CN111570944B - Manufacturing method of integrated PCD milling cutter head - Google Patents
Manufacturing method of integrated PCD milling cutter head Download PDFInfo
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- CN111570944B CN111570944B CN202010303914.0A CN202010303914A CN111570944B CN 111570944 B CN111570944 B CN 111570944B CN 202010303914 A CN202010303914 A CN 202010303914A CN 111570944 B CN111570944 B CN 111570944B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/06—Electrochemical machining combined with mechanical working, e.g. grinding or honing
- B23H5/08—Electrolytic grinding
Abstract
The invention relates to the technical field of precision machining, and discloses a manufacturing method of a connected PCD milling cutter head, which comprises the following steps: machining a plurality of spiral chip flutes on the side surface of the PCD parent metal by using a first copper wheel in a mechanical grinding composite electrolysis mode, wherein a cutting edge is defined between every two adjacent chip flutes; and machining a tooth breaking groove on the front end face of the PCD parent metal by using a second copper wheel in a mechanical grinding composite electrolysis mode, so that the two chip grooves arranged on the two opposite sides of the PCD parent metal are communicated one by one correspondingly. The invention has the beneficial effects that: the machining efficiency is high, the surface quality of the formed surface can be effectively improved by adjusting the discharge machining parameters, the cost is relatively low, the machining method is reliable, and the stability of the integrated PCD milling cutter head can be ensured.
Description
Technical Field
The invention relates to the technical field of precision machining, in particular to a manufacturing method of a connected PCD milling cutter head.
Background
The polycrystalline diamond (PCD) milling cutter head has the characteristics of high hardness, high compressive strength, good thermal conductivity and wear resistance and the like, so that high machining precision and machining efficiency can be obtained in high-speed cutting. Currently, the main manufacturing method of the PCD milling cutter head is to weld the PCD cutter head to the outer surface of the cutter body, which results in poor stability of the PCD milling cutter head and easy falling of the PCD cutter head.
To this technical problem, the integral type PCD milling cutter tool bit has been developed at present, with cutting edge integrated into one piece in the cutter body surface, can increase substantially the stability of PCD milling cutter tool bit. However, since the PCD milling cutter head is generally used for precision machining in fine milling, the PCD milling cutter head has a fine structure, and it is complicated to form a cutting edge on the surface of a cutter body, and the precision requirement is high. For some traditional mechanical processing, such as grinding processing and the like, the cutter body is stressed greatly and is easy to deform in the processing process, the forming time is long, and the efficiency is low; when ultrasonic processing is adopted, the forming process is complex, the processing cost is high, and the mass production is not facilitated; the laser machining of the cutter head is still in a research stage at present, the machining precision is low, and the forming quality cannot meet the requirements.
Disclosure of Invention
The purpose of the invention is: the manufacturing method of the integrated PCD milling cutter head overcomes the defects of the prior art, can improve the processing precision and the processing efficiency, reduces the processing cost, and ensures the stability of the integrated PCD milling cutter head.
In order to achieve the above object, the present invention provides a method of manufacturing a one-piece PCD milling cutter head, comprising the steps of:
machining a plurality of spiral chip flutes on the side surface of the PCD parent metal by using a first copper wheel in a mechanical grinding composite electrolysis mode;
and machining a tooth breaking groove on the front end face of the PCD parent metal by using a second copper wheel in a mechanical grinding composite electrolysis mode, so that the two chip grooves arranged on the two opposite sides of the PCD parent metal are communicated one by one correspondingly.
Preferably, when the chip flutes are processed, the method specifically comprises the following steps:
s1, connecting the PCD parent metal with the positive electrode of a pulse power supply, connecting the first copper wheel with the negative electrode of the pulse power supply, and immersing the first copper wheel and the PCD parent metal in electrolyte;
and S2, performing mechanical grinding composite electrolytic machining on the side surface of the PCD parent metal by utilizing the cutting surface of the first copper wheel to form a plurality of chip grooves.
Preferably, the step S2 specifically includes:
s21, the first copper wheel and the PCD parent metal rotate along the central axes of the first copper wheel and the PCD parent metal, an included angle of less than 90 degrees is formed between the central axis of the first copper wheel and the central axis of the PCD parent metal, and axial feeding is carried out between the PCD parent metal and the first copper wheel along the direction parallel to the axial direction of the PCD parent metal so as to form a chip groove on the outer surface of the PCD parent metal;
s22, adjusting the position of the first copper wheel relative to the PCD parent metal;
and S23, repeating the steps S21 and S22 until a preset number of chip grooves are formed on the PCD parent material.
Preferably, in step S21, the first copper wheel is fed to the side surface of the PCD base material by a single normal direction to a depth of 5 to 20 μm, and the chip pocket is formed on the side surface of the PCD base material by performing several cycles of machining.
Preferably, the rotating speed of the first copper wheel is 100-5000 r/min, and the rotating speed of the PCD parent metal is 0.1-1 r/min.
Preferably, the first copper wheel and the PCD parent metal are both axially fed;
the axial feeding speed of the first copper wheel is 0.1-5 mu m/s, and the axial feeding speed of the PCD parent metal is 0.1-5 mm/s.
Preferably, the pulse voltage of the pulse power supply is 10 to 200V, the pulse width is 0.1 to 100 μ s, and the inter-pulse width is 0.1 to 100 μ s when the chip pocket is machined.
As a preferred scheme, when the tooth breaking slot is machined, the method specifically comprises the following steps:
a1, fixedly mounting a PCD parent material;
a2, connecting the PCD parent metal with the positive electrode of a pulse power supply, connecting the second copper wheel with the negative electrode of the pulse power supply, and immersing the PCD parent metal and the second copper wheel in electrolyte;
and A3, performing mechanical grinding composite electrolytic machining on the front end face of the PCD parent metal by using the edge-forming profile of the second copper wheel to form a plurality of tooth breaking grooves.
Preferably, the step a3 specifically includes:
feeding the second copper wheel in a direction parallel to the end face of the PCD parent metal while rotating around the central axis of the second copper wheel A31, and performing mechanical grinding composite electrolytic machining on the front end face of the PCD parent metal by using the edge-protruding molded surface of the second copper wheel to form a tooth breaking groove;
a32, adjusting the position of the second copper wheel relative to the PCD parent material;
a33, repeating the steps A31 and A32 until the chip grooves oppositely arranged on the two sides of the PCD parent material are communicated in a one-to-one correspondence mode.
Preferably, in step a31, the second copper wheel is fed to the front end surface of the PCD base material by a single normal feeding depth of 5 to 20 μm, and the breaking grooves are formed in the front end surface of the PCD base material by performing a plurality of cycles.
Preferably, the rotating speed of the second copper wheel is 100-5000 r/min, and the feeding speed is 0.1-5 μm/s.
Preferably, the pulse voltage of the pulse power supply is 10 to 200V, the pulse width is 0.1 to 100 μ s, and the inter-pulse width is 0.1 to 100 μ s when the tooth-broken groove is machined.
Compared with the prior art, the manufacturing method of the integrated PCD milling cutter head provided by the embodiment of the invention has the beneficial effects that:
according to the manufacturing method of the integrated PCD milling cutter head, the first copper wheel and the second copper wheel are respectively used for machining the plurality of chip grooves on the side face of the PCD parent metal and machining the tooth breaking grooves on the front end face of the PCD parent metal in a mechanical grinding composite electrolysis mode, compared with mechanical grinding, ultrasonic machining and laser machining, the machining efficiency of the mechanical grinding composite electrolysis machining mode is high, the surface quality of a formed surface can be effectively improved by adjusting discharge machining parameters, the cost is relatively low, the machining method is reliable, and the stability of the PCD milling cutter head can be guaranteed.
Drawings
FIG. 1 is a schematic view of the chip pocket structure of a formed one-piece PCD milling cutter head in an embodiment of the present invention;
FIG. 2 is a schematic structural view of a tooth breaking groove of a formed integral PCD milling cutter head in an embodiment of the present invention;
FIG. 3 is a schematic flow chart of a method of making a one-piece PCD milling cutter head in accordance with an embodiment of the present invention;
FIG. 4 is a schematic flow diagram of a method of forming flutes of a one-piece PCD milling cutter head in accordance with an embodiment of the present invention;
FIG. 5 is a schematic flow chart of step S2 in FIG. 4;
FIG. 6 is a schematic flow diagram of a method of forming tooth breaking grooves of a one-piece PCD milling cutter head in accordance with an embodiment of the present invention;
FIG. 7 is a schematic flow chart of A3 in FIG. 6;
in the figure, 1, a PCD base material; 11. a chip pocket; 12. a cutting edge; 13. breaking the tooth socket; 2. a first copper wheel; 3. a second copper wheel.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
In the description of the present invention, it should be noted that the terms "front end" and "rear end" refer to the end close to the workpiece as the "front end" and the end away from the workpiece as the "rear end" when the integrated PCD milling cutter head is used for machining.
As shown in fig. 1 to 7, a method of manufacturing a one-piece PCD milling cutter head according to a preferred embodiment of the present invention includes the steps of:
b1, machining a plurality of spiral chip flutes 11 on the side surface of the PCD parent metal 1 by using the first copper wheel 2 in a mechanical grinding and electrolysis combined mode, and defining a cutting edge 12 between every two adjacent chip flutes 11;
b2, machining tooth breaking grooves 13 on the front end face of the PCD parent metal 1 by using the second copper wheel 3 in a mechanical grinding composite electrolysis mode, so that the two chip grooves 11 arranged on the two opposite sides of the PCD parent metal 1 are communicated in a one-to-one correspondence mode.
Based on the technical scheme, the first copper wheel 2 and the second copper wheel 3 are respectively used for machining the plurality of chip grooves 11 on the side face of the PCD parent metal 1 and the plurality of tooth breaking grooves 13 communicated with the chip grooves 11 on the front end face of the PCD parent metal 1 in a mechanical grinding composite electrolysis mode, compared with mechanical grinding, ultrasonic machining and laser machining, the machining efficiency of the mechanical grinding composite electrolysis machining mode is high, the surface quality of a formed surface can be effectively improved by adjusting discharge machining parameters, the cost is relatively low, the machining method is reliable, and the stability of the integrated PCD milling cutter head can be guaranteed.
Specifically, in this embodiment, as shown in fig. 4, the step B1 specifically includes the following steps:
s1, connecting the PCD parent metal 1 with the positive electrode of a pulse power supply, connecting the first copper wheel 2 with the negative electrode of the pulse power supply, and immersing the first copper wheel 2 and the PCD parent metal 1 in electrolyte;
s2, the side surface of the PCD base material 1 is subjected to mechanical grinding combined electrolytic machining using the cutting surface of the first copper wheel 2, thereby forming a plurality of spiral chip pockets 11.
In the environment of electrolyte, when the first copper wheel 2 approaches the PCD parent metal 1 and reaches an extremely small gap, the gap between the PCD parent metal 1 and the first copper wheel 2 forms a conductive path through the electrolyte, the PCD parent metal 1 serving as a positive electrode generates electrochemical reaction under the action of pulse voltage and starts to dissolve, the PCD parent metal is continuously electrolyzed along with the continuous feeding of the first copper wheel 2 relative to the PCD parent metal 1, an electrolysis product is continuously washed away by the electrolyte, and finally the blade profile of the first copper wheel 2 tends to be consistent relative to the gaps of all parts of the PCD parent metal 1, so that a chip pocket 11 with the shape of the blade profile of the first copper wheel 2 is formed on the PCD parent metal 1.
Further, as shown in fig. 5, in the method for manufacturing the integrated PCD milling cutter head according to the present embodiment, step S2 specifically includes:
s21, the first copper wheel 2 and the PCD parent metal 1 rotate along the central axes of the first copper wheel 2 and the PCD parent metal 1, an included angle of less than 90 degrees is formed between the central axis of the first copper wheel 2 and the central axis of the PCD parent metal 1, and axial feeding V occurs between the PCD parent metal 1 and the first copper wheel 2 along the direction parallel to the axial direction of the PCD parent metal 1fForming a chip pocket 11 on the outer surface of the PCD parent metal 1;
s22, adjusting the position of the first copper wheel 2 relative to the PCD parent material 1;
s23, repeating steps S21 and S22 until a predetermined number of chip flutes 11 are formed on the PCD parent material 1.
The entire feed path of the first copper wheel 2 is formed in a bow shape, and therefore, a plurality of spiral chip pockets 11 are formed at intervals on the side surface of the PCD base material 1.
In the embodiment, in order to ensure the forming precision of the chip grooves 11, each chip groove 11 needs to be formed by the first copper wheel 2 through multiple times of cyclic processing, and the single feeding depth of the first copper wheel 2 relative to the side surface of the PCD base material 1 is 5-20 μm.
During the process of machining the chip groove, the rotating speed of the first copper wheel 2 is ab100 to 5000r/min, and the rotating speed of the PCD parent metal 1 is aaThe machining efficiency can be maximized and the machining precision can be ensured by 0.1-1 r/min.
Similarly, in the present embodiment, the first copper wheel 2 and the PCD base material 1 are both axially fed, and the axial feeding of the first copper wheel 2 and the axial feeding of the PCD base material 1 are combined to form the Vf(ii) a Preferably, the axial feeding speed of the first copper wheel 2 is 0.1-5 μm/s, and the axial feeding speed of the PCD parent metal 1 is 0.1-5 mm/s.
In this embodiment, in order to achieve the best effect of the processing precision, when the chip pocket 11 is processed, the pulse voltage of the pulse power supply is 10-200V, the pulse width is 0.1-100 μ s, and the inter-pulse width is 0.1-100 μ s.
Referring to fig. 6, when the tooth breaking groove 13 is machined, the method specifically comprises the following steps:
a1, fixedly mounting the PCD parent material 1;
a2, connecting the PCD parent metal 1 with the positive pole of a pulse power supply, connecting the second copper wheel 3 with the negative pole of the pulse power supply, and immersing the PCD parent metal 1 and the second copper wheel 3 in electrolyte;
a3, performing mechanical grinding combined electrochemical machining on the front end face of the PCD base material 1 by using the cutting profile of the second copper wheel 3 to form a plurality of tooth breaking grooves 13.
And a plurality of tooth breaking grooves 13 are formed on the front end surface of the PCD parent metal 1 by using a mechanical grinding composite electrolytic machining method, and the two chip grooves 11 on the two opposite sides are correspondingly communicated one by one, so that the machining precision can be ensured and the machining efficiency can be improved.
As shown in fig. 7, step a3 specifically includes:
a31, the second copper wheel 3 rotates around the central axis thereof and simultaneously generates feeding relative to the direction parallel to the end surface of the PCD parent metal 1, and the front end surface of the PCD parent metal 1 is subjected to mechanical grinding composite electrolytic machining by utilizing the edge-out molded surface of the second copper wheel 3 to form a tooth breaking groove 13;
a32, adjusting the position of the second copper wheel 3 relative to the PCD parent material 1;
a33, repeating the steps A31 and A32 until the chip flutes 11 oppositely arranged on the two sides of the PCD parent material 1 are communicated one by one.
When the tooth breaking grooves 13 are machined, the whole feeding path of the second copper wheel 3 is also in a bow shape, so that the feeding distance can be reduced, and the machining efficiency can be effectively improved.
In order to ensure the forming precision of the tooth breaking grooves, the tooth breaking grooves 13 are formed by the second copper wheel 3 through multiple times of cyclic processing, and the single-time feeding depth of the second copper wheel 3 relative to the front end face of the PCD parent metal 1 is 5-20 mu m.
Similarly, in the present embodiment, the rotation speed of the second copper wheel 3 is ac100-5000 r/min, and the feeding speed is 0.1-5 mu m/s; when the tooth breaking grooves 13 are machined, the pulse voltage of the pulse power supply is 10-200V, the pulse width is 0.1-100 mu s, and the inter-pulse width is 0.1-100 mu s; not only can effectively improve the machining precision but also can improve the machining efficiency.
In summary, embodiments of the present invention provide a method for manufacturing a connected PCD milling cutter head, in which a plurality of chip pockets are machined on a side surface of a PCD parent material and a tooth breaking groove is machined on a front end surface of the PCD parent material through a first copper wheel and a second copper wheel respectively in a mechanical grinding combined electrolysis manner, and compared with mechanical grinding, ultrasonic machining and laser machining, the machining efficiency of the mechanical grinding combined electrolysis machining method is high, the surface quality of a formed surface can be effectively improved by adjusting discharge machining parameters, and the method is relatively low in cost, reliable in machining method, and capable of ensuring the stability of the connected PCD milling cutter head.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and substitutions can be made without departing from the technical principle of the present invention, and these modifications and substitutions should also be regarded as the protection scope of the present invention.
Claims (8)
1. A method of manufacturing a one-piece PCD milling cutter head, comprising the steps of:
machining a plurality of spiral chip flutes on the side surface of the PCD parent metal by using a first copper wheel in a mechanical grinding composite electrolysis mode;
machining a tooth breaking groove on the front end face of the PCD parent metal in a mechanical grinding composite electrolysis mode by using a second copper wheel so that two chip grooves arranged on two opposite sides of the PCD parent metal are communicated in a one-to-one correspondence mode;
when the chip groove is machined, the method specifically comprises the following steps:
s1, connecting the PCD parent metal with the positive electrode of a pulse power supply, connecting the first copper wheel with the negative electrode of the pulse power supply, and immersing the first copper wheel and the PCD parent metal in electrolyte;
s2, performing mechanical grinding composite electrolytic machining on the side face of the PCD parent metal by using the edge-forming molded surface of the first copper wheel to form a plurality of chip grooves; the step S2 specifically includes:
s21, enabling the first copper wheel and the PCD parent metal to rotate along the central axis of the first copper wheel, enabling the rotating speed of the first copper wheel to be 100-5000 r/min, enabling the rotating speed of the PCD parent metal to be 0.1-1 r/min, enabling the central axis of the first copper wheel and the central axis of the PCD parent metal to form an included angle smaller than 90 degrees, and enabling the PCD parent metal and the first copper wheel to axially feed in a direction parallel to the axial direction of the PCD parent metal so as to form a chip pocket on the side face of the PCD parent metal;
s22, adjusting the position of the first copper wheel relative to the PCD parent metal;
s23, repeating the steps S21 and S22 until a preset number of chip flutes are formed on the PCD parent material;
in step S21, the first copper wheel is fed to the side surface of the PCD base material by a single normal direction to a depth of 5 to 20 μm, and the chip pocket is formed on the side surface of the PCD base material by performing the processing for several cycles.
2. The method of manufacturing the one-piece PCD milling cutter insert according to claim 1, wherein the first copper wheel and the PCD base material are both axially fed;
the axial feeding speed of the first copper wheel is 0.1-5 mu m/s, and the axial feeding speed of the PCD parent metal is 0.1-5 mm/s.
3. The method of manufacturing a one-piece PCD milling cutter head according to claim 1, wherein a pulse voltage of the pulse power source is 10 to 200V, a pulse width is 0.1 to 100 μ s, and an inter-pulse width is 0.1 to 100 μ s when machining the chip pocket.
4. The method of manufacturing a one-piece PCD milling cutter head according to claim 1, characterised in that, when machining the tooth breaking grooves, it comprises the following steps:
a1, fixedly mounting a PCD parent material;
a2, connecting the PCD parent metal with the positive electrode of a pulse power supply, connecting the second copper wheel with the negative electrode of the pulse power supply, and immersing the PCD parent metal and the second copper wheel in electrolyte;
and A3, performing mechanical grinding composite electrolytic machining on the front end face of the PCD parent metal by using the edge-forming profile of the second copper wheel to form a plurality of tooth breaking grooves.
5. The method of making a one-piece PCD milling cutter head according to claim 4, wherein the step a3 specifically comprises:
feeding the second copper wheel in a direction parallel to the end face of the PCD parent metal while rotating around the central axis of the second copper wheel A31, and performing mechanical grinding composite electrolytic machining on the front end face of the PCD parent metal by using the edge-protruding molded surface of the second copper wheel to form a tooth breaking groove;
a32, adjusting the position of the second copper wheel relative to the PCD parent material;
a33, repeating the steps A31 and A32 until the chip flutes oppositely arranged on the two sides of the PCD parent material are communicated in a one-to-one correspondence mode.
6. The method of manufacturing the integrated PCD milling cutter insert according to claim 5, wherein in the step a31, the second copper wheel is processed in several cycles with a single normal feed depth of 5 to 20 μm with respect to the front end surface of the PCD base material, so as to form the tooth breaking grooves in the front end surface of the PCD base material.
7. The method of manufacturing a one-piece PCD milling cutter head according to claim 5, wherein the second copper wheel has a rotational speed of 100 to 5000r/min and a feed speed of 0.1 to 5 μm/s.
8. The method of manufacturing a one-piece PCD milling cutter head according to claim 5, wherein a pulse voltage of the pulse power supply is 10 to 200V, a pulse width is 0.1 to 100 μ s, and an inter-pulse width is 0.1 to 100 μ s when the tooth breaking groove is machined.
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