阅读说明：本技术 一种用于环槽加工的一次成型高效pcd刀具 (A high-efficient PCD cutter of one shot forming for annular processing ) 是由 熊朝 于 2020-06-02 设计创作，主要内容包括：为解决传统环槽加工方案无法满足大批量生产需求的问题,本发明提供一种用于环槽加工的一次成型高效PCD刀具,其刀体上的四个PCD成型刀片中,两个为A型刀片,两个为B型刀片；两个A型刀片分布在同一直线上,两个B型刀片分布在同一直线上；A型刀片的排屑槽设置在A型刀片的底面上,位于内径切削刃一侧,且与内径切削刃贯穿；B型刀片的排屑槽设置在B型刀片的底面上,位于外径切削刃一侧,且与外径切削刃贯穿；A型刀片和B型刀片的底面切削刃同时作用时能够加工出完整的环形槽底形状；A型刀片和B型刀片的槽口切削刃的倾角均为2°-5°。本发明一次轴向走刀,即可全部完成环槽及相应圆角的加工,且能满足加工精度。(In order to solve the problem that the traditional annular groove processing scheme cannot meet the requirement of mass production, the invention provides a once-forming efficient PCD cutter for annular groove processing, wherein two of four PCD forming blades on a cutter body are A-type blades and two of the four PCD forming blades are B-type blades; the two A-type blades are distributed on the same straight line, and the two B-type blades are distributed on the same straight line; the chip groove of the A-shaped blade is arranged on the bottom surface of the A-shaped blade, is positioned on one side of the inner diameter cutting edge and penetrates through the inner diameter cutting edge; the chip groove of the B-shaped blade is arranged on the bottom surface of the B-shaped blade, is positioned on one side of the outer diameter cutting edge and penetrates through the outer diameter cutting edge; when the bottom cutting edges of the A-type blade and the B-type blade act simultaneously, the complete bottom shape of the annular groove can be processed; the inclination angles of the notch cutting edges of the A-type blade and the B-type blade are 2-5 degrees respectively. The invention can complete the processing of the ring groove and the corresponding fillet by one axial feed and can meet the processing precision.)

1. A once-forming efficient PCD cutter for processing a ring groove comprises a cutter body (1); the method is characterized in that:

four PCD molding blades are uniformly arranged on the end face of the cutter body (1) along the same circumference;

two of the four PCD molding blades are A-type blades (2), and two of the four PCD molding blades are B-type blades (3); the two A-type blades (2) are distributed on the same straight line, and the two B-type blades (3) are distributed on the same straight line;

the A-type blade (2) and the B-type blade (3) respectively comprise an inner diameter cutting edge (8), an outer diameter cutting edge (7), a bottom surface cutting edge (9), a notch cutting edge (10) and a chip groove (6);

the shape of each cutting edge on the A-type blade (2) and the B-type blade (3) is consistent with the shape of the corresponding position on the section of the annular groove to be processed, and the size of each cutting edge is determined according to the size of the annular groove to be processed and the design requirement precision;

the chip groove (6) of the A-shaped blade (2) is arranged on the bottom surface of the A-shaped blade (2), is positioned on one side of the inner diameter cutting edge (8), and penetrates through the inner diameter cutting edge (8);

the chip groove (6) of the B-shaped blade (3) is arranged on the bottom surface of the B-shaped blade (3), is positioned on one side of the outer diameter cutting edge (7), and penetrates through the outer diameter cutting edge (7);

when the bottom cutting edges (9) of the A-type blade (2) and the B-type blade (3) act simultaneously, the complete bottom shape of the annular groove can be processed;

the inclination angles of the notch cutting edges (10) of the A-type blade (2) and the B-type blade (3) are 2-5 degrees.

2. The one-shot high efficiency PCD cutter for machining of ring grooves as claimed in claim 1, wherein: the chip grooves (6) of the A-type blade (2) and the B-type blade (3) are the same in shape and size.

3. The one-shot high efficiency PCD cutter for machining of ring grooves as claimed in claim 2, wherein: the chip groove (6) is a rectangular groove.

4. The one-shot high efficiency PCD cutter for machining of ring grooves of claim 3, wherein: the depth of the chip groove (6) is 0.1-0.3 mm.

5. The one-shot high efficiency PCD cutter for machining of ring grooves of claim 4, wherein: the minimum length of the chip groove (6) is 0.3mm, the maximum length of the chip groove does not exceed 1/3 of the length of the bottom of the blade, and the thickness of the chip groove is consistent with the thickness of the blade.

Technical Field

The invention relates to a once-forming efficient PCD cutter for processing a ring groove.

Background

Various specifications of different but similar ring grooves (such as the ring grooves shown in fig. 1 and 2) are usually required to be processed on the retarder shell and the rear cover of each model, and then O-shaped sealing rings are assembled in the ring grooves to ensure that oil leakage does not occur at the inlet and outlet oil passages, so that the processing requirements on the ring grooves are high.

At present, in mass production, to above-mentioned annular processing, the traditional processing thinking that generally adopts in the trade does:

1) d5 end milling cutter is adopted for interpolation;

2) designing a special tool chamfering fillet.

The above-described conventional scheme is very inefficient, and the notch chamfer size is very difficult to control, and this scheme can be adopted during the prototype trial-manufacturing, but cannot meet the mass production requirements.

Disclosure of Invention

In order to solve the technical problem that the traditional annular groove machining scheme cannot meet the requirement of mass production, the invention provides a once-forming efficient PCD cutter for annular groove machining.

The technical scheme of the invention is as follows:

a once-forming efficient PCD cutter for processing a ring groove comprises a cutter body; it is characterized in that:

four PCD molding blades are uniformly arranged on the end face of the cutter body along the same circumference;

two of the four PCD molding blades are A-type blades, and two of the four PCD molding blades are B-type blades; the two A-type blades are distributed on the same straight line, and the two B-type blades are distributed on the same straight line;

the A-type blade and the B-type blade respectively comprise an inner diameter cutting edge, an outer diameter cutting edge, a bottom surface cutting edge, a notch cutting edge and a chip groove;

the shape of each cutting edge on the A-type blade and the B-type blade is consistent with the shape of the corresponding position on the section of the annular groove to be processed, and the size of each cutting edge is determined according to the size of the annular groove to be processed and the precision required by design;

the chip groove of the A-shaped blade is arranged on the bottom surface of the A-shaped blade, is positioned on one side of the inner diameter cutting edge and penetrates through the inner diameter cutting edge;

the chip groove of the B-shaped blade is arranged on the bottom surface of the B-shaped blade, is positioned on one side of the outer diameter cutting edge and penetrates through the outer diameter cutting edge;

when the bottom cutting edges of the A-type blade and the B-type blade act simultaneously, the complete bottom shape of the annular groove can be processed;

the inclination angles of the notch cutting edges of the A-type blade and the B-type blade are both 2-5 degrees.

Furthermore, the chip removal grooves of the A-type blade and the B-type blade are the same in shape and size.

Further, the chip groove is a rectangular groove.

Furthermore, the depth of the chip removal groove is 0.1-0.3 mm.

Further, the minimum length of the chip groove is 0.3mm, the maximum length of the chip groove does not exceed 1/3 of the length of the bottom of the blade, and the thickness of the chip groove is consistent with the thickness of the blade.

The invention has the advantages that:

1. the invention has stable processing process, and the roughness of the processed groove bottom of the ring groove completely meets the requirements of design and subsequent assembly.

2. The processing of the ring grooves and the corresponding fillets can be completely finished by one-time axial feed, the efficiency is far higher than that of the traditional processing scheme of 'end milling cutter + chamfering cutter', and the processing precision required by design can be met.

3. When the annular groove is processed on the aluminum alloy material, the service life of the retarder can reach more than 6000 pieces, and the requirement of mass production of the retarder shell and the rear cover can be met.

4. The PCD cutter has low single piece processing cost and is suitable for large-batch processing.

5. The invention has been already tried on the retarder shell and various ring groove structures on the back cover on a large scale, the result is good.

Drawings

FIG. 1 is a schematic structural diagram of a ring groove machined on a retarder housing.

Fig. 2 is an enlarged view at F in fig. 1.

FIG. 3 is a front view of a PCD cutter in accordance with the present invention.

Fig. 4 is a left side view of a PCD cutter of the present invention.

Fig. 5 is a schematic structural view of an insert of the PCD cutter of the present invention.

Fig. 6 is a view showing the effect of machining the composite ring groove milling cutter with the cemented carbide insert.

FIG. 7 is a view showing the effect of the PCD cutting tool of the present invention.

Description of reference numerals:

1, a cutter body; 2-type a blades; 3-type B blades; 4-tool setting point; 5-ring groove; 6-chip removal groove; 7-an outside diameter cutting edge; 8-inner diameter cutting edge; 9-a bottom cutting edge; 10-notch cutting edge.

Detailed Description

The invention will be further explained below by taking as an example the machining of a ring groove of the specification shown in fig. 1 and 2 on a retarder housing made of ADC 12.

In order to improve the processing efficiency, a composite ring groove milling cutter with a hard alloy blade is originally designed, 4 same formed blades are uniformly and symmetrically arranged on the periphery of a cutter body, and the dimensional characteristics required by the graph 1 and the graph 2 can be directly processed by one-time feeding. Compared with the traditional scheme, the processing efficiency of the scheme is remarkably improved, but the roughness of the groove bottom of the ring groove cannot meet the requirement of Ra1.6, obvious knife grains (the processing effect is shown in figure 6) appear at the groove bottom after two or three hundred pieces are processed by the cutter, and the phenomenon of knife vibration often occurs.

On the basis of the originally designed composite ring groove milling cutter, a once-forming efficient PCD cutter for processing the ring groove as shown in figures 3, 4 and 5 is finally redesigned, and through practical processing verification, the machining process is stable, the groove bottom roughness completely meets the Ra1.6 requirement (the processing effect is shown in figure 7), the service life of the cutter can reach more than 6000 pieces, and the requirement of mass production of the retarder shell can be met.

In contrast to the once-formed high-efficiency PCD cutter shown in fig. 3, 4, and 5 for machining the ring groove with the machining parameters of the rotation speed S2800 and the feed F400, and the initially designed composite ring groove milling cutter of the cemented carbide insert with the machining parameters of the rotation speed S2000 and the feed F100, the PCD cutter shown in fig. 3, 4, and 5 has the machining efficiency improved by 4 times, the machining quality is higher, and the requirements of the design drawing can be satisfied. The originally designed composite ring slot milling cutter with the hard alloy blade has the service life of 500 parts, the unit price of the cutter is 700 yuan, and the unit cost is 1.4 yuan/part; the PCD cutter life shown in figures 3 and 4 was 6000 pieces, the cutter unit price was 2000 units, the unit cost was 0.33 units/piece, and the cost was reduced by 76%.

As shown in fig. 3 and 4, the once-formed high-efficiency PCD cutter for machining the ring groove provided by the invention comprises a cutter body 1 and four PCD forming blades which are welded on the cutter body and are uniformly distributed on the end surface of the cutter body 1 along the same circumference; two of the four PCD molding blades are A-type blades 2, and the other two PCD molding blades are B-type blades 3; the two A-type blades 2 are arranged on the same straight line, and the two B-type blades 3 are arranged on the same straight line.

As shown in fig. 5, each of the a-type insert 2 and the B-type insert 3 includes an inner diameter cutting edge 8 for milling an inner diameter of the ring groove, an outer diameter cutting edge 7 for milling an outer diameter of the ring groove, a bottom surface cutting edge 9 for milling a bottom surface of the ring groove, a notch cutting edge 10 for machining a notch fillet of the ring groove, and a chip flute 6 for discharging chips; the shape of each cutting edge on the A-type blade 2 and the B-type blade 3 is consistent with the shape of the corresponding position of the section of the annular groove to be processed, and the size of each cutting edge is determined according to the size of the annular groove to be processed and the design requirement precision.

For convenience of description, the end surface where the bottom surface cutting edge 9 is located on the a-type insert 2 and the B-type insert 3 is defined as an insert bottom surface, and the a-type insert 2 is different from the B-type insert 3 only in that: the chip groove 6 of the A-shaped blade 2 is arranged on the bottom surface of the A-shaped blade 2, is positioned on one side of the inner diameter cutting edge 8 of the A-shaped blade 2 and penetrates through the inner diameter cutting edge 8; the chip groove 6 of the B-type insert 3 is provided on the bottom surface of the B-type insert 3, is located on the side of the outer diameter cutting edge 7 of the B-type insert 3, and penetrates through the outer diameter cutting edge 7. In order to ensure the chip removal amount and avoid the vibration of the blade during the processing, the chip removal grooves 6 on the A-type blade 2 and the B-type blade 3 are rectangular grooves, the minimum length is 0.3mm, the maximum length does not exceed 1/3 of the length of the bottom of the blade, the depth is 0.1-0.3mm, and the thickness (namely the width) is consistent with the thickness of the blade. Due to the design, the chip containing space is increased, and the chip removal is smoother; meanwhile, the cutting resistance of the bottom surface cutting edge 9 is reduced, so that the cutting is more stable, and the shape of the complete annular groove bottom can be processed when the A-type blade 2 and the B-type blade 3 act simultaneously. In addition, the inclination angles (the angle of the notch cutting edge relative to the ring groove end face) of the notch cutting edges 10 on the A-type blade 2 and the B-type blade 3 are both 2-5 degrees, the rounding effect is better, the ring groove end face cannot be damaged, and the precision of the chamfering position can meet the design requirement.

A method of machining a ring groove as shown in figures 1 and 2 using a PCD cutter as shown in figures 3 and 4:

1. on the tool rest, the tool body 1 is arranged in a BT50-C32-110 powerful tool holder;

2. measuring the length of the knife on a knife setting gauge by taking the knife setting point 4 in the figure 5 as a reference;

3. inputting a tool compensation (tool length) and cutting parameters in a vertical machining center, starting machining after checking no error, and simultaneously participating in cutting by the two A-type blades 2 and the two B-type blades 3;

4. after the machining is finished (after the tool is changed, the first workpiece) is subjected to size measurement, and all technical requirements of the drawing are guaranteed to be met.