WO2016067985A1 - セラミックスエンドミル及びそれを用いた難削材の切削方法 - Google Patents
セラミックスエンドミル及びそれを用いた難削材の切削方法 Download PDFInfo
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- WO2016067985A1 WO2016067985A1 PCT/JP2015/079641 JP2015079641W WO2016067985A1 WO 2016067985 A1 WO2016067985 A1 WO 2016067985A1 JP 2015079641 W JP2015079641 W JP 2015079641W WO 2016067985 A1 WO2016067985 A1 WO 2016067985A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/16—Milling-cutters characterised by physical features other than shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/04—Angles
- B23C2210/0407—Cutting angles
- B23C2210/0442—Cutting angles positive
- B23C2210/045—Cutting angles positive axial rake angle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/54—Configuration of the cutting part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2220/00—Details of milling processes
- B23C2220/44—High speed milling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2226/00—Materials of tools or workpieces not comprising a metal
- B23C2226/18—Ceramic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
- B23C2228/24—Hard, i.e. after being hardened
Definitions
- the present invention relates to a radius-type or square-type ceramic end mill capable of ultra-high-speed cutting of difficult-to-cut materials such as heat-resistant alloys, and a cutting method of difficult-to-cut materials using the same.
- a radius end mill or a square end mill has a shape in which a corner R blade or bottom blade near the outer periphery in the radial direction at the tip of a tool (end mill) cuts the surface of the work material first, and cuts at the center of the tool end surface. Since the ability is not expected, in principle, it is not suitable for thrust machining in which the tool is propelled in the axial direction or helical machining that cuts in a spiral. Since the ball end mill is based on the premise that the entire cutting edge including the center portion of the tool end face is cut, the cutting edge may pass through the center of the tool end face (see Patent Document 6).
- the end mill of Patent Document 1 which is a cutting tool made of a typical high-hardness material, has a core part for securing the rigidity of the tool at the center part on the side of the end surface (tip of the cutting edge part) in the tool axis direction. It has a shape in which a gash that is continuous with the chip discharge groove (vertical groove) is formed between the core portion and each bottom blade. However, since the bottom blade does not continue to the core in the radial direction (FIGS. 4, 6, and 7), the portion near the center of the tool end surface does not have cutting ability.
- the end mill of Patent Document 1 corresponds to a radius end mill in terms of form.
- a gash 56a continuous with the longitudinal groove 24a is formed in a spiral shape near the core portion 48a of the bottom blade (cutting blade) 16a (16b) (claim 1, paragraph 0026). ).
- this end mill is viewed from the tip end side of the tool end face, a gash that is recessed in the radial direction between the end portion on the core portion 48a side of the bottom blade 16a and the core portion 48a toward the shank portion 8a side with respect to the tip end of the tool. 56a exists (FIGS. 5 to 7). For this reason, there is no bottom blade in the region between the core portion 48a and the bottom blade 16a, and cutting is impossible in this region.
- Patent Document 2 while using ceramics that are considered to be poor in toughness for the material of the tool body, a margin is formed on the flank face of the cutting edge, and the flank roughness is made a certain value or less to compensate for the lack of material toughness.
- the tool life can be extended.
- Patent Document 3 the relationship between the outer peripheral cutting edge and the outer peripheral cutting edge flank when the tool is viewed in a cross section orthogonal to the tool axis, and the curved surface from the outer peripheral cutting edge to the deepest portion of the chip discharge groove on the front side in the rotational direction. And the curved surface from the outer peripheral cutting edge clearance surface to the deepest part of the chip discharge groove on the rear side in the rotation direction are specified (paragraphs 0015 to 0032, FIGS. 2 to 4). However, the shape of the tool end surface near the center of the cutting edge is not specified.
- the bottom blade is continuous to the vicinity of the center of the tool end face, but the portion near the center of the bottom blade is curved forward in the rotational direction, and the flank and gash of the bottom blade located on the forward side in the rotational direction. 2 (FIG. 2), a portion near the center of each bottom blade flank is gathered at the center of the tool end surface. Since this example also has a shape in which a core portion is formed as in Patent Document 1, there is no bottom blade in the center portion of the tool end surface.
- the bottom blade is continuous in one direction across the center near the center of the tool end face (FIG. 2), but when the end face is viewed in the tool axis direction as in Patent Document 4, the bottom blade is continuous. Since the portion closer to the center is bent to the front side in the rotation direction and is continuous with the bottom blade on the front side in the rotation direction, the bottom blade does not pass through the center of the tool end surface. Since the portion near the center of the bottom blade is retracted to the shank side from the tool end surface on the vertical surface of the tool (paragraph 0029, FIG. 3), the portion near the center of the bottom blade may be involved in cutting at the start of cutting. I can't (paragraph 0032).
- the conventional radius end mill cannot be cut near the center of the tool end face or has a difficult shape, so that the work material cannot be cut uniformly over the entire tool end face. It is hard to say that it has the ability to cope with thrust machining and helical machining.
- the present invention ensures a cutting ability in the vicinity of the center of the tool end face, can cut the work material on the entire face of the tool end face, and can cope with plunging and the like, and a hard-to-cut material using the same A cutting method is proposed.
- a ceramic end mill is formed between a plurality of cutting blades arranged at intervals in the rotational direction on the tip end side in the axial direction of the tool body and the cutting blades adjacent in the rotational direction.
- a ceramic end mill with a cutting edge portion having a gash, A center blade facing the rotation shaft, a bottom blade continuous to the center blade, and a peripheral blade continuous from the bottom blade to the tool rear end side, each cutting edge from the rotation axis toward the radially outer peripheral side.
- passing through the axis of rotation between each bottom blade second surface and each center blade located on the rear side in the direction of rotation also serving as a rake face of each center blade and continuing to the gasche A central groove is formed.
- “Having a peripheral blade continuous from the bottom blade to the rear end of the tool” means a square-type end mill in which the peripheral blade is directly continuous from the bottom blade and a corner R that is continuous between the bottom blade and the peripheral blade. It is intended to include a radius type end mill (claim 3) in which a blade is interposed.
- the “tool rear end side” is the “rear end side” when viewed from the cutting edge portion, and indicates the shank portion 30 side.
- the corner R blades 3a to 3d are continuous to the radially outer peripheral side of the bottom blades 2a to 2d, and the outer peripheral blades 13a from the corner R blades 3a to 3d to the shank portion 30 side. ⁇ 13d are continuous (claim 3).
- “The blade is continuous” means that convex ridge lines are continuous, and when the blade draws a curve, the curvature of the curve does not need to be constant.
- the “center blade facing the rotation shaft” in claim 1 is a tool (end mill) or an end surface of the cutting edge portion 1 in the direction of the rotation axis O as shown in FIG. 1, FIG. 2- (a), (b).
- the central blades 10a to 10d start from the rotation axis O and are formed radially toward the outer peripheral side in the radial direction, and the ends of the central blades 10a to 10d near the rotation axis O face the rotation axis O. Say that you are in a state.
- the center blades 10a to 10d passing through the rotation axis O are formed on the tool end face, the center blades 10a to 10d are formed as edges (convex ridge lines) on the rear side in the rotation direction of the center grooves 10A to 10D. .
- the center blades 10a to 10d are formed from the rotation axis O to the gashes 8 and 9 so as to face the center grooves 10A to 10D.
- the gashes 8 and 9 are composed of a first gash 8 located on the center side in the radial direction and a second gash 9 continuous on the outer peripheral side in the radial direction. Point to.
- the central grooves 10A to 10D are formed radially from the rotation axis O by the number of cutting edges (FIG. 2- (a)) or in a band shape having a substantially uniform width (FIG. 2- (b)).
- the central grooves 10A to 10D also serve as the rake surfaces of the central blades 10a to 10d” means that the central grooves 10A to 10D are formed in a concave shape on the front side in the rotational direction of the central blades 10a to 10d ( Center blade) Says to include a rake face.
- the central grooves 10A to 10D are composed of only the (center blade) rake face 25d, the (center blade) rake face and then the second bottom blade on the front side in the rotation direction.
- FIG. 3B when the central grooves 10A to 10D are composed of only the (center blade) rake face 25d, the (center blade) rake face and then the second bottom blade on the front side in the rotation direction.
- a scoop surface 25d is included between the second surfaces 4a-4b (4b-4c, 4c-4d, 4d-4a) of the bottom blades adjacent to each other in the rotational direction. In some cases, it is formed in the shape of a groove recessed in the direction of the rotation axis O.
- FIGS. 3A and 3B show a cross section taken along line zz in FIG. 2-B.
- the center grooves 10A to 10D are formed in a concave groove shape, so that the center grooves 10A to 10D and the bottom blade second surfaces 4a to 4d on the front side in the rotational direction are discontinuous. Therefore, boundary lines indicated by G may appear between the central grooves 10A to 10D and the bottom blade second surfaces 4a to 4d.
- the rake face 25d constituting the central grooves 10A to 10D and the bottom blade second surfaces 4a to 4d on the front side in the rotation direction can be formed as a continuous surface. A line does not appear.
- the “grooves” of the center grooves 10A to 10D do not necessarily mean a groove shape recessed in the direction of the rotation axis O from the tool end face, and the bottom blade second face as shown in FIGS. 3- (a) and (b) It includes a shape recessed from the 4a to 4d side toward the rear side in the rotational direction.
- the center grooves 10A to 10D are formed between the bottom blade second surfaces 4a to 4d and the center blades 10a to 10d located on the rear side in the rotation direction, so that the bottom blade second surfaces 4a to 4d are formed.
- the portion near the rotation axis O and the center blades 10a to 10d on the rear side in the rotation direction are partitioned by the center grooves 10A to 10D. That is, the central grooves 10A to 10D on the rear side in the rotation direction of the portions near the rotational axis O of the bottom blade second surfaces 4a to 4d form a shape that separates the bottom blade second surfaces 4a to 4d and the center blades 10a to 10d. As a result, as shown in FIGS.
- center grooves 10A to 10D are formed on the front side and the rear side in the rotation direction of the portions near the rotation axis O of the bottom blade second surfaces 4a to 4d, In the vicinity of the rotation axis O, the central grooves 10A to 10D and the bottom blade second surfaces 4a to 4d are alternately arranged in the rotation direction (circumferential direction) of the rotation axis O.
- the central blades 10a to 10d are formed simultaneously with the formation (grinding) of the central grooves 10A to 10D on the tool end surface, the central blades 10a to 10D are formed according to the planar shape when viewed from the end surface side of the tool.
- the shape of ⁇ 10d is determined.
- FIG. 1 and FIG. 2- (a) when the tool is viewed from the end face side, the central blades 10a to 10d are straight lines or straight lines, but a curve may be drawn as shown in FIG. 2- (b). is there.
- the center grooves 10A to 10D gradually have a width from the rotation axis O to the first gash 8 as shown in FIGS. 1 and 2- (a) when the end face of the cutting edge portion 1 is viewed in the direction of the rotation axis O.
- a width from the rotation axis O to the first gash 8 as shown in FIGS. 1 and 2- (a) when the end face of the cutting edge portion 1 is viewed in the direction of the rotation axis O.
- a strip shape having a uniform width or a gradually changing width Wc from the rotation axis O to the first gash 8 as shown in FIG. (Claim 2).
- “Uniform width” means that the region including the rotation axis O in the central grooves 10A to 10D is constant in such a size that the chips cut by the central blades 10a to 10d can be discharged to the first gash 8. That is, the width is substantially or substantially uniform from the rotation axis O to the first gash 8.
- “Slowly changing width” means that the width Wc of the central grooves 10A to 10D is clearly not uniform in the radial direction, as shown in FIG. It means that it can be said that it is uniform in the radial direction in terms of discharging waste.
- the central grooves 10A to 10D have at least a certain width in the entire length in the radial direction, in the region including the rotation axis O, or in the region near the rotation axis O. Good. Therefore, the central grooves 10A to 10D have a shape close to FIG. 2- (a), a shape in which the width gradually increases from the rotation axis O to the first gash 8, and a shape in which the width of each part in the radial direction is different. Or conversely, a shape that gradually expands from the first gash 8 to the rotation axis O is included. In FIG. 2B, the width Wc of the central grooves 10A to 10D slightly increases from the rotation axis O to the first gash 8.
- Blade flank surfaces 4a to 4d are formed.
- “continuous to the position where the bottom blade second surfaces 4a to 4d face the rotation axis O” in claim 1 means that the center blades 10a to 10d face the rotation axis O as in FIG. -As shown in (a), the portion near the rotational axis O of the bottom blade second surfaces 4a to 4d faces the rotational axis O and faces the rotational axis O. Since the center grooves 10A to 10D exist on the rotation axis O, strictly speaking, the bottom blade second surfaces 4a to 4d are in a state of facing the rotation axis O through the center grooves 10A to 10D.
- the bottom blade second surfaces 4a to 4d continue to a position approaching the rotation axis O
- the central grooves 10A to 10F are formed in a strip shape as shown in FIG.
- the bottom blade second surfaces 4a to 4d are formed so as to be close to the rotation axis O and face the rotation axis O through the central grooves 10A to 10F.
- Parts near the rotational axis O of the bottom blade second surfaces 4a to 4d refer to the regions in contact with the central grooves 10A to 10D on the front side and the rear side in the rotational direction, and in the case of the example shown in FIG. Is in a state where it can come into contact with the rotation axis O on the center side in the radial direction.
- Both the edge on the front side in the rotational direction and the edge on the rear side in the rotational direction of the portions near the rotational axis O of the bottom blade second surfaces 4a to 4d formally boundaries with the central grooves 10A to 10D. Since the edges on the front side in the rotational direction of the portions near the rotation axis O of the bottom blade second surfaces 4a to 4d are the center blades 10a to 10d, they become convex ridgelines, and the boundary lines clearly appear. However, since the edge on the rear side in the rotation direction is not a blade, a clear boundary line does not always appear as a convex ridgeline as described above, as shown in FIGS. 2- (b) and 3- (a). Furthermore, the bottom blade second surfaces 4a to 4d may continue from the central grooves 10A to 10D through a curved surface, or may continue through a flat surface and a curved surface as shown in FIG.
- the bottom blade second surfaces 4a to 4d and the central grooves 10A to 10D are continuous through a plane and a curved surface” means that the bottom blade second surfaces 4a to 4d are close to the rotation axis O.
- the curvature gradually increases from 0 and continuously changes from the rear side in the rotational direction of the bottom blade second surfaces 4a to 4d to the center grooves 10A to 10D.
- the transition from the flat surface to the central groove 10A to 10D is continued.
- a clear boundary line does not appear in the portion of the bottom blade second surfaces 4a to 4d that transitions to the central grooves 10A to 10D, and the central grooves 10A to 10D extend from the central blade rake face 25d that continues to the central blades 10a to 10d.
- the shape is constituted by a center blade scoop surface 25d and a transition surface to the bottom blade second surfaces 4a to 4d.
- the thin lines in the central grooves 10A to 10D indicate that the surfaces of the central grooves 10A to 10D are concave curved surfaces.
- the bottom blades 2a to 2d are continuous on the radially outer peripheral side of the center blades 10a to 10d, which is the edge on the front side in the rotational direction near the rotational axis O of the bottom blade second surfaces 4a to 4d.
- Convex ridge lines that serve as boundary lines with the first gash surfaces 8a to 8d constituting the first gash 8 are continuous on the outer peripheral side in the radial direction of the edges on the rear side in the rotational direction of the blades second surfaces 4a to 4d.
- the central grooves 10A to 10D are formed in the rotation direction front side and rear side of the portions near the rotation axis O of the bottom blade second surfaces 4a to 4d around the rotation axis O, so that the rotation direction
- the portions close to the rotation axis O of the bottom blade second surfaces 4a to 4d defined by the front edge (center blades 10a to 10d) and the rear edge in the rotation direction (boundary with the center grooves 10A to 10D) It becomes a shape gathered around the rotation axis O, and becomes a region (center blade portion 10) having a certain area around the rotation axis O.
- the portions near the rotation axis O of the bottom blade second surfaces 4a to 4d referred to here are virtual triangles sandwiched between the boundaries between the central blades 10a to 10d on the front side in the rotational direction and the central grooves 10A to 10D on the rear side. Or, it refers to a sector-shaped area.
- the portions near the rotational axis O of the bottom blade second surfaces 4a to 4d are left on the end surface of the tool when the central grooves 10A to 10D are formed on the tool end surface.
- the shape is substantially equivalent to that in which the core is formed at the center of the tool, which contributes to ensuring the rigidity of the tool.
- Patent Document 1 while leaving the core portion near the rotation axis of the tool end surface, in the section from the vicinity of the middle portion in the radial direction of the bottom blade to the core portion, from the bottom blade clearance surface to the bottom blade rake surface on the rear side in the rotation direction. Since the gash 56a is formed in a deeply cut shape, the rigidity of each cutting edge is sacrificed and reduced in comparison with the case where the bottom edge continues to the core.
- the first gash 8 is positioned on the outer peripheral side in the rotational direction of the portion of the bottom blade second surfaces 4a to 4d near the rotation axis O (the bottom blade second surfaces 4a to 4d and the bottom blade third From the boundary lines of the surfaces 6a to 6f and the first gash surfaces 8a to 8f) to the bottom edge rake surfaces 11a to 11d on the rear side in the rotation direction.
- the portion of the bottom blade second surface (bottom blade relief surface) 4a to 4d near the rotation axis O is not formed in the shape of being deeply cut from the outer peripheral side in the radial direction.
- Patent Document 1 the rigidity of each cutting edge and the rigidity of the tool (end mill) itself are increased.
- the center blades 10a to 10d are formed so as to face the center grooves 10A to 10D passing on the rotation axis O, and on the radially outer peripheral side of the center blades 10a to 10d.
- the tool has a cutting ability continuously from the rotation axis O of the end surface on the cutting side to the outer peripheral side in the radial direction. That is, the tool has the ability to cut the work material uniformly over the entire end face of the tool.
- the end mill has a form equivalent to that the cutting edge portion 1 of the tool has a core portion as described above, but secures the ability to cope with thrust processing and helical processing that enable cutting at the center portion. .
- the central grooves 10A to 10D serve as a discharge path for chips cut by the central blades 10a to 10d, and the first groove 8 and the blade grooves 20a to 20d are continuous with the central grooves 10A to 10D. Since clogging of chips in ⁇ 10D is avoided, a situation in which the cutting ability of the central blades 10a to 10d is reduced during plunging or helical machining is also avoided.
- the first gash surfaces 8a to 8d constituting the first gash 8 are continuous on the rear side in the rotational direction of the portions of the bottom blade second surfaces 4a to 4d near the rotational axis O, and the radial directions of the first gash surfaces 8a to 8d are continuous.
- Second gash surfaces 9a to 9d constituting the second gash 9 are continuous on the outer peripheral side.
- the first gash 8 is composed of first gash surfaces 8a to 8d and bottom blade rake surfaces 11a to 11d
- the second gash 9 is composed of second gash surfaces 9a to 9d and bottom blade rake surfaces 11a to 11d.
- the first gash 8 (space) is continuous with the blade grooves 20a to 20d (spaces). “Surfaces are continuous” means that continuous surfaces are different from each other and are adjacent to each other with a convex or concave ridgeline (boundary line) interposed therebetween.
- the bottom blade third surfaces 6a to 6d are continuous to the rear side in the rotation direction of the portion near the outer periphery in the radial direction of the bottom blade second surfaces 4a to 4d, and the bottom blade third surfaces 6a to 6d are connected to the rear side in the rotation direction.
- Two gash surfaces 9a to 9d are continuous.
- the first gash surfaces 8a to 8d are continuous with the radially inner peripheral side of the second gash surfaces 9a to 9d.
- the corner R blade second surfaces 5a to 5d are continuous to the rear side in the rotational direction of the corner R blades 3a to 3d, and the rear side in the rotational direction.
- the corner R blade third face 7a to 7d is continuous.
- the corner R blade third surfaces 7a to 7d are continuous to the radially outer peripheral side of the bottom blade third surfaces 6a to 6d.
- the bottom blades 2a to 2d may have a medium and low gradient angle (watermark angle) ⁇ (Claim 4).
- ⁇ watermark angle
- an axial cutting line passing through the rotation axis O is used.
- the portions near the outer periphery in the radial direction of the bottom blades 2a to 2d are projected from the center blades 10a to 10d on the tool tip side. For this reason, when the tool performs a plunging process or a helical process, the center blades 10a to 10d are brought into contact with the surface of the work material behind the bottom blades 2a to 2d to be cut.
- the ceramic end mill according to any one of claims 1 to 5, which is a cutting tool made of a hard material, cuts a difficult-to-cut material at an ultra high speed with a cutting speed Vc of 500 m / min to 1200 m / min. 6) With cutting, wear may occur in the cutting edge 1 of the cutting tool tip. However, if the progress of wear is within about 10% of the tool diameter, the remaining portion from the bottom blades 2a to 2f of the cutting blade 1A after wear to the corner R blades 3a to 3f can still function as the cutting blade 1A. It has the characteristics that can maintain the cutting ability.
- An appropriate or desirable range of the cutting speed Vc is 500 m / min to 1200 m / min, but it may be 300 m / min or more at the low speed side.
- the ability of the remaining portion after the wear to function as the cutting edge 1A is remarkably exhibited when silicon nitride ceramics, particularly SiAlON is used as the base material of the tool (claim 5).
- a base material for the tool it is particularly suitable to use a sintered body containing magnesium and at least one of magnesium compounds together with an RE element compound (wherein RE is at least one element of rare earth elements).
- RE is at least one element of rare earth elements.
- the end mill of the present invention can further improve the tool performance by coating the cutting edge with a hard coating (for example, TiSiN, TiAlN, TiAlSiN, CrN, CrSiN, AlCrN, AlCrSiN, AlTiCrN, or AlCrVBN) as necessary. Is possible.
- a hard coating for example, TiSiN, TiAlN, TiAlSiN, CrN, CrSiN, AlCrN, AlCrSiN, AlTiCrN, or AlCrVBN
- Each cutting edge has a center blade that faces the rotation axis from the rotation axis side toward the outer periphery in the radial direction, and a bottom blade that is continuous with the center blade, and is located on the rear side in the rotation direction of the center blade and the bottom blade.
- the central blade can be formed so as to face the central groove passing on the rotational axis in the portion near the rotational axis of the tool end surface, and the end mill is continuously connected from the rotational axis of the end surface on the cutting side to the radially outer peripheral side.
- the end mill possesses the ability to cut the work material uniformly over the entire tool end face, so that the cutting edge of the tool is in the same form as having a core, but cutting at the center is possible. Capable of ensuring the ability to cope with plunging and helical machining.
- FIG. 2 is an enlarged view of the vicinity of a rotation axis in FIG. 1 when a central groove is formed in a sector shape.
- FIG. 2 is an enlarged view of the vicinity of the rotation axis in FIG. 1 when the central groove is formed in a shape having a uniform width in the radial direction or a gradually changing width.
- FIG. 2A shows an example of formation of the center groove when the center edge is formed in a concave groove shape when the tool end surface is viewed in the direction of the rotation axis including the rake face.
- FIG. 2 is a side view of FIG. 1, and is an arrow view taken along line xx. It is the perspective view which showed the mode when FIG. 4 was seen from the end surface side a little.
- FIG. 5 is a cross-sectional view taken along the line II of FIG. 4 showing the relationship between the end mill core thickness Dw and the tool diameter D and the state of the outer peripheral rake angle. It is the end view which showed the end surface by the side of the cutting edge part of a (radius) end mill in case of six cutting edges.
- FIG. 8 is an enlarged view of the vicinity of the rotation axis in FIG. 7.
- FIG. 8 is a side view of FIG. 7 and is a view taken along the line yy. It is the perspective view which showed the mode when FIG. 9 was seen from the end surface side a little.
- FIG. 10 is a cross-sectional view taken along the line II of FIG. 9 showing the relationship between the end mill core thickness Dw and the tool diameter D and the state of the outer peripheral rake angle.
- FIG. 1 shows a plurality of cutting blades 1A arranged at intervals in the rotational direction on the tip end side in the axial direction of the tool body, and a cylindrical shank portion 30 formed on the axial rear end side of the tool body.
- an end mill also referred to as a tool
- FIG. 1 shows a plurality of cutting blades 1A arranged at intervals in the rotational direction on the tip end side in the axial direction of the tool body, and a cylindrical shank portion 30 formed on the axial rear end side of the tool body.
- an end mill also referred to as a tool
- Each cutting edge 1A is directed from the vicinity of the rotation axis O toward the outer peripheral side in the radial direction, center blades 10a to 10f facing the rotation axis O, bottom blades 2a to 2f continuous to the center blades 10a to 10f, and bottom blades 2a to 2f.
- Outer peripheral blades 13a to 13f that are continuous from the tool to the tool rear end (shank portion 30) side.
- corner R blades 3a to 3f are connected to the radially outer peripheral sides of the bottom blades 2a to 2f
- the outer peripheral blades 13a to 13f are connected from the corner R blades 3a to 3f to the tool rear end side as shown in FIG.
- end mill 40 An example of a continuous radius type end mill 40 is shown, but the end mill 40 may be a square type in which the corner R blades 3a to 3f are absent. E and f of the central blades 10a to 10f and the like are the symbols when there are six cutting blades 1A (FIGS. 7 to 11), and the symbols when there are four blades 1A (FIGS. 1 to 6) are a to d. .
- outer peripheral blade second surfaces 14a to 14f are formed on the rear side in the rotational direction of the outer peripheral blades 13a to 13f, and outer peripheral blade third surfaces 15a to 15f are formed on the rear side in the rotational direction.
- the outer peripheral blade second surfaces 14a to 14d have a convex shape (eccentric blade shape) toward the radially outer peripheral side, and the outer peripheral blade third surfaces 15a to 15d have a concave shape (concave blade shape) toward the radially outer peripheral side. It is preferable.
- outer peripheral blade second surfaces 14a to 14d are convex, the rigidity of the outer peripheral blades 13a to 13f is enhanced, and the outer peripheral blade third surfaces 15a to 15d are concave, so that the cutting edge is free from cutting edges. The generated resistance is reduced and the progress of wear is suppressed.
- the center blades 10a to 10f and the bottom blade are continuous on the rear side in the rotation direction of the center blades 10a to 10f and the bottom blades 2a to 2f that are continuous in the radial direction.
- 2a to 2f are formed, and the bottom blade second surfaces (bottom blade flank surfaces) 4a to 4f are formed so as to straddle 2a to 2f to the position facing the rotation axis O or to the approaching position as shown in FIG. Is done.
- the bottom blade second surfaces 4a to 4f and the center blades 10a to 10f located on the rear side in the rotation direction pass on the rotation axis O.
- Central grooves 10A to 10F which serve as rake faces of the respective central blades 10a to 10f and are continuous with the gashes 8 and 9, are formed.
- Each of the central blades 10a to 10f is formed as a convex ridge line on the rear side in the rotational direction of each of the central grooves 10A to 10F as a result of the formation of the central grooves 10A to 10F.
- the bottom blade second surfaces 4a to 4f may be flat or curved.
- the center grooves 10A to 10F may not have a clear boundary with the bottom blade second surfaces 4a to 4f on the front side in the rotational direction (FIG. 3- (b)).
- the surfaces 4a to 4f and the central blades 10a to 10f are partitioned.
- the surfaces of the central grooves 10A to 10F on the side of the central blades 10a to 10f on the front side in the rotational direction of the central blades 10a to 10f are the central blade rake face (25d), and the central blades 10a to 10f are disposed on the rear side in the rotational direction.
- the continuous surface is the center blade second surface (center blade clearance surface).
- the bottom blades 2a to 2f are continuous to the outer peripheral side in the radial direction of the center blades 10a to 10f, and the bottom blade second surface 4a to the rear side in the rotational direction of both the center blades 10a to 10f and the bottom blades 2a to 2f.
- the center blade second surface becomes a part near the rotation axis O of the bottom blade second surfaces 4a to 4f
- the center blade rake surface (25d) is the bottom blade rake surface 11a to 11f. It has become a part.
- the bottom edge rake faces 11a to 11f including the center edge rake face (25d) may be flat or curved.
- first gash together with the bottom blade rake surfaces 11a to 11f near the center in the radial direction.
- First gash surfaces 8 a to 8 f constituting 8 are formed.
- the second gash surfaces 9a to 9f constituting the second gash 9 are continuous with the bottom edge scooping surfaces 11a to 11f near the outer periphery in the radial direction on the radially outer peripheral side of the first gash surfaces 8a to 8f.
- the first gash 8 is composed of bottom blade rake surfaces 11a to 11f and first gash surfaces 8a to 8f formed on the front side in the rotation direction
- the second gash 9 is composed of bottom blade rake surfaces 11a to 11f and second gash surfaces. 9a to 9f.
- outer peripheral blades 13a-13b, 13b-13c adjacent to the rotation direction of the tool indicated by R in FIG. 1 are provided on the radially outer peripheral side of the second gash surfaces 9a to 9f (second gash 9).
- the blade grooves 20a to 20f which are formed as a chip discharge groove formed in a spiral, are continuous between 13c-13d, 13d-13e, and 13e-13f.
- the first gash surfaces 8a to 8f and the second gash surfaces 9a to 9f may be flat or curved.
- bottom blade third surfaces 6a to 6f that are continuous with the first gash surfaces 8a to 8f are continuous on the rear side in the rotation direction of the portions near the outer periphery in the radial direction of the bottom blade second surfaces 4a to 4f.
- the second gash surfaces 9a to 9f are continuous to the rear side in the rotational direction of the bottom blade third surfaces 6a to 6f.
- the bottom blade third surfaces 6a to 6f may be flat or curved.
- the corner R blade second surfaces 5a to 5f are continuous on the rear side in the rotation direction of the corner R blades 3a to 3f, and the corner R is on the rear side in the rotation direction.
- the R blade third face 7a to 7d is continuous.
- blade grooves 20a to 20f are continuous on the rear side in the rotational direction of the corner R blade second surfaces 5a to 5f and the corner R blade third surfaces 7a to 7d.
- the blade grooves 20a to 20f are smoothly continuous so as not to be discontinuous with the outer peripheral blade rake surfaces 16a to 16f on the rear side in the rotation direction, for example, to be curved surfaces with continuously changing curvature.
- the corner R blade second surfaces 5a to 5f and the corner R blade third surfaces 7a to 7d may be flat or curved.
- the center grooves 10A to 10F forming the center blades 10a to 10f are connected to the connection points F1 to F of the center blades 10a to 10f and the bottom blades 2a to 2f as shown in FIG. 1 and an enlarged view of FIG.
- the width of the central grooves 10A to 10F is gradually generated and expanded from the rotation axis O to the first gash 8.
- the central grooves 10A to 10F increase the volume of the central grooves 10A to 10F in the direction of the rotation axis O (depth direction), and in order to ensure the discharge of chips cut by the central blades 10a to 10f, FIG. As shown in a) and (b), when viewed from the bottom blade second surfaces 4a to 4f on the rear side in the rotation direction of the respective central grooves 10A to 10F, or the first outer side in the radial direction of the respective central grooves 10A to 10F. When viewed from the gash surfaces 8a to 8f, it is formed in a groove shape having a certain depth.
- the cross sectional shape of the central grooves 10A to 10F is formed in a curved shape (concave curved surface shape) having a concave on the tool body side as shown in FIG. In some cases, it may be formed in a polygonal shape (concave polyhedron shape).
- connection points F1 to F4 are also boundaries between the central grooves 10A to 10F and the first gash 8 on the central blades 10a to 10f.
- the center blades 10a to 10f are formed as convex ridge lines on the rear side in the rotational direction of the center grooves 10A to 10F as a result of the formation (grinding) of the center grooves 10A to 10F on the tool body as described above, and the center grooves 10A to 10F are formed. Is formed through the rotation axis O. For this reason, the center blades 10a to 10f are formed so as to face the rotation axis O, or are formed toward the outer peripheral side in the radial direction (radially outward) through the rotation axis O.
- the center blades 10a to 10f can cut the work material in a circular shape in the region from the rotation axis O to the outer peripheral side in the radial direction when the tool rotates, the end mill 40 is thrust into scanning in the direction of the rotation axis O. It has the ability to handle machining and helical machining that cuts into a spiral.
- the length Lc of the center blades 10a to 10f shown in FIG. 2- (a) is suitably in the range of about 0.01 to 0.3 times the tool diameter D shown in FIG. If Lc ⁇ 0.01D, the length of the central blades 10a to 10f becomes extremely small, resulting in a decrease in resistance (stiffness) to the resistance from the work material that the central blades 10a to 10f receive during cutting. Further, chipping due to a decrease in the cutting ability of the center blades 10a to 10f is likely to occur.
- the medium / low gradient angle (watermark angle) of the center blades 10a to 10f is equal to or equivalent to the medium / low gradient angle ⁇ of the bottom blades 2a to 2f shown in FIG. 4, and is about 0.5 to 3.0 °. It is appropriate to be in the range. If ⁇ ⁇ 0.5 °, the bottom blades 2a to 2f and the center blades 10a to 10f easily come into contact with the work material at the time of plunging, so that the cutting resistance that the end mill 40 itself receives from the work material increases. There are concerns about the occurrence of chipping and defects.
- the outer peripheral rake angles ⁇ 1 and ⁇ 2 of the end mill 40 shown in FIGS. 6 and 11 are in the range of about ⁇ 20 to ⁇ 12 °. -Means that the peripheral edge scoop surfaces 16a to 16f are inclined rearward in the rotational direction from a radial line passing through the rotation axis O. If the peripheral edge rake angles ⁇ 1, ⁇ 2 ⁇ 20 ° (the absolute values of the rake angles ⁇ 1, ⁇ 2 are greater than 20 °), the cutting ability of the outer peripheral blades 13a to 13f tends to decrease.
- the twist angles ⁇ 1 and ⁇ 2 of the end mill 40 are suitably in the range of about 35 to 55 °, and more preferably 40 to 50 °. If the torsion angles ⁇ 1, ⁇ 2 ⁇ 35 °, stable cutting is difficult because the cutting resistance that each of the outer peripheral blades 13a to 13f receives in the rotation direction during rushing is large. On the other hand, if the torsion angles ⁇ 1, ⁇ 2> 55 °, the axial milling or helical machining of the end mill 40 increases the force with which each of the outer peripheral blades 13a to 13f pulls up the work material, and stable cutting cannot be performed. In addition, the corner thicknesses of the corner R blades 3a to 3f are reduced, and chipping and chipping are likely to occur due to a decrease in the strength of the blade edge.
- the core thickness Dw of the end mill 40 is 60 to 75%, more preferably 65 to 70% of the tool diameter D shown in FIG. 4, as shown in FIG. 6, in order to ensure the stability during cutting by thrusting or helical machining. It is set to be within the range of. As shown in FIG. 6, when the cross section perpendicular to the rotation axis O of the end mill 40 is viewed in the direction of the rotation axis O, the shapes of the blade grooves 20a to 20f including the outer peripheral edge rake surfaces 16a to 16f are concave curved surfaces. Yes.
- the total area of the plurality of blade grooves 20a to 20f on the cross section perpendicular to the rotation axis O of the outer peripheral blades 13a to 13f is: It is appropriate to be in the range of about 0.3 to 0.4S.
- the sum of the areas of the blade grooves 20a to 20f with respect to the area S of the end mill 40 on the cross section orthogonal to the rotation axis O of the end mill 40 is an index that indicates whether chips are discharged through the blade grooves 20a to 20f.
- the chip discharge property is likely to be lowered, so that the end mill 40 is likely to be broken. It becomes difficult to maintain the corners, and the rigidity of the end mill 40 is extremely reduced, so that the possibility of breakage of the end mill 40 is increased. From these points, if the total area of the blade grooves 20a to 20f is in the range of about 0.3 to 0.4S, it is possible to ensure good chip discharging performance by the wide blade grooves 20a to 20f. Become.
- the base material of the end mill 40 is made of silicon nitride ceramics as described above, even though the core thickness is 60 to 75%, With high heat resistance, it is possible to suppress the damage of the tool for a long time and continue cutting without causing breakage. As a result, even if the cutting edge 1A is worn, the worn cutting edge 1A, in particular, the section from the bottom blades 2a to 2f to the corner R blades 3a to 3f can continue to function as the cutting edge.
- the edge edge line portion of the cutting edge 1A is processed to give a minute curvature, thereby improving the edge strength and extending the cutting life.
- the curvature radius of the cutting edge ridge line of the bottom blades 2a to 2f is smaller than the curvature radius of the cutting edge ridge line of the outer peripheral blades 13a to 13f, and the curvature radius of the cutting edge ridge line of the bottom cutting edges 2a to 2f is 1.0 ⁇ m to 4 ⁇ m. More preferably, the curvature radius of the edge line of the edge of the outer peripheral blades 13a to 13f is 4.5 ⁇ m to 15.0 ⁇ m.
- 7 to 11 show an example of manufacturing a radius type end mill 60 with 6 blades.
- the configuration of each cutting edge 1A in the case of 6 blades, and the configuration of each rake face continuous on the front side in the rotation direction of each cutting edge 1A and each flank surface continuous on the rear side in the rotation direction are in principle a case of 4 blades. And there is no difference.
- blade grooves 20a to 20f are formed on the rear side in the rotation direction of the second surfaces of the corner R blades 5a to 5f.
- the blade grooves 20a to 20f are formed on the third surfaces 7a to 7d of the corner R blade. Also serves as.
- Example 1 shows the results when the end mill 60 as Example 1 of the present invention having the above requirements and the end mills of Comparative Examples 1 and 2 not having the requirements of the present invention are used for side machining of the work material. The comparison is shown.
- the base material of the end mill 60 of the present invention is a SiAlON ceramic, whereas the base material of the end mills of Comparative Examples 1 and 2 is a cemented carbide, and the present invention is provided with a hard coating on the tool surface.
- Example 1 is different from Comparative Examples 1 and 2.
- Comparative Example 2 is different from Inventive Example 1 and Comparative Example 1 in that the cutting speed Vc is set to be low so that the cutting temperature does not become high.
- end mill 60 of the invention example 1 and the end mill of the comparative example 1 perform cutting under the same processing conditions, and the processing conditions of the comparative example 2 adopt the side cutting conditions of the Ni-base heat-resistant alloy in a general carbide end mill. .
- Example 1 of the present invention did not break up to 25 m and was able to cut the Ni-base heat-resistant alloy in a short time of 7 minutes (life distance, processing time).
- the end mill of Comparative Example 1 since the tool was largely damaged immediately after the start of cutting (0.2 m), the cutting process had to be interrupted.
- the processing time until the service life is about 1.17 times longer than Example 1 of the present invention (8.2 minutes), but only up to 5 m which is 1/5 of the service life distance of Example 1 of the present invention. Processing was not possible, and the amount of chips discharged remained at about 1 / 3.5 (28%) of Example 1 of the present invention.
- the end mill of the present invention has high heat resistance in comparison with Comparative Examples 1 and 2 because the base material is ceramic. Because of this property, it is possible to perform ultra-high speed cutting with the cutting temperature raised to 1,000 ° C. or more, which is the softening region of the Ni-base heat-resistant alloy, so that wear of the cutting edge is suppressed and occurrence of chipping is avoided. It is thought that.
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Abstract
Description
前記各切れ刃が回転軸寄りから半径方向外周側へ向け、前記回転軸に面する中心刃と、この中心刃に連続する底刃と、この底刃から工具後端側へ連続する外周刃を有し、
半径方向に連続する前記各中心刃と前記各底刃の回転方向後方側に、これらの両刃に跨って形成された底刃二番面が前記回転軸に面する位置、もしくは接近する位置にまで連続し、前記各底刃二番面とその回転方向後方側に位置する前記各中心刃との間に、前記回転軸上を通り、前記各中心刃のすくい面を兼ね、前記ギャッシュに連続する中心溝が形成されていることを特徴とする。
以下、上記要件を備えた本発明の実施例1としてのエンドミル60と、本発明の要件を備えない比較例1、2のエンドミルを被削材の側面加工に使用した場合の結果を表1に対比して示す。本発明のエンドミル60の母材はSiAlON系のセラミックスであるのに対し、比較例1、2のエンドミルの母材は超硬合金であり、工具表面にハードコーティングを施している点で、本発明例1と比較例1、2は相違する。比較例2は、切削温度が高温にならないように切削速度Vcを遅く設定している点で本発明例1及び比較例1と相違する。また本発明例1のエンドミル60と比較例1のエンドミルは同様の加工条件で切削を行い、比較例2の加工条件は一般的な超硬ラジアスエンドミルにおけるNi基耐熱合金の側面切削条件を採用した。
2a~2f……底刃、3a~3f……コーナーR刃、
4a~4f……底刃二番面、5a~5f……コーナーR刃二番面、6a~6f……底刃三番面、7a~7d……コーナーR刃三番面、
8……第1ギャッシュ、8a~8f……第1ギャッシュ面、
9……第2ギャッシュ、9a~9f……第2ギャッシュ面、
10……中心刃部、10a~10f……中心刃、10A~10F……中心溝、
11a~11f……底刃すくい面、12a~12f……コーナーR刃すくい面、
13a~13f……外周刃、
14a~14f……外周刃二番面、15a~15f……外周刃三番面、
16a~16f……外周刃すくい面、
20a~20f……刃溝、
30……シャンク部、
40……4枚刃ラジアスエンドミル、
60……6枚刃ラジアスエンドミル、
Wc……中心溝の幅、
D……工具径、Dw……心厚、
F1~F6……中心刃と底刃との連結点、
O……回転軸、
α……中低勾配角、
β1、β2……外周刃すくい角、
γ1、γ2……ねじれ角。
Claims (6)
- 工具本体の軸方向先端部側に、回転方向に間隔を置いて配列した複数枚の切れ刃と、回転方向に隣接する前記切れ刃間に形成されたギャッシュを有する切れ刃部を備えたセラミックスエンドミルであり、
前記各切れ刃は回転軸寄りから半径方向外周側へ向け、前記回転軸に面する中心刃と、この中心刃に連続する底刃と、この底刃から工具後端側へ連続する外周刃を有し、
半径方向に連続する前記各中心刃と前記各底刃の回転方向後方側に、これらの両刃に跨って形成された底刃二番面が前記回転軸に面する位置、もしくは接近する位置にまで連続し、前記各底刃二番面とその回転方向後方側に位置する前記各中心刃との間に、前記回転軸上を通り、前記各中心刃のすくい面を兼ね、前記ギャッシュに連続する中心溝が形成されていることを特徴とするセラミックスエンドミル。 - 前記切れ刃部の端面を前記回転軸方向に見たとき、前記中心溝は前記回転軸から前記ギャッシュにかけて一様な幅、もしくは緩やかに変化する幅を持つ帯状に形成されていることを特徴とする請求項1に記載のセラミックスエンドミル。
- 前記各底刃の半径方向外周側にコーナーR刃が連続し、この各コーナーR刃から前記工具後端側へ各外周刃が連続することを特徴とする請求項1、もしくは請求項2に記載のセラミックスエンドミル。
- 前記底刃に中低勾配角が付いていることを特徴とする請求項1乃至請求項3のいずれかに記載のセラミックスエンドミル。
- 前記エンドミルの母材はSiAlONであることを特徴とする請求項1乃至請求項4のいずれかに記載のセラミックスエンドミル。
- 請求項1乃至請求項5のいずれかに記載のセラミックスエンドミルを用いて難削材を切削する方法であり、前記セラミックスエンドミルを500~1200m/minの切削速度Vcで回転させながら、前記難削材を切削することを特徴とする難削材の切削方法。
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CN201580056827.7A CN107073602B (zh) | 2014-10-28 | 2015-10-21 | 陶瓷立铣刀以及使用该陶瓷立铣刀的难切削材料的切削方法 |
US15/521,563 US9975187B2 (en) | 2014-10-28 | 2015-10-21 | Ceramic end mill and method for cutting difficult-to-cut material using the same |
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JP2009056587A (ja) * | 2007-08-30 | 2009-03-19 | Snecma | 高速送りおよび低切削深さの機械加工用溝切りフライスカッタ |
WO2013118829A1 (ja) * | 2012-02-07 | 2013-08-15 | 日立ツール株式会社 | 多刃ボールエンドミル |
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JP2019202378A (ja) * | 2018-05-23 | 2019-11-28 | 三菱日立ツール株式会社 | エンドミル |
JP7089171B2 (ja) | 2018-05-23 | 2022-06-22 | 株式会社Moldino | エンドミル |
JP7086313B1 (ja) * | 2022-01-21 | 2022-06-17 | 武久 左甲斐 | ラジアスエンドミル |
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EP3213845A1 (en) | 2017-09-06 |
SG11201703248YA (en) | 2017-05-30 |
CN107073602B (zh) | 2019-03-15 |
JP6508212B2 (ja) | 2019-05-15 |
EP3213845A4 (en) | 2018-09-12 |
US20170304910A1 (en) | 2017-10-26 |
EP3213845B1 (en) | 2021-06-16 |
JPWO2016067985A1 (ja) | 2017-09-07 |
CN107073602A (zh) | 2017-08-18 |
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