阅读说明：本技术 用于制造刀具头部的方法 (Method for producing a tool head ) 是由 斯蒂芬·弗赖德 于 2018-11-22 设计创作，主要内容包括：一种用于制造刀具头部的方法,该方法包括：-由粉末组分形成第一部件(4)和第二部件(4’),其中,该第一部件和该第二部件包括对应的结合表面(5),并且其中,这些部件包括外表面部分(6、6’),这些外表面部分构造用以形成所述刀具头部的外围包络表面的部分；-在所述对应的结合表面中形成对应的凹槽(15)；-通过使得所述结合表面相接触以形成接口,而将所述部件组装成所述刀具头部的形状,以使得每对对应的凹槽形成在所述接口中延伸的通道,该通道具有处在所述刀具头部的后端中的入口开口和处在所述刀具头部的前端或所述外围包络表面中的出口开口；-在烧结操作中结合已组装的部件,以形成所述刀具头部。(A method for manufacturing a cutter head, the method comprising: -forming a first part (4) and a second part (4 ') from a powder composition, wherein the first part and the second part comprise respective bonding surfaces (5), and wherein the parts comprise outer surface portions (6, 6') configured to form part of a peripheral envelope surface of said tool head; -forming a corresponding groove (15) in said corresponding bonding surface; -assembling the components into the shape of the tool head by bringing the joining surfaces into contact to form an interface, such that each pair of corresponding grooves forms a channel extending in the interface, the channel having an inlet opening in a rear end of the tool head and an outlet opening in a front end of the tool head or the peripheral envelope surface; -joining the assembled components in a sintering operation to form the tool head.)

1. A method for manufacturing a tool head (1, 30) of a rotary cutting tool (3), the tool head (1, 30) having a front end (10, 42) and a rear end (26, 31) between which a central rotation axis (C) and a peripheral envelope surface (7, 37) extend, the method comprising:

-forming at least a first part (4, 34) and a second part (4 ', 34') from a powder component, wherein the first part (4, 34) comprises a first bonding surface (5, 35), and wherein the second part (4 ', 34') comprises a second bonding surface, the first bonding surface (5, 35) being configured to be in contact with the second bonding surface, wherein the first part (4, 34) further comprises a first outer surface portion (6, 36) configured to form a first portion of the peripheral envelope surface (7, 37) of the cutter head (1, 30), and wherein the second part (4 ', 34') further comprises a second outer surface portion (6 ', 36') configured to form a second portion of the peripheral envelope surface (7, 37) of the cutter head (1, 30), 30) Of said peripheral envelope surface (7, 37),

-forming at least one groove (15, 17, 18, 38, 40) in the first bonding surface (5, 35) and at least one corresponding groove in the second bonding surface, wherein the at least one groove (15, 17, 18, 38, 40) of the first bonding surface (5, 35) is configured to: said at least one groove facing said at least one corresponding groove of said second bonding surface when said first bonding surface (5, 35) is in contact with said second bonding surface,

-assembling the components (4, 34, 4 ', 34') into the shape of a tool head (1, 30) by bringing at least the first and second joining surfaces (5, 35) into contact to form an interface (22), such that at least one pair of facing grooves (15, 17, 18, 38, 40) forms a channel (23, 24, 41) extending in the interface (22), the channel (23, 24, 41) having an inlet opening (25) in the rear end (26, 31) of the tool head (1, 30) and an outlet opening (27) in the front end (10, 42) and/or the peripheral envelope surface (7, 37) of the tool head (1, 30),

-joining the assembled components (4, 34, 4 ', 34') in a sintering operation to form the tool head (1, 30).

2. The method of claim 1, comprising forming the component (4, 34, 4 ', 34') using one of powder injection molding, multi-axial pressing, uniaxial pressing, and additive manufacturing.

3. The method of claim 1 or 2, wherein assembling the components (4, 34, 4 ', 34') comprises assembling the components in a non-sintered condition.

4. The method according to any of the preceding claims, comprising forming the first part (4, 34) and the second part (4 ', 34') into the same or substantially the same shape.

5. The method according to any one of the preceding claims, comprising forming the components (4, 4 ') such that the first and second bonding surfaces (5, 4 ') extend along the central axis (C) of the tool head (1, 30) when the components (4, 4 ') are assembled.

6. The method according to any of the preceding claims, comprising forming the at least one groove (15, 17, 18, 38, 40) as a curved groove and/or comprising forming the at least one groove as a groove having a variable cross-sectional shape and/or size.

7. Method according to any of the preceding claims, comprising forming at least one part of the at least one groove (15, 17, 18, 38, 40) with a smooth surface, preferably forming a majority of the at least one groove (15, 17, 18, 38, 40) with a smooth surface, more preferably forming the entire at least one groove (15, 17, 18, 38, 40) with a smooth surface.

8. The method according to claim 7, wherein the smooth surface of the at least one portion of the at least one groove (15, 17, 18, 38, 40) is a surface of: said surface having an arithmetic mean roughness Ra ≦ 3 μm, more preferably having an arithmetic mean roughness Ra ≦ 2 μm, even more preferably having an arithmetic mean roughness Ra ≦ 1 μm, and most preferably having an arithmetic mean roughness Ra ≦ 0.5 μm; preferably, the arithmetic mean roughness is the arithmetic mean roughness when measured in any direction,

and/or

The smooth surface is a directly pressed surface, or preferably an abrasive surface, or preferably a polished surface, or preferably a surface produced by powder injection moulding.

9. The method according to any one of the preceding claims, wherein forming the at least one groove (15, 17, 18, 38, 40) comprises: in each of the first and second joining surfaces, at least two grooves (15, 17, 18, 38) are formed extending from a common recess (16, 19, 39) such that when the first and second components (4, 34, 4 ', 34') are assembled, at least two channels (23, 24, 41) are formed in the interface, which share a common inlet opening (25) in the rear end of the tool head (1, 30).

10. The method according to any one of the preceding claims, further comprising providing the tool head (1, 30) with at least one cutting edge, wherein each of the at least one cutting edge is provided adjacent to the outlet opening (27) of at least one of the channels (23, 24, 41).

11. The method of claim 9, comprising forming at least three components, wherein the number of components corresponds to the number of cutting edges provided in the cutter head.

12. Method according to any of the preceding claims, comprising providing the bonding surface (5) with positioning means (20, 21), wherein the positioning means (20, 21) of the first bonding surface (5) are configured to be engageable with the positioning means of the second bonding surface, thereby ensuring the relative position of the first and second components (4, 4') during sintering.

13. The method of any one of the preceding claims, wherein the powder component is a hard metal powder component or a cermet powder component.

14. A tool head (1, 30) for use with a body (2) of a rotary cutting tool (3), the tool head (1, 30) having a front end (10, 42) and a rear end (26, 31) between which a central axis of rotation (C) and a peripheral envelope surface (7, 37) extend,

-wherein the rear end (26, 31) is configured for connection to the main body (2), and wherein the front end (10, 42) is configured for cutting engagement with a workpiece,

-wherein the tool head (1, 30) comprises at least one channel (23, 24, 41) intended for conveying liquid coolant to a cutting edge of the tool head (1, 30), each of the at least one channel (23, 24, 41) extending from an inlet opening (25) in the rear end (26, 31) of the tool head (1, 30) to an outlet opening (27) in the front end (10, 42) or the peripheral envelope surface (7, 37) of the tool head (1, 30),

-wherein said at least one passage is formed in at least one interface (23, 24, 41) formed by joining at least two parts (4, 34, 4 ', 34') to form the tool head (1, 30), each part (4, 34, 4 ', 34') being formed by a powder component.

15. A rotary cutting tool (3) comprising a tool head (1, 30) according to claim 13 and a body (2).

16. The rotary cutting tool according to claim 14, wherein the tool head (1) has been bonded to the body (2) by sintering.

Technical Field

The present invention relates to a method for manufacturing a tool head of a rotary cutting tool, i.e. a tool intended for chip removing machining of workpieces, in particular metal workpieces or workpieces made of composite materials. The invention further relates to a tool head for use with a body of a rotary cutting tool, and a rotary cutting tool comprising such a tool head.

Background

Tool heads made of cemented carbide or cermet intended for rotary cutting tools are typically manufactured by single or multi-axial pressing of a composite powder into a green body, followed by sintering of the green body. Alternatively, the green body may be formed, for example, by Powder Injection Molding (PIM) or extrusion. After sintering, the cutting edges of the tool head are formed in a grinding operation, but since machining of the sintered body is expensive, it is preferable to keep machining to a minimum. It is therefore desirable to obtain a sintered body having a shape as close as possible to the final shape of the tool head.

It is often necessary to provide a cooling system in the tool head capable of supplying coolant to the cutting edges in order to achieve optimum performance of the tool head. To minimize the machining requirements after sintering, it is preferable to form internal coolant channels in the green body prior to sintering.

US2013/0223943 discloses a cutter head and a method for manufacturing a cutter head from two separate parts that have been formed by injection molding or die casting. The components are assembled together and compressed and sintered together to form the joint region. One of the components forms the front end (including the cutting edge) of the cutter head and the other component forms the rear end of the cutter head. Two or more coolant channels extending from the distributor chamber are formed in the one part forming the front end of the cutter head, and a central coolant channel leading to the distributor channel is formed in the one part forming the rear end of the cutter. By using a movable mold core, coolant channels are formed during the injection molding process.

Disclosure of Invention

In at least some aspect, it would be desirable to provide a convenient method of manufacturing a cutter head having improved performance.

To better address this problem, a method for manufacturing a tool head for a rotary cutting tool according to claim 1 is provided. Preferred embodiments are defined in the dependent claims.

The proposed method comprises:

-forming at least a first part and a second part from a powder component, wherein the first part comprises a first bonding surface and the second part comprises a second bonding surface, the first bonding surface being configured to be in contact with the second bonding surface, wherein the first part further comprises a first outer surface portion configured to form a first part of the peripheral envelope surface of the tool head, and wherein the second part further comprises a second outer surface portion configured to form a second part of the peripheral envelope surface of the tool head,

-forming at least one groove in the first bonding surface and at least one corresponding groove in the second bonding surface, wherein the at least one groove of the first bonding surface is configured to: the at least one groove faces the at least one corresponding groove of the second bonding surface when the first bonding surface is in contact with the second bonding surface,

assembling the components into the shape of the tool head by bringing at least a first and a second joining surface into contact to form an interface, such that at least one pair of facing grooves form a channel extending in the interface, the channel having an inlet opening in a rear end of the tool head and an outlet opening in a front end and/or a peripheral envelope surface of the tool head,

-joining the assembled parts in a sintering operation to form a tool head.

The proposed method enables cost-effective generation of channels for supplying liquid coolant (coolant channels) in the tool head without any expensive post-sintering machining (e.g., electro-discharge machining (EDM)) for generating coolant holes. In particular, the method facilitates the production of coolant channels having a non-linear configuration, since these coolant channels are produced in the interface between two prefabricated components. This improves the conditions for manufacturing coolant channels with more complex shapes, thereby increasing the possibility of supplying coolant to all the cutting edges of the tool head. This facilitates, for example, the creation of curved or variable cross-section coolant channels extending from the rear end of the tool head to cutting edges provided at the front end and/or the peripheral envelope surface of the tool head. Since the coolant channels are formed by corresponding grooves which face each other and extend parallel in the interface, they can be formed with walls which do not have any sharp transitions or edges in the transverse direction. Thereby, a pressure drop in the coolant channel can be avoided and the performance of the tool head can be improved compared to a tool head having a transverse transition or edge in the coolant channel.

When forming the parts, for example by using a pre-grooved die or by using a punch with pre-grooves, it may be preferable to form the grooves in the respective parts. This facilitates the formation of these grooves. The grooves formed in this manner after sintering of the parts and the channels formed by the grooves when assembling the parts and subsequently joining the parts in a sintering operation have a directly pressed surface that is a smooth surface having an arithmetic mean roughness Ra ≦ 3 μm. The arithmetic mean roughness value depends on the size of the powder grains, the amount of binder in the powder composition and the surface finish of the die or punch in which the grooves have been formed. Since the components are preferably also cleaned after sintering and before assembly, the cleaning process (e.g., grit blasting) also has some effect on the arithmetic mean roughness value. In most cases, the arithmetic average roughness value Ra is less than 0.5 μm, and sometimes as low as 0.1. mu.m. The grooves in the first and/or second component may also be ground after sintering the components and before assembling the components and joining the assembled components in a sintering operation. Grinding can be used to obtain an even smoother surface with improved surface roughness and/or to form grooves. The surface to be abraded has an arithmetical mean surface roughness of usually 0.1. ltoreq. Ra.ltoreq.1.6, sometimes even better/smaller values. It is also possible to apply other treatments to improve the surface roughness of the grooves, such as polishing of the grooves, which gives the grooves an even better surface finish than grinding. The smooth surface of the grooves, i.e. the surface directly pressed or ground or polished or the surface with a surface roughness Ra of 3 μm, has the advantage that pressure drops in the coolant channels can be avoided and the performance of the tool head can be improved.

Preferably, the first and second portions of the peripheral envelope surface extend from the front end to the rear end of the tool head. The outer surfaces of the respective parts thus together form the entire peripheral surface of the tool head.

The sintering operation is preferably a liquid phase sintering operation, i.e. a sintering operation in which the binder of the powder component melts and solid grains coexist with the wetted liquid binder. In the case of cemented carbide, this represents solid grains of tungsten carbide (WC) and liquid phase cobalt (Co). Thus, for WC-Co based cemented carbides, the sintering temperature should be higher than a temperature of at least 1250 ℃.

According to one embodiment, the method includes forming the components using one of powder injection molding, multi-axial pressing, uniaxial pressing, and additive manufacturing.

By Powder Injection Molding (PIM), relatively complex shapes can be formed with smoother surface finishes and in a more cost effective manner, for example, as compared to additive manufacturing. Thus, the PIM is particularly suitable for cost-effectively forming components with variable material thicknesses and for forming grooves or curved grooves with variable dimensions. The grooves formed in this way, and the channels formed by these grooves, have a smooth surface, i.e. a surface having an arithmetic mean roughness Ra ≦ 3 μm, under the subsequent sintering operation. Furthermore, in this case, the arithmetic mean roughness value depends on the size of the powder grains, the powder composition and the process parameters. In most cases, the arithmetic average roughness value Ra is less than 1 μm, and in many cases less than 0.5 μm. The grooves in the first and/or second component may also be ground after sintering and before assembling the components and joining the assembled components in a sintering operation. Grinding can be used to obtain even smoother surfaces with improved arithmetic mean roughness. The ground surface has a typical surface roughness Ra of between 0.1 Ra 1.6, sometimes even better/less. It is also possible to apply other treatments to improve the surface roughness of the grooves, such as polishing, which gives an even better surface finish than grinding. The smooth surface of the grooves, i.e. the surface directly pressed or ground or polished or produced by powder injection moulding or the surface having a surface roughness Ra < 3 μm, has the advantage that pressure drops in the coolant channels can be avoided and the performance of the tool head can be improved.

Complex shapes can be formed by additive manufacturing, typically relying on layer-by-layer deposition of materials.

Multi-axial pressing and uniaxial pressing are cost-effective alternatives for producing less complex shapes because they enable parts with high shape accuracy to be produced quickly. By multi-axis pressing, more complex shapes can be formed than by uniaxial pressing. Forming the grooves in the bonding surface enables a more efficient production process compared to a process in which a movable mold core is used for forming the coolant channels.

According to one embodiment, assembling the component comprises assembling the component in a non-sintered condition. Thus, only one sintering operation is required and a smooth bonding surface is generally obtained without grinding, resulting in a relatively low complexity of the production process. The sintering conditions (e.g., time, pressure, and temperature) in the bonded sintering operation depend on the materials of the components, but preferably should be such that liquid phase sintering can occur. In the case of cemented carbide, the sintering may be performed at a sintering temperature of 1350 ℃ to 1500 ℃, for example.

According to one embodiment, the method further comprises sintering the components prior to assembling the components. In this case, the bonding surface of the sintered part should preferably be ground before assembling the assembly to produce a smooth bonding surface.

According to one embodiment, the method comprises forming the first part and the second part into the same or substantially the same shape. Thus, the same tool or die can be used to form the components. Making all the components the same also facilitates the assembly process, since there is no need to keep track of different types of components. Furthermore, the tool head becomes symmetrical about the centre axis, which results in the desired dynamic characteristics.

According to one embodiment, the method includes forming the components such that the first and second bonding surfaces extend along a central axis of the tool head when the components are assembled. Preferably, the bonding surface may extend parallel to the central axis. This helps the cutter head to produce desired dynamic characteristics, such as reduced tendency to vibrate.

The components may also be formed such that the first and second joining surfaces extend at an angle relative to a central axis of the tool head. The angle should preferably be such that: such that the channel formed in the interface has an opening proximate the cutting edge of the tool head. The angle is preferably such that: such that the interface intersects the rear end surface and/or the front end surface of the tool head. Most preferably, the angle is such that the interface intersects the back end surface, the front end surface and the peripheral envelope surface.

According to an embodiment, the method comprises forming said at least one groove as a curved groove and/or comprises forming said at least one groove as a groove having a variable cross-sectional shape and/or size. The coolant channel may for example be formed with a helical extension around the centre axis of the tool head and/or with a cross-sectional shape and/or area that varies along the coolant channel. Furthermore, the coolant channel may be curved in a plane parallel to the central axis. Thereby, the channels may be tailored to achieve desired characteristics of the coolant flow. A curved groove is a groove that deviates from straightness in a smooth, continuous manner. The radius of curvature of the curved portion of the groove may be constant or vary along the curved portion. The curvature of the recess preferably extends along at least 5%, or at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90% of the length of the cutter head. Preferably, the curvature of the groove constitutes at least 5%, or at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90% of the total length of the groove, measured from the inlet opening in the rear end to the outlet opening in the front end of the cutter head. After assembling the first and second components into the shape of the cutter head and joining the assembled components in a sintering operation to form the cutter head, the channel formed will have at least one bend. The curved grooves in the first and second components may be arranged such that, for a channel formed after assembling the first and second components and joining the assembled components in a sintering operation to form the tool head, a central axis of a curve of the channel is continuously curved while a shortest distance from a central axis of the curve of the channel to a central axis of the tool head continuously changes along the curve of the channel.

According to one embodiment, the method comprises forming at least one portion of said at least one groove with a smooth surface, preferably forming a majority of said at least one groove with a smooth surface, more preferably forming the entire said at least one groove with a smooth surface. In this embodiment, it is preferred to form the components using PIM or uniaxial or multiaxial pressing that produces a smooth surface. A smooth surface with low surface roughness is desirable to achieve coolant channels with low pressure drop. The smooth surface of the groove is the following surface: the surface preferably has an arithmetic average roughness Ra < 3 μm, more preferably an arithmetic average roughness Ra < 2 μm, even more preferably an arithmetic average roughness Ra < 1 μm, and most preferably an arithmetic average roughness Ra < 0.5 μm; preferably, the arithmetic mean roughness is the arithmetic mean roughness when measured in any direction. The smooth surface of the recess is preferably a directly pressed surface, or preferably an abrasive surface, or preferably a polished surface, or preferably a surface produced by powder injection moulding.

According to one embodiment, forming the at least one groove comprises: in each of the first and second joining surfaces, at least two grooves are formed extending from a common recess such that when the first and second components are assembled, at least two channels are formed in the interface that share a common inlet opening in the rear end of the tool head. Thus, a plurality of coolant channels can be provided, which can all be supplied with coolant from a common coolant conduit of the body of the cutting tool. The common conduit may be a central conduit.

According to one embodiment, the method further comprises providing the tool head with at least one cutting edge, wherein each of said at least one cutting edge is arranged adjacent to an outlet opening of at least one of the channels. The outlet opening of each channel is positioned such that the coolant provided via the respective channel can be used to cool the associated cutting edge. It is ensured that coolant is supplied to all cutting edges, thereby enabling proper cooling of all cutting edges. The cutting edges may for example be prefabricated in the parts and, after joining of the assembled parts, ground to the final shape and sharpness.

According to one embodiment, the method comprises forming at least three components, wherein the number of components corresponds to the number of cutting edges provided in the tool head. This is advantageous for a tool head having more than two cutting edges, which are arranged in the front end and/or in the peripheral envelope surface and/or in the transition between the front end and the peripheral envelope surface, since channels for coolant can be provided in all interfaces and thereby all cutting edges can be cooled appropriately.

According to one embodiment, the method comprises providing the bonding surfaces with positioning means, wherein the positioning means of the first bonding surface is configured to be engageable with the positioning means of the second bonding surface, thereby ensuring the relative position of the first and second parts during sintering. This facilitates assembly and ensures proper alignment during sintering. In this case, assembling the components comprises engaging the positioning means of the corresponding joining surfaces with each other. The positioning means can for example be in the form of projections and recesses.

According to one embodiment, the powder component is a hard metal powder component or a cermet powder component. The hard metal powder component may be, for example, a cemented carbide powder component that includes a carbide and a binder (e.g., WC and Co). In addition to WC and Co, one or more of the following may be included: metal carbides (Ti, Nb, Ta) C, chromium (Cr), metal carbonitrides such as titanium carbonitride (Ti (C, N)) having the usual composition. In addition to Co, the binder may include Co, Ni, and Fe or a combination of Ni and Fe.

Preferably, the at least two parts are made of the same powder composition.

After joining the components in a sintering operation, the tool head may be ground or otherwise machined to its final shape, e.g., provided with cutting edges and clearance surfaces. Furthermore, the tool head may be provided with a coating, such as a Physical Vapour Deposition (PVD) or Chemical Vapour Deposition (CVD) coating.

According to another aspect of the invention, there is provided a tool head for use with a body of a rotary cutting tool according to the independent product claim. The tool head having a front end and a rear end between which the central axis of rotation and the peripheral envelope surface extend,

-wherein the rear end is configured to be connected to a main body, and wherein the front end is configured for cutting engagement with a workpiece,

wherein the tool head comprises at least one channel intended for conveying liquid coolant to a cutting edge of the tool head, each of said at least one channel extending from an inlet opening in a rear end of the tool head to an outlet opening in a front end or a peripheral envelope surface of the tool head,

-wherein the at least one passage is formed in at least one interface, said at least one interface being formed by joining at least two parts to form a cutter head, and each part being formed from a powder component.

The proposed tool head may be constructed to be replaceable. In this case, the tool head is provided with an interface for fastening the tool head to the body, for example by means of a male/female engagement means. The tool head may also be configured to be permanently attached to the body of a rotary cutting tool. The tool head is preferably manufactured according to the proposed method according to any of the above embodiments.

The tool head may also be configured for drilling or for milling.

The interface in which the channels are formed generally acquires the same microstructure as the other components of the tool head. The inner edges may be formed due to the manufacturing process, which extend in the longitudinal direction in the channel. Since these edges extend in the longitudinal direction, they have the lowest influence on the flow of the coolant through the channel.

According to another aspect of the present invention, a rotary cutting tool is provided, comprising a body and the proposed tool head. The rotary cutting tool may be a drilling tool or a milling tool.

The body may include a central coolant conduit for providing coolant to the cutter head. The body may alternatively include two or more coolant conduits, each configured to connect to a channel of the cutter head. The body may be made of metal (e.g., steel alloy) or of a hard metal (e.g., cemented carbide or cermet). The tool head may be integrally formed with the body, permanently attached to the body, or releasably attached to the body (i.e., replaceable).

According to one embodiment, the tool head has been bonded to the body by sintering. Thus, the tool head and the body are firmly joined, but the body and the tool head may be made of different materials. For example, the body may be made of a cheaper brand than the cutter head. If cemented carbide is used for the tool head, the body may also be formed of cemented carbide, but with a different composition.

Other advantageous features and advantages of the invention will become apparent from the detailed description that follows.

Drawings

Embodiments of the invention will hereinafter be described, by way of example, with reference to the accompanying drawings, in which:

figure 1 is a flow chart illustrating a method according to an embodiment of the invention,

figure 2 is a perspective view of two components used to form a cutter head according to a first embodiment,

figure 3 is a side view of the component from figure 2,

figure 4 is a perspective view showing the components of figure 2 assembled to form a cutter head,

figure 5 is a front end view of the assembled components from figure 4,

fig. 6 is a cross-sectional view showing a drilling tool, which comprises a tool head according to a first embodiment,

figure 7 is a perspective view of the drilling tool in figure 6,

figure 8 is a perspective view of two components used to form a cutter head according to a second embodiment,

figure 9 is a front end view showing the components of figure 8 assembled to form a cutter head,

fig. 10 is a perspective view showing a drilling tool, which comprises a tool head according to a second embodiment,

figure 11 is a perspective view of two components used to form a cutter head according to a third embodiment,

FIG. 12 is a side view of the component from FIG. 11, an

Fig. 13 is a perspective view of a cutter head according to a third embodiment.

Detailed Description

A method for forming a tool head according to one embodiment of the invention is schematically illustrated in a flow chart in fig. 1. The method comprises the following steps A to C:

a: the first and second parts of the tool head are formed from a powder composition comprising a binder phase in metallic form and a hard phase, for example in the form of carbides and/or carbonitrides and/or nitrides.

And B, assembling the first component and the second component into the shape of the cutter head.

And C, combining the assembled components in a sintering operation to form the cutter head.

After step C, the formed tool head is machined to form cutting edges and clearance surfaces, and may also be provided with a coating. The final configuration of the tool head (e.g., including the chisel edge cutting edges and clearance surfaces) is not shown in the drawings.

Reference is now made to fig. 2 to 10, which illustrate the manufacture of a tool head 1 according to a first embodiment (fig. 2 to 7) and according to a second embodiment (fig. 8 to 10). The same reference numerals are used for the same or corresponding features. The tool head 1 is intended to be permanently attached to a body 2 to form a rotary cutting tool 3, the tool head and the body extending along a common centre axis C about which the tool 3 is rotatable in a direction R. The tool head 1 may also be a replaceable head, which can be attached to the body in a removable manner. In this case, the tool head is provided with a coupling interface.

Step A

In fig. 2 to 5, a first part 4 and a second part 4 'for a tool head 1 according to a first embodiment are shown, and in fig. 8 to 9, a first part 4 and a second part 4' for a second embodiment according to the invention are shown, respectively. The first part 4 and the second part 4' correspond to a first half and a second half, respectively, of the tool head 1 to be formed. In the embodiment shown, the first part 4 and the second part 4' are identical.

As shown in fig. 2 to 3 and 8, respectively, the first component 4 comprises a first bonding surface 5 and the identical second component 4' comprises an identical second bonding surface configured to be in contact with the first bonding surface 5 in step B. The joining surface 5 extends parallel to the centre axis C of the tool head 1 to be formed. The first component 4 further comprises a first outer surface portion 6 and the second component 4 'comprises an identical second outer surface portion 6'. Each outer surface portion 6, 6' is configured to form a first and a second portion, respectively, of the peripheral envelope surface 7 of the tool head 1.

A chip flute 8 is prefabricated in each part, so that a cutting edge can then be produced in a grinding operation at the intersection 9 between the chip flute 8 and the front end 10 of the tool head 1. A cut-out 11 is also provided to widen the chip flute 8 at the front end 10 of the tool head 1.

In the first embodiment, four grooves 15 are formed in each bonding surface 5, which grooves have the same rounded shallower cross-sectional shape. The groove 15 of the first bonding surface 5 is configured to face the corresponding groove of the second bonding surface. Each groove 15 extends from a common central depression 16 formed at the rear end of the member 4 to the front end of the member 4. The groove 15 is curved with a relatively large radius of curvature.

In the second embodiment, two curved grooves 17, 18 are formed in each bonding surface 5. The grooves 17, 18 extend from a common recess 19. Of the two grooves 17, 18 formed in each bonding surface 5, one groove 17 is relatively shallow and one groove 18 is relatively deep. The shape of the grooves 17, 18 is such that the resulting channel formed by the two grooves 17, 18 obtains a cross-sectional shape having a so-called Reuleaux (Reuleaux) triangle. This cross-sectional shape prevents rotational movement of the coolant about the longitudinal axis of the channel. Otherwise, such rotational movement may cause a pressure drop within the channel.

In both embodiments, the grooves 15, 17, 18 each have a smooth or substantially smooth surface, without transverse ridges or the like that would affect the flow of coolant through the channels formed by the grooves.

In each joining surface 5, positioning means are formed in the form of one recess 20 and one projection 21.

Powder Injection Molding (PIM) may be used to form the components 4 of the embodiments shown in figures 2 to 5 and 8 to 9 respectively. Using the PIM forming means comprises the following successive steps:

i) a granulated composite powder (e.g., a cemented carbide powder component including WC and Co) is mixed with a binder system (e.g., a polymer) to form a feedstock.

ii) performing injection moulding using the feedstock, comprising heating the feedstock to 100 ℃ to 240 ℃, forcing the feedstock into a mould to form a part, cooling, and demoulding the obtained part from the mould.

iii) removing the binder system from the obtained component (debinding).

If necessary, irregularities (irregularities) may be removed from the part prior to step B.

Step B

To assemble the components 4, 4' into the shape of a tool head as shown in fig. 4 to 5 and 9 respectively, the first and second joining surfaces 5, 9 are brought into contact to form the interface 22, such that each pair of facing grooves 15, 17, 18 forms a channel extending in the interface 22. In the first embodiment, four passages 23 are formed in the mouthpiece 22, and in the second embodiment, two passages 24 are formed. These channels extend from a common inlet opening 25 in the rear end 26 of the tool head 1 to an outlet opening 27 in the front end 10 of the tool head 1. The positioning means 20, 21 ensure correct alignment of the parts 4, 4' when the positioning means 20, 21 of the first bonding surface 5 are in contact with the positioning means of the second bonding surface. The interface 22 extends parallel to the centre axis C such that it intersects the peripheral surface of the tool head 1 at the front end 10, at the rear end 26 and at the peripheral envelope surface 7.

The tool head 1 is formed rotationally symmetrical about a centre axis C. When the tool head 1 is rotated about the central axis C in the direction R, the front end 10 of the tool head 1 will be configured for cutting engagement with a workpiece.

Step C

The sintering is performed at a temperature and time such that the binder phase, i.e. the metal of the composite powder, is in a liquid state for at least one minute. The temperature may be between 1350 ℃ and 1500 ℃ for a period of time of 10 minutes to 120 minutes, for example. The time and temperature used depend on the material composition but also on the size and shape of the component 4.

In an alternative embodiment, the individual components 4 are sintered after step a, i.e. before assembling the components. Thereafter, the sintered parts are assembled as previously described. In this case, the final sintering operation that joins the parts can be shortened so as not to alter the material properties of the tool head. Depending on the size, composition and shape of the part, a time period of 10 to 20 minutes may be sufficient.

In the first and second embodiments, the sintered tool head 1 is joined to the body 2 in another sintering operation to form a rotary cutting tool 3, which rotary cutting tool 3 here is in the form of a drilling tool as shown in fig. 6 to 7 and 10, respectively. In the embodiment shown, the body 2 has been formed by extrusion and then by sintering. The body comprises a central coolant conduit 28 for supplying liquid coolant to the tool head 1. Thus, the common central inlet opening 25 in the rear end 26 of the tool head 1 is connected to the central coolant conduit 28 of the main body 2.

Fig. 11 to 13 illustrate the manufacture of a replaceable tool head 30 according to a third embodiment of the invention. The tool head 30 is intended for use with a body (not shown) of a drilling tool, wherein the body is made of steel, for example. The rear end 31 of the tool head 30 as shown is machined to form an engagement means for securely attaching the tool head 30 to a body (not shown). The tool head 30 is rotationally symmetrical about a central axis C, about which it can rotate in the direction R.

To manufacture the cutter head 30, a first part 34 and an identical second part 34' are formed in step a. However, in this embodiment, it is preferred to form the parts 34, 34' from composite powder in a multi-axis compaction process rather than using PIM.

The first part 34 comprises a first bonding surface 35 and the second part 34' comprises an identical second bonding surface configured to contact the first bonding surface 35 in step B. Similar to the first and second embodiments, the first component 34 also includes a first outer surface portion 36, and the second component 34 'includes an identical second outer surface portion 36'. Each outer surface portion 36, 36' is configured to form a first and a second portion, respectively, of the peripheral envelope surface 37 of the tool head 30.

The bonding surface 35 lacks locating means. Alternatively, the joining surface 35 is twisted about the central axis C so that the parts 34, 34' will automatically align during assembly. In each joining surface 35, two front grooves 38 are formed in the pressing process, which extend from a common recess 39 near the rear end of the component 34 to the front end of the component 34. A common rear recess 40 extends from the common recess 39 to the rear end of the member 34. All of the grooves 38, 40 have a smooth or substantially smooth surface.

When the components 34, 34 'are assembled in step B, the front grooves 38 form two front channels 41 with a circular cross section, which extend in the interface between the assembled components 34, 34'. The front channel 41 has an outlet opening in the front end 42 of the cutter head 30 adjacent to a cutting edge that will later be formed in a grinding operation. The rear recesses 40 form a common rear channel (not shown) extending from an inlet opening in the rear end 31 of the cutter head 30 to the central distribution chamber formed by the common recess 39. Thus, the liquid coolant can be supplied to the outlet opening at the front end 42 of the tool head 30 via the common rear, distribution chamber and front channel 41.

As described above, in step C, the assembled components 34, 34' are bonded in a sintering operation. After bonding, the tool head 30 is machined to obtain the final shape of the tool head (not shown), including the cutting edges and the engagement means for mounting the tool head 30 in the front seat of the body configured to be mounted, for example, in the spindle of a machine tool.

The invention is of course not limited to the embodiments disclosed but may be varied and modified within the scope of the following claims. For example, the components used to form the cutter head need not be identical, and more than two components may be used, such as three components having joining surfaces extending along a central axis. Furthermore, the rotary cutting tool may be a milling tool instead of a drilling tool, in which case the outlet openings of the channels are preferably arranged in the peripheral envelope surface of the tool head, close to the cutting edges of the milling tool.