WO2021190529A1 - 一种实现以铣代磨加工的pcd刀具、其制备方法及应用 - Google Patents

一种实现以铣代磨加工的pcd刀具、其制备方法及应用 Download PDF

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WO2021190529A1
WO2021190529A1 PCT/CN2021/082562 CN2021082562W WO2021190529A1 WO 2021190529 A1 WO2021190529 A1 WO 2021190529A1 CN 2021082562 W CN2021082562 W CN 2021082562W WO 2021190529 A1 WO2021190529 A1 WO 2021190529A1
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processing
laser
tool
pcd
pcd tool
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PCT/CN2021/082562
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English (en)
French (fr)
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王成勇
胡小月
林海生
郑李娟
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广东工业大学
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Publication of WO2021190529A1 publication Critical patent/WO2021190529A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/22—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by cutting, e.g. incising
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D5/00—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor
    • B28D5/02—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills
    • B28D5/022—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills by cutting with discs or wheels
    • B28D5/029—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills by cutting with discs or wheels with a plurality of cutting blades

Definitions

  • the invention belongs to the technical field of tool processing, and specifically relates to a PCD tool that realizes milling instead of grinding processing, and a preparation method and application thereof.
  • Grinding is a traditional semi-finishing and finishing method; it is a comprehensive result of the three functions of sliding, scoring and cutting on the surface of the workpiece using a large number of randomly distributed abrasive particles on the surface of the high-speed rotating grinding wheel; Refers to a machining method in which a rotating tool is used to cut a workpiece. Compared with milling processing, grinding processing has a smaller removal depth at one time and can obtain higher processing accuracy; and milling processing has higher processing efficiency and flexible processing methods than grinding processing.
  • Sapphire, glass, ceramics and other hard and brittle materials have high hardness, high brittleness, low fracture toughness, and the material's elastic limit is close to the strength; these characteristics make it prone to cracks and surface damage during processing.
  • the surface profile of these hard and brittle materials is The electroplated diamond grinding head is used for grinding to achieve the processing effect of smooth and detailed surface, smooth contour, no vibration lines, no chipping, and low grinding surface roughness. After polishing, it can reach a mirror surface.
  • the grinding efficiency of the electroplated diamond grinding head is low. After a long time of use, the abrasive grains are damaged and fall off, and the sharpness is reduced, which is easy to cause the surface damage, scratches and micro-cracks after the parts are processed. Especially when the contours of thin-walled structural parts are precisely shaped, the grinding shape and dimensional accuracy are difficult to control stably; at the same time, due to the high surface roughness of the processed surface, long-term polishing is required, which greatly increases the subsequent processing time and cost.
  • Milling is a removal method in which the teeth of the milling cutter periodically participate in intermittent cutting at high speeds.
  • the number of blades of traditional milling cutters is mostly 1-4.
  • the ambassador material produces micro-cracks and breaks during the removal process. Therefore, the milling of hard and brittle materials puts high demands on the quality of traditional tools, processing parameters and machine tool quality. Therefore, traditional grinding and milling have certain defects in processing hard and brittle materials such as sapphire, glass, and ceramics.
  • the cutting tool is prepared by mixing diamond micropowder and bonding agent at high temperature and high pressure to prepare a PCD sheet, and then cutting into a corresponding shape and welding on the substrate to make the cutting tool.
  • PCD tools have high hardness and strength similar to those of natural diamond, and the tools can produce sharp cutting edges, which are suitable for processing materials with higher hardness.
  • traditional PCD tools with 1-4 blades will also produce greater stress when processing hard and brittle materials.
  • the material produces microcracks and breakage. Therefore, it is necessary to optimize the cutting edge structure and processing methods of PCD tools in combination with the characteristics of grinding. .
  • the present invention provides a PCD tool that realizes milling instead of grinding, and its preparation method and application.
  • the PCD tool of the present invention increases the number of blades, reduces the amount of single-tooth cutting, and reduces the cutting stress and cutting heat;
  • the cutting edge is distributed evenly around the cutter head to make the force uniform; laser processing is used to improve the accuracy of the cutting edge, and at the same time, the diamond particles on the cutting edge are involved in the cutting, which plays a role of micro-grinding. It achieves milling instead of diamond grinding head grinding, which greatly shortens the follow-up polishing time and improves the processing quality.
  • a PCD tool that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 10-100.
  • the cutting edges of the PCD cutter are distributed on the cutting head in a uniformly encircling manner, the rake angle of the cutting edge is -5°-15°, the helix angle is 10°-40°, and the cutting edge depth is 1-4 mm.
  • the cutting edge of the PCD tool is designed according to the required processing mode, and can be designed as any one of face milling cutter, chamfering cutter, round nose cutter, T-shaped cutter, and forming cutter, and is not limited to the above several types of milling. Tool.
  • the number of cutting edges of the tool is designed according to the processing requirements and the characteristics of the processed materials, and the cutting amount of a single tooth in the cutting process is reduced by increasing the number of cutting edges, achieving micro cutting, reducing cutting stress and cutting heat, and avoiding material collapse.
  • the number of blades is 10-100; the geometric parameters of the blade are designed according to the cutting requirements and the number of blades.
  • the design rake angle is -5°-15°, the helix angle is 10°-40°, the blade depth is 1-4mm, It is distributed evenly around the cutter head.
  • diamond particles are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing methods of the PCD tool include grinding processing, electric discharge processing, laser processing or a combination of processing.
  • the laser processing of the edge of the PCD tool is any one of nanosecond laser, picosecond laser, femtosecond laser, or a combination of laser processing methods.
  • the laser processing parameters of the PCD tool edge processing are: nanosecond laser parameters are laser power 10-100w, spot diameter 0.1-0.3mm, scanning speed 200-500mm/min, scanning times 1-10 times, laser The taper is 5°-10°.
  • the laser processing parameters of the PCD tool cutting edge processing are: picosecond laser parameters are laser power 10-50w, repetition frequency 200-500khz, spot diameter 0.05-0.2mm, scanning speed 400-1000mm/s, scanning times 5-50 times, the laser taper is 5°-10°.
  • the laser processing parameters of the PCD tool edge processing are: the femtosecond laser parameters are laser power 1-20w, repetition frequency 200-1000khz, spot diameter 0.01-0.1mm, scanning speed 500-2000mm/s, scanning times 10-100 times, the laser taper is 5°-10°.
  • the invention increases the number of cutting edges of the overall PCD tool, so that the cutting edges evenly surround the tool head, and optimize the overall structure, including tool geometric parameters , Edge type and number of edges, obtain small cutting force, low tool wear rate, small damage to the material surface/subsurface, high quality of the processed surface, fast processing efficiency, and optimize the design of the overall PCD multi-edge milling cutter without post-processing, and It is proposed to use a laser to process it to obtain a cutting edge with a complex shape and good processing quality. Through the cutting of the cutting edge of the tool and the micro-grinding of diamond micro-particles distributed on the cutting edge, the machining of hard and brittle materials can be realized by milling instead of grinding. .
  • the working principle of the present invention is: combining the cutting/grinding characteristics of hard and brittle materials, on the basis of the traditional PCD milling cutter, increasing the number of cutting edges of the cutting tool, so that the cutting edge of the cutting tool evenly surrounds the cutting head, so that a single cutting edge cuts each time.
  • the amount of removal when contacting the material is reduced to reduce the cutting force and cutting heat generated in milling to realize micro-cutting. On this basis, the damage to the material is reduced.
  • the diamond particles on each edge of the laser processing affect the material.
  • the surface is subjected to auxiliary micro-grinding, through the combination of two processing methods, high-quality and high-efficiency processing of the surface of the material is realized, replacing the grinding processing of the traditional diamond grinding head.
  • the new PCD tool structure and preparation method of the present invention can overcome the abrasive wear and shedding of traditional grinding processing and the material cracking and damage caused by excessive cutting force and cutting heat in traditional milling processing. Disadvantages, increase the processing quality and processing efficiency.
  • Figure 1 is a schematic diagram of the structure of the cutter of the present invention
  • Figure 2 is a top view of the blade structure of the cutter of the present invention.
  • Figure 3 is a partial enlarged view of the cutting edge of the tool of the present invention.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 10 blades.
  • the cutting edges 1 of the PCD tool are distributed on the cutting head in a uniformly circumferential manner, the rake angle of the cutting edge 11 is -5°, the helix angle is 10°, and the cutting edge depth is 1 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a nanosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the nanosecond laser parameters are laser power 10w, spot diameter 0.1mm, scanning speed 200mm/min, scanning times 10 times, and laser taper 5°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 20 blades.
  • the cutting edges of the PCD tool are distributed on the cutting head in a uniformly circumferential manner, the rake angle of the cutting edge 11 is 0°, the helix angle is 15°, and the cutting edge depth is 2 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a picosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are: the picosecond laser parameters are laser power 50w, repetition frequency 2000khz, spot diameter 0.050mm, scanning speed 4000mm/s, scanning times 050 times, and laser taper 5°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of cutting edges of the PCD tool is 30.
  • the cutting edge 1 of the PCD tool is uniformly distributed on the cutting head, the rake angle of the cutting edge 11 is 10°, the helix angle is 20°, and the cutting edge depth is 2 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a femtosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the femtosecond laser parameters are laser power 5w, repetition frequency 1000khz, spot diameter 0.05mm, scanning speed 500mm/s, scanning times 50 times, and laser taper 10°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 40 blades.
  • the cutting edge 1 of the PCD tool is uniformly distributed on the cutting head, the rake angle of the cutting edge 11 is 15°, the helix angle is 40°, and the cutting edge depth is 3 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a nanosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the nanosecond laser parameters are laser power 50w, spot diameter 0.2mm, scanning speed 300mm/min, scanning times 3 times, and laser taper 7°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 50 blades.
  • the cutting edge 1 of the PCD tool is uniformly distributed on the cutting head, the rake angle of the cutting edge 11 is 15°, the helix angle is 40°, and the cutting edge depth is 4 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a picosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are: picosecond laser parameters: laser power 30w, repetition frequency 350khz, spot diameter 0.1mm, scanning speed 800mm/s, scanning times 30 times, laser taper 8°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 60 blades.
  • the cutting edges 1 of the PCD tool are distributed on the cutting head in a uniformly distributed manner, the rake angle of the cutting edge 11 is 5°, the helix angle is 30°, and the cutting edge depth is 4 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a femtosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the femtosecond laser parameters are laser power 10w, repetition frequency 600khz, spot diameter 0.05mm, scanning speed 1000mm/s, scanning times 50 times, and laser taper 7°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 50 blades.
  • the cutting edge 1 of the PCD tool is uniformly distributed on the cutting head, the rake angle of the cutting edge 11 is -5°, the helix angle is 10°, and the cutting edge depth is 2 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a nanosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the nanosecond laser parameters are laser power 30w, spot diameter 0mm, scanning speed 200mm/min, scanning times 2 times, and laser taper 7°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 60 blades.
  • the cutting edges 1 of the PCD tool are distributed on the cutting head in a uniformly distributed manner, the rake angle of the cutting edge 11 is 5°, the helix angle is 20°, and the cutting edge depth is 3 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a picosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are: picosecond laser parameters: laser power 50w, repetition frequency 500khz, spot diameter 0.05mm, scanning speed 800mm/s, scanning times 20 times, laser taper 5.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.
  • a PCD tool 10 that realizes milling instead of grinding is characterized in that the number of blades of the PCD tool is 100 blades.
  • the cutting edge 1 of the PCD tool is uniformly distributed on the cutting head, the rake angle of the cutting edge 11 is 10°, the helix angle is 30°, and the cutting edge depth is 2.5 mm.
  • diamond particles 2 are distributed on the surface of the cutting edge.
  • a method for preparing the above-mentioned PCD tool which is characterized in that, after determining the overall structure of the tool, the tool is processed, the whole PCD tool bit is welded to the carbide tool base, the tool contour is processed to the desired shape, and then the laser is used Process the blade.
  • contour processing method of the PCD tool is laser processing.
  • the laser processing of the cutting edge of the PCD tool is a femtosecond laser processing method.
  • the laser processing parameters of the PCD tool edge processing are that the femtosecond laser parameters are laser power 20w, repetition frequency 1000khz, spot diameter 0.01mm, scanning speed 1000mm/s, scanning times 100 times, and laser taper 5°.
  • the novel PCD tool structure and preparation method of the present invention can overcome the shortcomings of the wear and shedding of abrasive grains in the traditional grinding process and the material breakage and damage caused by the excessive cutting force and cutting heat in the traditional milling process, and increase the processing quality and Processing efficiency.

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Abstract

一种实现以铣代磨加工的PCD刀具（10）及其制备方法，PCD刀具（10）的刀刃（1）的数量为10-100刃，刀刃（1）以均匀环绕形式分布在刀头，刃口（11）的前角角度为-5°-15°，螺旋角度为10°-40°，刀刃深度1-4mm；制备方法的步骤为：确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，刃口（11）的加工形式为激光加工。

Description

一种实现以铣代磨加工的PCD刀具、其制备方法及应用 技术领域
本发明属于刀具加工技术领域，具体涉及一种实现以铣代磨加工的PCD刀具、其制备方法及应用。
背景技术
磨削加工是一种传统的半精加工和精加工方法；是利用高速旋转的砂轮表面大量随机分布的磨粒在工件表面进行滑擦、刻划和切削三种作用的综合结果；铣削加工是指使用旋转的刀具切削工件的一种加工方式。相比铣削加工，磨削加工一次去除深度小，可以获得较高的加工精度；而铣削加工相比磨削加工具有更高的加工效率与灵活的加工方式。
蓝宝石、玻璃、陶瓷等硬脆材料具有硬度高，脆性大，断裂韧性低，材料弹性极限与强度接近；这些特点使其加工中容易出现裂纹、表面破损等，通常这些硬脆材料的表面轮廓是使用电镀金刚石磨头磨削加工，以达到表面平滑细致、轮廓光顺、无振纹、无崩边、磨削表面粗糙度低的加工效果，经抛光后可达镜面。
但电镀金刚石磨头磨削效率低，经过长时间使用后磨粒破损、脱落，锋利性下降，易导致零件加工后表面破损、产生划痕及微裂纹。特别是在针对于薄壁结构件轮廓精确成形时，磨削形状与尺寸精度难以稳定控制；同时由于加工表面粗糙度高，需要长时间抛光，大大增加后续加工时间及成本。
铣削加工是利用铣刀在高转速下，各刀齿周期性地参与间断切削的一种去除方式，传统铣刀刀刃数量多为1-4刃，在硬脆材料的切削中，由于切削力、切削热、切削振动、切削加工不均匀变形易导致零件加工后表面破损、划痕及产生微裂纹。大使材料在去除过程中产生微裂纹及破碎。因此硬脆材料的铣削加工对传统刀具质量、加工参数及机床质量都提出了很高的要求。因此传统磨削与铣削在加工蓝宝石、玻璃、陶瓷等硬脆材料上都存在一定的缺陷。
刀具是将金刚石微粉与结合剂混和起来在高温高压下制备成PCD片，然后通过切割成相应的形状焊接在基体上制作成刀具。PCD刀具具有与天然金刚石相近的高硬度高强度，且刀具可以加工出锋利的刃口，适合加工硬度较高的材料。但传统1-4刃的PCD刀具在加工硬脆材料时也会产生较大的应力是材料产生微裂纹及破碎，因此需要结合磨削的特点对PCD刀具的刃口结构及加工方式进行优化设计。
发明内容
有鉴于此，本发明提供一种实现以铣代磨加工的PCD刀具、其制备方法及应用，本发明的PCD刀具通过增大刀刃数量，减少单齿切削量，降低切削应力与切削热；使刀刃以均匀环绕形式分布在刀头，使受力均匀；采用激光加工，提到刃口精度，同时使刃口上的金刚石颗粒参与切削，起微量磨削的作用。达到铣削代替金刚石磨头磨削，极大缩短后续抛光时间、提高了加工质量。
本发明的技术方案为：
一种实现以铣代磨加工的PCD刀具，其特征在于，所述PCD刀具的刀刃数量为10-100刃。
进一步的，所述PCD刀具的刀刃以均匀环绕形式分布在刀头，刃口的前角角度为-5°-15°，螺旋角度为10°-40°，刀刃深度1-4mm。
进一步的，所述PCD刀具的刀刃根据需要加工方式进行设计，可设计为面铣刀、倒角刀、圆鼻刀、T型刀、成型刀中的任一种，且不限于以上几种铣削刀具。
本发明中，根据加工要求及加工材料特点设计刀具刀刃数量，通过增大刀刃数量减少切削过程中单齿切削量，达到微切削，降低切削应力与切削热，避免材料崩碎。根据研究设计刀刃数量为10-100刃；根据切削要求及刀刃数量设计刃口几何参数，设计前角角度-5°-15°，螺旋角10°-40°，刀刃深度1-4mm，刀刃以均匀环绕形式分布在刀头。
特别的，所述刃口表面分布有金刚石颗粒。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式包括磨削加工、电火花加工与激光加工或其组合加工。
进一步的，所述PCD刀具刃口的激光加工为纳秒激光、皮秒激光、飞秒激光中的任一种或其组合的激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，纳秒激光参数为激光功率10-100w，光斑直径0.1-0.3mm，扫描速度200-500mm/min，扫描次数1-10次，激光锥度5°-10°。
进一步的，所述PCD刀具刃口加工的激光加工参数为，皮秒激光参数为激光功率10-50w、重复频率200-500khz，光斑直径0.05-0.2mm、扫描速度400-1000mm/s、扫描次数5-50次，激光锥度5°-10°。
进一步的，所述PCD刀具刃口加工的激光加工参数为，飞秒激光参数为激光功率 1-20w、重复频率200-1000khz，光斑直径0.01-0.1mm、扫描速度500-2000mm/s、扫描次数10-100次，激光锥度5°-10°。
本发明根据传统金刚石磨头及PCD铣刀结构特点，结合硬脆材料切削/磨削加工特点，增加整体PCD刀具刃口数量，使刃口均匀环绕于刀头，优化总体结构，包括刀具几何参数、刃型和刃数，获得切削力小，刀具磨损率低，对材料表面/亚表面损伤小、加工表面质量高、加工效率快，无须后处理的整体PCD多刃铣刀优化设计方案，并提出用激光对其进行加工，可获得形状复杂且加工质量好的刃口，通过刀具刃口的切削以及刃口分布的金刚石微颗粒微量磨削，实现硬脆材料加工中以铣代磨的加工。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用，且不限于以上几种硬脆材料。
本发明的工作原理为：结合硬脆材料切削/磨削加工特点，在传统PCD铣刀的基础上，增加刀具刃口数量化，使刀具刃口均匀环绕于刀头，使单个刀刃每次切削接触材时的去除量减少，以降低铣削中产生的切削力与切削热，实现微切削，在此基础上，减小对材料的损伤，同时激光加工后每一个刃口上的金刚石颗粒又对材料表面进行辅助微量的磨削，通过两种加工方式结合，实现材料表面的高质高效加工，取代传统金刚石磨头的磨削加工。
本发明的有益技术效果为：本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
附图说明
图1为本发明刀具的结构示意图；
图2为本发明刀具的刀刃结构俯视图；
图3为本发明刀具刃口局部放大图。
具体实施方式
为使本发明的目的、技术方案及优点更加清楚明白，以下结合具体实施方式，对本发明进行进一步的详细说明。应当理解的是，此处所描述的具体实施方式仅用以解释本发明，并不限定本发明的保护范围。
实施例1
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为10刃。
进一步的，所述PCD刀具的刀刃1以均匀环绕形式分布在刀头，所述刃口11的前角角度为-5°，螺旋角度为10°，刀刃深度1mm，。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为纳秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，纳秒激光参数为激光功率10w，光斑直径0.1mm，扫描速度200mm/min，扫描次数10次，激光锥度5°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例2
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为20刃。
进一步的，所述PCD刀具的刀刃以均匀环绕形式分布在刀头，所述刃口11的前角角度为0°，螺旋角度为15°，刀刃深度2mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为皮秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，皮秒激光参数为激光功率50w、重复频率2000khz，光斑直径0.050mm、扫描速度4000mm/s、扫描次数050次，激光锥度5°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例3
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为30刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为10°，螺旋角度为20°，刀刃深度2mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为飞秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，飞秒激光参数为激光功率5w、重复频率1000khz，光斑直径0.05mm、扫描速度500mm/s、扫描次数50次，激光锥度10°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例4
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为40刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为15°，螺旋角度为40°，刀刃深度3mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为纳秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，纳秒激光参数为激光功率50w，光斑直径0.2mm，扫描速度300mm/min，扫描次数3次，激光锥度7°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例5
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为50刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为15°，螺旋角度为40°，刀刃深度4mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为皮秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，皮秒激光参数为激光功率30w、重复频率350khz，光斑直径0.1mm、扫描速度800mm/s、扫描次数30次，激光锥度8°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例6
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为60刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为5°，螺旋角度为30°，刀刃深度4mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为飞秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，飞秒激光参数为激光功率10w、重复频率600khz，光斑直径0.05mm、扫描速度1000mm/s、扫描次数50次，激光锥度7°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工 效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例7
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为50刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为-5°，螺旋角度为10°，刀刃深度2mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为纳秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，纳秒激光参数为激光功率30w，光斑直径0.mm，扫描速度200mm/min，扫描次数2次，激光锥度7°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例8
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为60刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为5°，螺旋角度为20°，刀刃深度3mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为皮秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，皮秒激光参数为激光功率50w、重复频率500khz，光斑直径0.05mm、扫描速度800mm/s、扫描次数20次，激光锥度5。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
实施例9
一种实现以铣代磨加工的PCD刀具10，其特征在于，所述PCD刀具的刀刃数量为100刃。
进一步的，所述PCD刀具的刀刃1以均匀分布形式分布在刀头，所述刃口11的前角角度为10°，螺旋角度为30°，刀刃深度2.5mm。
特别的，所述刃口表面分布有金刚石颗粒2。
一种上述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
进一步的，所述PCD刀具的轮廓加工方式为激光加工。
进一步的，所述PCD刀具刃口的激光加工为飞秒激光加工方式。
进一步的，所述PCD刀具刃口加工的激光加工参数为，飞秒激光参数为激光功率20w、重复频率1000khz，光斑直径0.01mm、扫描速度1000mm/s、扫描次数100次，激光锥度5°。
本发明的新型PCD刀具结构与制备方法，可以克服传统磨削加工磨粒磨损、脱落与传统铣削加工中切削力与切削热过大带来的材料破裂、损伤等缺点，增大了加工质量与加工效率。
一种上述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。
此外，应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其他实施方式。需注意的是，本发明中所未详细描述的技术特征，均可以通过本领域任一现有技术实现。

Claims (10)

  1. 一种实现以铣代磨加工的PCD刀具，其特征在于，所述PCD刀具的刀刃数量为10-100刃。
  2. 根据权利要求1所述的实现以铣代磨加工的PCD刀具，其特征在于，所述PCD刀具的刀刃以环绕分布形式分布在刀头，刃口的前角角度为-5°-15°，螺旋角度为10°-40°，刀刃深度1-4mm。
  3. 根据权利要求1所述的实现以铣代磨加工的PCD刀具，其特征在于其刀刃根据需要加工方式进行设计，可设计为面铣刀、倒角刀、圆鼻刀、T型刀、成型刀中的任一种。
  4. 一种权利要求1-3任一项所述的PCD刀具的制备方法，其特征在于，确定刀具总体结构后进行刀具加工，将整体PCD刀头焊接在硬质合金刀具基体上，将刀具轮廓加工至所需形状，然后再用激光对刀刃进行加工。
  5. 根据权利要求4所述的PCD刀具的制备方法，其特征在于，所述PCD刀具的轮廓加工方式包括磨削加工、电火花加工与激光加工或其组合加工。
  6. 根据权利要求5所述的PCD刀具的制备方法，其特征在于，所述PCD刀具刃口的激光加工为纳秒激光、皮秒激光、飞秒激光中的任一种或其组合的激光加工方式。
  7. 根据权利要求6所述的PCD刀具的制备方法，其特征在于，所述PCD刀具刃口加工的激光加工参数为，纳秒激光参数为激光功率10-100w，光斑直径0.1-0.3mm，扫描速度200-500mm/min，扫描次数1-10次，激光锥度5°-10°。
  8. 根据权利要求6所述的PCD刀具的制备方法，其特征在于，所述PCD刀具刃口加工的激光加工参数为，皮秒激光参数为激光功率10-50w、重复频率200-500khz，光斑直径0.05-0.2mm、扫描速度400-1000mm/s、扫描次数5-50次，激光锥度5°-10°。
  9. 根据权利要求6所述的PCD刀具的制备方法，其特征在于，所述PCD刀具刃口加工的激光加工参数为，飞秒激光参数为激光功率1-20w、重复频率200-1000khz，光斑直径0.01-0.1mm、扫描速度500-2000mm/s、扫描次数10-100次，激光锥度5°-10°。
  10. 一种权利要求1-3任一项所述的PCD刀具在蓝宝石、玻璃、陶瓷任一种硬脆材料加工的应用。
PCT/CN2021/082562 2020-03-25 2021-03-24 一种实现以铣代磨加工的pcd刀具、其制备方法及应用 WO2021190529A1 (zh)

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