とよび工具回転方向T側と反対側の領域を回転方向後方側と呼ぶ場合がある。
なお、本明細書において、逃げ面の逃げ角は、軸線Oに直交する切断面において測定される。測定時には、まず外周刃の先端を結ぶ仮想円を求め、測定対象の外周刃の先端を通過する仮想円の接線に対して、逃げ面の角度を求める。
なお、本明細書において、1段目の逃げ面(第1領域25a)の幅wは、軸線Oに直交する切断面において測定される。測定時には、まず外周刃の先端を結ぶ仮想円を求め、測定対象の外周刃の先端を通過する仮想円の接線方向における第1領域25aの長さ寸法を幅wとする。
外周刃の外径寸法Dは、外周刃の全長において一様である。このため、刃長Lの上半分の領域による加工における取り代は、微小なものとなる。
ここで、8つの外周刃21のうち1つの外周刃に着目し、当該外周刃21の軸方向に沿う刃長をL、当該外周刃21のねじれ角をθ、当該外周刃21の下端21bにおいて当該外周刃21と当該外周刃21の工具回転方向後方に隣接する他の外周刃21との周方向距離をaとする。なお、ここで周方向距離とは、軸線Oを中心として周方向に延びる円弧長を意味する。
n=(L×tanθ)/(2×a) …(式1)
また、上述の構成を満たす範囲で、外周刃21の刃長を軸方向に長く確保することができ、等高線加工を行う際の1ステップでより広範囲を加工でき、結果的に加工コストを低減できる。
m=(L×tanθ)/a …(式2)
以下の条件において、試験例1-1、試験例1-2、試験例1-3、試験例1-4および試験例1-5の立壁における仕上げ加工の切削試験を行った。
・被削材:DAC(H)48HRC
・エンドミル:外周刃の外径寸法Φ6mm、芯厚80%
・機械:MAKINO V33(HSK-F63)
・切削条件:回転数n=2650回転/分
送り速度Vf=636mm/分
取りしろ0.1mm
加工深さ40mm
ダウンカット
ドライ-エアブロー加工
試験例1-1に用いるエンドミルは、外周刃の刃長6mmを有する。
試験例1-1に用いるエンドミルの外周刃は、2段の逃げ面を有する。
試験例1-1に用いるエンドミルは、ねじれ角が38°の等リードの8つの外周刃を有する。
試験例1-1に用いるエンドミルは、外周刃のすくい角がポジティブタイプを有する。
試験例1-2に用いるエンドミルは、外周刃の刃長3mmを有する。
試験例1-2に用いるエンドミルの外周刃は、2段の逃げ面を有する。
試験例1-2に用いるエンドミルは、ねじれ角が38°の等リードの8つの外周刃を有する。
試験例1-2に用いるエンドミルは、外周刃のすくい角がポジティブタイプを有する。
試験例1-3に用いるエンドミルは、外周刃の刃長12mmを有する。
試験例1-3に用いるエンドミルの外周刃は、2段の逃げ面を有する。
試験例1-3に用いるエンドミルは、ねじれ角が38°の等リードの8つの外周刃を有する。
試験例1-3に用いるエンドミルは、外周刃のすくい角がポジティブタイプを有する。
ただし、試験例1-4に用いるエンドミルの外周刃は、1段の逃げ面を有する。
試験例1-4に用いるエンドミルは、外周刃の刃長3mmを有する。
試験例1-4に用いるエンドミルは、ねじれ角が38°の等リードの8つの外周刃を有する。
試験例1-4に用いるエンドミルは、外周刃のすくい角がポジティブタイプを有する。
試験例1-5に用いるエンドミルは、外周刃の刃長6mmを有する。
試験例1-5に用いるエンドミルの外周刃は、2段の逃げ面を有する。
試験例1-5に用いるエンドミルは、ねじれ角が21°の等リードの8つの外周刃を有する。
試験例1-5に用いるエンドミルは、外周刃のすくい角がポジティブタイプを有する。
表1において、「Ra」は加工面の算術平均粗さであり、「Rz」は加工面の最大高さである。また、「外観・光沢感」は、加工面の目視による評価結果である。「加工スジ」は、深さ方向の送りの各ステップに起因して形成される等間隔な筋の状態の目視による評価結果である。「倒れ精度」は、図7に示すグラフを基にした評価結果である。切削抵抗は、切削抵抗の測定結果を基に、評価した評価結果である。なお、各項目において、Aが最も良く、Bが次に良く、Cがさらに次に良く、Dが好ましくない状態であったことを示す。
試験例1-1は、倒れ精度も面性状も優れており、補正のためのゼロカットは不要であった。切り込み量が大きい試験例1-3、1-5では、倒れ精度が悪く、追加工程として、ゼロカットを5~10回行っても、10μm程度の削り残り量が確認された。試験例1-2、1-4は倒れ精度は5μm以下におさまったが、試験例1-1に比べて面性状が悪化した。
次に、外周刃の刃数を8とすることの優位性を示す試験2について説明する。
以下の条件において、試験例2-1および試験例2-2の切削試験を行う。
・被削材:DAC(H)48HRC
・エンドミル:外周刃の外径寸法Φ6mm
・機械:MAKINO V33(HSK-F63)
・切削条件:回転数n=2650回転/分
送り速度Vf=636mm/分
取りしろ0.1mm
ダウンカット
ドライ-エアブロー加工
一方で試験例2-2に用いるエンドミルは、等リードの2つの外周刃を有し、外周刃のねじれ角は、72°である。試験例2-2に用いるエンドミルのその他の構成は、試験例2-1のエンドミルと同様である。
11…首部(軸部)
20…刃部
21…外周刃
21b…下端
22…底刃
24b…すくい面
25…逃げ面
a…周方向距離
d,D…外径寸法
L…刃長
O…軸線(中心軸)
T…工具回転方向
θ…ねじれ角
Claims (11)
- 中心軸に沿って延びる円柱形状の軸部と、
前記軸部の先端側に位置する刃部と、を備え、
前記刃部には、前記軸部よりも大きい外径寸法の8つの外周刃が周方向に沿って設けられ、
前記外周刃は、前記中心軸まわりに螺旋状に延びるねじれ刃であり、
8つの前記外周刃のうち1つの外周刃に着目し、当該外周刃の軸方向に沿う刃長をL、当該外周刃のねじれ角をθ、当該外周刃の下端において当該外周刃と当該外周刃の工具回転方向後方に隣接する他の前記外周刃との周方向距離をaとした時、前記外周刃の下端から少なくとも前記刃長の半分の領域において、以下の式で表されるnが、8つの前記外周刃について全て略1である、
エンドミル。
n=(L×tanθ)/(2×a) - 前記nが、0.9以上、1.1以下である、
請求項1に記載のエンドミル。 - 前記外周刃の全長において、以下の式で表されるmが、8つの前記外周刃について全て略2である、
請求項1に記載のエンドミル。
m=(L×tanθ)/a - 前記mが、1.9以上、2.1以下である、
請求項3に記載のエンドミル。 - 前記外周刃の外径寸法が、4mm以上である。
請求項1~4の何れか一項に記載のエンドミル。 - 前記ねじれ角が、35°以上、40°以下である、
請求項1~5の何れか一項に記載のエンドミル。 - 前記外周刃は、ポジティブタイプのすくい面を有する、
請求項1~5の何れか一項に記載のエンドミル。 - 前記外周刃が、2段の逃げ面を有する、
請求項1~7の何れか一項に記載のエンドミル。 - 前記刃部には、8つの前記外周刃に加えて、先端に設けられ前記中心軸側から径方向外側に延びる8つの底刃と、前記外周刃と前記底刃との間を滑らかに繋ぐ8つのラジアス刃と、が設けられ、
前記刃部の最先端点は、前記ラジアス刃と前記外周刃の境界と前記ラジアス刃と前記底刃の境界との間において、前記ラジアス刃に位置する、
請求項1~8の何れか一項に記載のエンドミル。 - 深さ方向の切り込み量を刃長の半分として等高線加工を行う、
請求項1~9の何れか一項に記載のエンドミル。 - 請求項1~10の何れか一項に記載のエンドミルを用いた加工方法であって、
深さ方向の切り込み量を前記刃長の半分として等高線加工を行う、
加工方法。
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EP3747580A4 (en) | 2021-11-03 |
CN111670081B (zh) | 2023-06-23 |
KR20200102499A (ko) | 2020-08-31 |
EP3747580A1 (en) | 2020-12-09 |
JP6683299B2 (ja) | 2020-04-15 |
JPWO2019151169A1 (ja) | 2020-02-27 |
US20200353544A1 (en) | 2020-11-12 |
US11471958B2 (en) | 2022-10-18 |
KR102365447B1 (ko) | 2022-02-18 |
CN111670081A (zh) | 2020-09-15 |
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