阅读说明：本技术 加工镍基高温合金的复杂刃形SiAlON陶瓷刀片及盘铣刀刀柄 (Complex-edge SiAlON ceramic blade for processing nickel-based superalloy and disc milling cutter handle ) 是由 殷增斌 洪东波 郭福州 于 2021-09-30 设计创作，主要内容包括：本发明属于切削刀具领域,具体涉及一种加工镍基高温合金的复杂刃形SiAlON陶瓷刀片及盘铣刀刀柄。盘铣刀刀柄包括复杂刃形SiAlON陶瓷方刀片、铣刀盘、垫块、垫块上固定螺丝、垫块下固定螺丝、弹簧、压块固定螺丝、压块。所述刀具中垫块由垫块上固定螺丝和垫块下固定螺丝固定在铣刀盘上；复杂刃形SiAlON陶瓷刀片置于垫块的固定槽中,上置压块紧固；铣刀刀柄与复杂刃形SiAlON陶瓷刀片共同构成最终的切削角度。与常规的简单形状陶瓷刀具相比,具有复杂刃形的SiAlON陶瓷刀具在加工镍基高温合金时具有更低的切削温度和切削力,同时刀尖应力也更低,具有更好的切削性能。(The invention belongs to the field of cutting tools, and particularly relates to a complex-edge SiAlON ceramic blade for processing nickel-based superalloy and a disc milling cutter handle. The disc milling cutter handle comprises a complex-edge SiAlON ceramic square blade, a milling cutter disc, a cushion block, an upper cushion block fixing screw, a lower cushion block fixing screw, a spring, a pressing block fixing screw and a pressing block. The middle cushion block of the cutter is fixed on the milling cutter disc through an upper cushion block fixing screw and a lower cushion block fixing screw; the complex-edge-shaped SiAlON ceramic blade is arranged in a fixing groove of the cushion block, and a pressing block is arranged on the complex-edge-shaped SiAlON ceramic blade for fastening; the milling cutter handle and the complex-edge SiAlON ceramic blade jointly form a final cutting angle. Compared with the conventional simple-shaped ceramic cutter, the SiAlON ceramic cutter with the complex blade shape has lower cutting temperature and cutting force when processing the nickel-based superalloy, and simultaneously has lower stress of a tool nose and better cutting performance.)

1. A complex-edge SiAlON ceramic blade for processing nickel-based superalloy is characterized in that the whole blade is square and has no back angle, the four corners of the blade are provided with circular arcs, a through hole is formed in the center of the blade, a central boss and a complex edge shape are arranged on the upper surface of the blade, the complex edge shape consists of a chamfer, a cutting edge and a circular arc chip breaker which are sequentially arranged, the circular arc radius R2 of the chip breaker is 1.0-1.6mm, and the front of the blade is provided with a concave convex surfaceAngle gamma₁6-10 degrees, the width L2 of the cutting edge of the tool nose is 0.8-1.6mm, the radius R1 of the arc of the tool nose is 0.8-1.6mm, and the width L1 of the chamfer is 0.04-0.12 mm.

2. The ceramic insert of claim 1, wherein the insert inner circle diameter d1 is 12-16mm, the thickness h is 4.5-6.5mm, the insert central through hole diameter d2 is 4-5mm, and the principal deflection angle is κ_r30-75 degrees, and the height difference H1 between the central boss and the knife tip is 0.1-0.2 mm.

3. A disc cutter handle, characterized in that it comprises a ceramic insert according to any one of claims 1-2.

4. The disc milling cutter handle according to claim 3, characterized by further comprising a spacer (2), a milling cutter disc (3), a spacer lower fixing screw (4), a spacer upper fixing screw (5), a pressing block fixing screw (7) and a pressing block (8);

the cushion block is installed on the milling cutter head (3) through the lower cushion block fixing screws (4) and the upper cushion block fixing screws (5), a ceramic blade installing surface is arranged on the cushion block (2), the ceramic blade is placed on the installing surface of the cushion block (2), and the ceramic blade is clamped and fixed on the milling cutter head (3) through the pressing block (8) and the pressing block fixing screws (7).

5. The disc milling cutter handle according to claim 4, characterized by further comprising a spring (6), wherein two countersunk holes are formed in the cushion block (2) and used for mounting a lower cushion block fixing screw (4) and an upper cushion block fixing screw (5), respectively, a stepped hole is further formed in the cushion block (2), the main body of the stepped hole is a threaded hole for the pressing block fixing screw (7) to pass through, and the spring (6) is sleeved on the periphery of the pressing block fixing screw (7) and is arranged between the cushion block (2) and the pressing block (8).

6. A disc cutter handle according to claim 5 wherein the mounting surface of the mounting insert is axially mounted at an angle γ_zIs 6-10 degrees and the radial installation angle gamma_JIs 6-10 degrees.

Technical Field

The invention belongs to the field of cutting tools, and particularly relates to a complex-edge SiAlON ceramic blade for processing nickel-based superalloy and a disc milling cutter handle.

Background

The aviation high-temperature alloy material has good high-temperature strength, oxidation resistance, corrosion resistance, fatigue strength, fracture toughness and plasticity, and can bear large complex stress in a high-temperature environment of more than 600 ℃, so the aviation high-temperature alloy material is widely applied to industries of aviation, aerospace, ships, energy sources and the like. However, the excellent performance of high temperature alloys also puts higher demands on cutting, and due to high cutting temperature, large cutting force and the like, the cutting tools are worn quickly, the machining efficiency is low and the machining cost is high. The hard alloy cutter has high strength and hardness, but the heat resistance is poor, so that the cutting speed is very low, and the requirement of high-efficiency cutting processing of the integral blank of the difficult-to-process material is not met. The ceramic cutter has high hardness, high wear resistance, high heat resistance and good chemical stability, and has incomparable advantages compared with the traditional cutter in the field of high-speed cutting and the aspect of cutting difficult-to-process materials. SiAlON ceramic is a solid solution of Al2O3 and Si3N4, has excellent comprehensive mechanical properties and good high-temperature performance, and researches show that the SiAlON ceramic milling cutter can cut and process high-temperature alloy at a high speed at a cutting speed of 585m/min, the service life of the cutter reaches 26 minutes and is about 10 times of that of a hard alloy cutter. For efficient cutting machining of complex components such as high-temperature alloy blades, blade discs and casings of aircraft engines, the SiAlON ceramic cutter is one of the most potential cutters.

Since sintering and manufacturing of ceramic cutting tools are difficult, commercially available ceramic cutting tools are mainly round cutting tools and square cutting tools with simple flat surfaces, and related researches are very few. However, the cutting performance of the tool as a metal cutting tool having a predetermined function depends on geometrical parameters during cutting in addition to the material of the tool. For the cutting part of the tool directly participating in the cutting process, the geometric parameters of the tool can influence the deformation and interaction among the tool, the chip and the workpiece, so that the cutting force, the cutting heat and the wear of the tool are changed, the surface integrity of the machined workpiece and the curling, breaking and flowing direction of the chip are influenced, and the cutting performance and the cutting effect of the tool are greatly influenced. Therefore, reasonably optimizing the geometric parameters of the cutter has great significance for improving the cutting performance of the cutter.

In a study by the inventors [ Dongbo Hong, Juntang Yuan, Zengbin Yin, et. al. ultrasonic-associated prediction of complex-shaped ceramic cutting tools by microwave sintering.2020, Ceramics International,46(12):20183-20190, DOI:10.1016/j. ceramint.2020.05.097]Ceramic cutters with complex blade shapes have been prepared by imitating hard alloy cutters through microwave sintering technology, and the prepared ceramic cutters have excellent compactness and excellent mechanical properties on both the cutter tips and the cutter bodies. In another study by the inventors [ Dongbo Hong, Zengbin Yin, Fuzhou Guo, et al. microwave sintering of duplex α/β -SiAlON ceramic cutting inserts: modifying m, n, z values, sintering temperature and process Y₂O₃ sintering additive.2021.DOI:10.21203/rs.3.rs-515032/v1]The SiAlON ceramic blade with excellent performance is prepared by a microwave sintering technology. The study showed that the same insert configuration (circular insert) and cutting parameters (v) were obtained_c＝800m/min,f_z＝0.12mm/z,a_p1.5mm), compared with a foreign commercial SiAlON ceramic blade (kenna KYS30 blade), the SiAlON ceramic blade prepared by microwave sintering has a tool life increased by 75% in high-speed processing of a nickel-based superalloy, and shows excellent cutting performance.

In the two studies, the optimization of the tool structure is not performed with respect to the material properties of the ceramic tool and the object to be machined (superalloy). Because the ceramic cutter has high hardness and poor toughness, the ceramic cutter is easy to break and break in the processing process, and the unsuitable cutter structure can greatly weaken the performance of the cutter. Meanwhile, the nickel-based high-temperature alloy has poor heat conductivity, so that cutting heat is more easily accumulated at a tool tip, and the performance of the tool is weakened.

Disclosure of Invention

The invention aims to provide a complex-edge SiAlON blade and a disc milling cutter handle for processing nickel-based high-temperature alloy, which can ensure that the cutting performance of a cutter is improved under the condition of no breakage.

The technical solution for realizing the purpose of the invention is as follows: a complex-edge SiAlON ceramic blade for processing nickel-based high-temperature alloy is characterized in that the whole blade is square and has no back angle, four corners of the blade are provided with circular arcs, the center of the blade is provided with a through hole, the upper surface of the blade is provided with a central boss and a complex edge shape, the complex edge shape consists of a chamfer, a cutting edge and a circular arc chip breaker which are sequentially arranged, the circular arc radius R2 of the chip breaker is 1.0-1.6mm, and the front angle gamma of the blade is gamma₁Is at an angle of 6 to 10 degrees,the width L2 of the cutting edge of the tool nose is 0.8-1.6mm, the radius R1 of the arc of the tool nose is 0.8-1.6mm, and the width L1 of the chamfer is 0.04-0.12 mm.

Further, the diameter d1 of the blade inscribed circle is 12-16mm, the thickness h is 4.5-6.5mm, the diameter d2 of the blade center through hole is 4-5mm, and the main deflection angle is kappa_r30-75 degrees, and the height difference H1 between the central boss and the knife tip is 0.1-0.2 mm.

The milling cutter further comprises a cushion block, a milling cutter disc, a cushion block lower fixing screw, a cushion block upper fixing screw, a pressing block fixing screw and a pressing block;

the cushion block is arranged on the milling cutter disc through the lower cushion block fixing screws and the upper cushion block fixing screws, a ceramic blade mounting surface is arranged on the cushion block, the ceramic blade is placed on the cushion block mounting surface, and the ceramic blade is clamped and fixed on the milling cutter disc through the pressing block and the pressing block fixing screws.

The spring is further arranged, two counter bores are formed in the cushion block and are respectively used for mounting a lower fixing screw of the cushion block and an upper fixing screw of the cushion block, a step hole is further formed in the cushion block, a main body of the step hole is a threaded hole for the pressing block fixing screw to penetrate through, and the spring is sleeved on the periphery of the pressing block fixing screw and is arranged between the cushion block and the pressing block.

Further, the axial installation angle gamma z of the installation surface for installing the blade is 6-10 degrees, and the radial installation angle gamma J is 6-10 degrees.

Compared with the prior art, the invention has the remarkable advantages that:

(1) compared with the simple flat blade sold in the market, the SiAlON milling cutter blade with the complex blade shape has the advantages that the cutting force is smaller, the cutting temperature is lower, the stress of a tool nose is lower, and a ceramic cutter is not easy to break and lose effect in processing, so that the SiAlON milling cutter blade has better cutting performance;

(2) the complex-edge SiAlON milling cutter blade is provided with a chip breaker groove, so that the chip size can be reduced in the machining process, and the machining working condition is improved;

(3) the through hole is selected in the blade instead of the counter bore, so that cracks possibly occurring near the counter bore in the sintering process of the ceramic cutter can be reduced;

(4) the cushion block of the disc milling cutter handle has an axial installation angle and a radial installation angle, the cushion block is designed into a replaceable part, and the cutter installation angle can be conveniently changed by replacing the cushion block and is suitable for blades with different structures.

Drawings

Fig. 1 is an exploded assembly view of the shank of the disc milling cutter of the present invention.

Fig. 2 is a schematic view of the cushion block structure of the present invention.

Fig. 3 is a schematic view of the installation angle of the milling cutter of the present invention.

Figure 4 is a three-dimensional structure diagram of a complex-edged SiAlON ceramic blade of the present invention.

FIG. 5 is a schematic two-dimensional angle view of a complex-edged SiAlON ceramic blade of the present invention; wherein, fig. (a) is a top view, fig. (b) is a side view, and fig. (c) is a partially enlarged schematic view of fig. (a).

FIG. 6 is a diagram of a cutting simulation result; the equivalent stress cloud picture of the complex-edge-shaped SiAlON blade is shown in the drawing, wherein the equivalent stress cloud picture of the SiAlON blade with the common flat blade surface is shown in the drawing (a), the equivalent stress cloud picture of the blade tip part of the complex-edge-shaped SiAlON blade is shown in the drawing (b), the equivalent temperature cloud picture of the SiAlON blade with the common flat blade surface is shown in the drawing (c), and the equivalent temperature cloud picture of the blade tip part of the complex-edge-shaped SiAlON blade is shown in the drawing (d).

Figure 7 is a graph of cutting force versus milling angle for a plain-edged SiAlON insert and a complex-edged SiAlON insert of the present invention in a cutting simulation.

Description of reference numerals:

1-complex-edge SiAlON ceramic square blade, 2-cushion block, 3-milling cutter disc, 4-cushion block lower fixing screw, 5-cushion block upper fixing screw, 6-spring, 7-pressing block fixing screw, 8-pressing block, 21-blade mounting surface, 2-cushion block lower fixing screw mounting stepped hole, 3-cushion block upper fixing screw mounting stepped hole, 4-pressing block fixing screw mounting threaded hole and 5-pressing block clamping surface.

Detailed Description

The present invention is described in further detail below with reference to the attached drawing figures.

As shown in fig. 1 to 5, the complex-edged SiAlON ceramic blade and the disc cutter handle for processing nickel-based superalloy, the complex-edged SiAlON ceramic blade comprises a complex-edged SiAlON ceramic blade 1, a cushion block 2, a milling cutter disc 3, a cushion block lower fixing screw 4, a cushion block upper fixing screw 5, a spring 6, a pressing block fixing screw 7 and a pressing block 8.

As shown in fig. 3-5, the complex-edge SiAlON ceramic blade 1 is a square blade without a back angle, the blade has four corners with circular arcs, and the center of the blade is a through hole for installation and positioning. The complex edge shape of the blade is positioned on the upper surface and is provided with a chamfer, a cutting edge and a circular arc chip breaker, and the complex edge shape is embodied by the groove design of four edge surfaces. The central boss of the blade is higher than the cutting edge vertex.

As shown in fig. 1-2, the spacer block 2 is used to connect a complex-edged SiAlON ceramic insert 1 and a milling cutter disc 3. The cushion block 2 is provided with two step holes, and the cushion block can be fixed on the milling cutter disc 3 through a cushion block lower fixing screw 4 and a cushion block upper fixing screw 5. After the cushion block 2 is installed on the milling cutter disc 3, the complex-edge-shaped SiAlON ceramic blade 1 is placed on the installation surface of the cushion block 2, the pressing block 8 is arranged on the cushion block, and the complex-edge-shaped SiAlON ceramic blade 1 can be clamped tightly by the pressing block fixing screw 7 which penetrates through the pressing block 8 and is screwed into the pressing block fixing screw installation threaded hole in the cushion block 2 and is finally fixed on the milling cutter disc 3. In addition, a spring 6 is arranged between the threaded hole of the cushion block 2 and the pressing block 8 and is mainly used for adjusting pressing force.

The diameter d1 of the blade inscribed circle is 12.7mm, the thickness h is 4.76mm, the diameter d2 of the blade central through hole is 4.0mm, and the main deflection angle is kappa_r45 degrees, the radius R2 of the chip breaker groove is 1.0-1.6mm, the height difference H1 between the boss and the tool nose is 0.1mm, and the front angle gamma of the tool is₁6-10 degrees, the width L2 of the cutting edge of the tool nose is 0.8-1.6mm, the radius R1 of the arc of the tool nose is 0.8-1.6mm, and the width L1 of the chamfer is 0.04-0.12 mm.

Axial installation angle gamma of installation surface for installing blade_zIs 6-10 degrees and the radial installation angle gamma_JIs 6-10 degrees.

Example 1

The cutting process of machining the nickel-base superalloy by the SiAlON blade with the complex edge shape is simulated through finite element simulation software Third Wave Advantedge, and the simulation is compared with a common flat blade surface SiAlON cutter.

The modeling parameters were as follows:

a blade: simple flat face square blade milling cutters and square blade milling cutters with complex blade shapes;

installation angle: the axial installation angle is 6 degrees, and the radial installation angle is 10 degrees;

the blade constitutive model is as follows: SiAlON ceramic;

workpiece constitutive model: inconel718 nickel-base superalloys;

grid parameters: the maximum grid is 0.3mm, and the minimum grid is 0.03 mm;

the processing type is as follows: reverse milling;

processing parameters are as follows: cutting speed is 800m/min, feed rate is 0.12mm/z, cutting depth is 1.5mm, milling width is 33mm, and milling angle is 90 degrees;

coefficient of friction: 0.6.

and (3) simulation results:

as can be seen from fig. 6, under the same processing conditions, the nose portion of the SiAlON ceramic insert with the complex edge shape had a lower stress area than the flat facet SiAlON ceramic insert, indicating a lower likelihood of insert wear and chipping; meanwhile, as can be seen from the temperature cloud chart, the high temperature area of the knife tip part of the SiAlON ceramic blade with the complex edge shape is smaller than that of the flat knife surface SiAlON ceramic blade, which indicates that the heat dissipation condition is changed, which is beneficial to the blade performance.

As can be seen from fig. 7, the edge portion slitting force of the SiAlON ceramic blade having the complex edge shape is significantly smaller than that of the plain surface SiAlON ceramic blade. Under the same processing conditions, the lower cutting force can reduce the stress of the tool nose of the blade so as to improve the cutting service life of the tool.

In conclusion, the SiAlON ceramic blade designed by the invention has the result of being more suitable for processing nickel-based high-temperature alloy and has extremely high market application potential.