JP4359221B2 - Manufacturing method of chips for non-ferrous metal processing - Google Patents

Description

  The present invention relates to a nonferrous metal machining tip, and more particularly to a nonferrous metal machining tip suitable for cutting an aluminum alloy or the like having poor chip separation.

  Conventionally, a chip breaker has been used to curl chips generated when cutting a steel material, cut them to an appropriate length, and control the chip discharge direction.

  This chip breaker has been used not only for steel materials but also for machining non-ferrous metals, but when cutting ductile non-ferrous metals, long chips are generated and sometimes entangled with the tool and cannot be cut.

  In order to solve this problem, for example, in the rotary multi-blade tool of Patent Document 1, a chip breaker is provided on the rake face of the diamond tip in the rotary multi-blade tool in which a plurality of diamond chips are joined to the main body.

  The above chip breaker is formed by joining a diamond tip made of sintered diamond to the cutting edge of a cemented carbide body by brazing, and a cutting edge is formed on this diamond tip. A chip breaker is formed at the corner.

  Thus, what formed the chip breaker directly on the rake face of a diamond chip has high abrasion resistance, and even if it cuts, the cutting performance of a chip breaker does not fall easily.

In the cutting tool of Patent Document 2, an ultra-high hardness sintered body mainly composed of polycrystalline diamond is joined to the upper surface of the corner of the base metal, and a chip breaker and a cutting blade are attached to the ultra-high hardness sintered body. As a result, finish cutting of aluminum alloys and non-ferrous metals can be performed.
JP 2001-322029 A JP-A-8-118113

  However, the above-described conventional chip breaker for processing nonferrous metal is expensive because it contains diamond or diamond as a main component, and there is a problem that it is missing when a load is applied. For example, in Patent Document 1, the use of a chip breaker using diamond has been limited to precision finishing so that the diamond chip on which the chip breaker is formed is a very small part having a width of only 2 mm.

  For this reason, when roughing aluminum, the carbide tool for steel materials is still used, and the point that cutting cutting property is bad is not solved.

  The present invention has been made in consideration of the problems in the conventional chip breaker for processing non-ferrous metals as described above, and provides a chip for processing non-ferrous metals that can be used in a wide range from roughing to finishing. It is.

The manufacturing method of the chip for non-ferrous metal processing according to the present invention includes a cutting blade (4d) perpendicular to the chip feeding direction at the time of cutting and a cutting blade (4c) in the same direction as the chip feeding direction. A chip breaker for forming a chip for non-ferrous metal processing, in which a chip breaker is formed with the cutting edge (4d) and a predetermined arrangement angle θa , and a first model equation is a cutting amount t <nose radius r In this case, the following formula (1) is used, and when the cutting amount t ≧ nose radius r, the following formula (2) is used, and the chip breaker arrangement angle θa is obtained from these formulas (1) or (2), The following formula (3) is used as a model formula, the chip breaker width S is obtained from this formula (3), and the chip breaker is formed on the chip according to the obtained chip breaker arrangement angle θa and the chip breaker width S. With features That.
θa = 90−cos ⁻¹ [(rt) / r] × 0.5−α (1)
θa = (r / t) × 45 ° −α (2)
θa: Chip breaker arrangement angle [°]
r: Nose radius [mm]
t: Cutting depth [mm]
α: Angle correction value [°] (however, the maximum value is 10 °)
S = f × 25 mm ± 0.3 mm (3)
S: Chip breaker width [mm]
f: Feed [mm / rev]
That is, the present invention provides a chip breaker arrangement angle based on the chip discharge angle estimated from the shape of the cutting edge of the chip and the cutting amount t, in the chip for non-ferrous metal processing provided with a chip breaker for chip disposal on the chip. A first model formula for calculating θa and a second model formula for calculating the chip breaker width S, which is the maximum distance between the chip breaker surface and the cutting blade, from the thickness f of the workpiece cut by the cutting blade. The chip breaker arrangement angle θa is obtained from the chip discharge angle estimated from the first model formula based on the nose radius r and the cutting depth t as the shape of the cutting blade, and based on the thickness f of the work material to be cut. The chip breaker width S is obtained from the second model formula, and the chip breaker is formed on the chip according to the obtained chip breaker arrangement angle θa and the chip breaker width S. A manufacturing method of metal working chip.

In the present invention, when t ≧ r as the first model formula, the chip breaker arrangement angle θa is set to (r / t) × 45 ° −α,
When t <r, the breaker arrangement angle θa is 90−cos ⁻¹ [(rt) / r] × 0.5−α.
Where α: Angle correction value [°]
Respectively.

Further, as the second model formula, the chip breaker width S is S = f × 25 mm ± 0.3 mm
Can be calculated from

Further, the inclination angle of the chip breaker surface is preferably 40 to 60 ° with respect to the rake face of the chip, and is preferably formed in a state where it is inclined downward.
The height of the chip breaker is preferably 1.0 to 1.5 mm.

  ADVANTAGE OF THE INVENTION According to this invention, the chip | tip for nonferrous metal processing which can be used in a wide range from roughing of nonferrous metal to finishing can be provided.

  Hereinafter, the present invention will be described in detail based on the embodiments shown in the drawings.

  FIG. 1 shows the configuration of a cutting tool for outside diameter processing in which a quadrilateral tip for processing nonferrous metal (hereinafter abbreviated as a tip) is attached to the tip.

  A concave groove 2 for tip attachment is formed at the tip of the holder 1a of the cutting tool 1, and a chip 4 is attached to the concave groove 2 via a clamp screw 3, so that the outer periphery A and the end face B are respectively provided. A cutting blade is formed.

  In addition, 5 shown with a dashed-two dotted line in a figure shows a rod-shaped workpiece, W shows the feed direction and V has shown the rotation direction.

  FIG. 2 is an enlarged view of the chip 4. FIG. 2A is a side view, FIG. 2B is a plan view, and FIG. 2C is a front view.

  In these drawings, a chip breaker 4b is formed on the rake face 4a of the chip 4.

The chip breaker 4b, as shown in FIG. (C), over the cutting edge 4 c formed on the outer circumferential A from cutting edge 4 d formed on the end surface B, with a later-described chip breaker arrangement angle θa It is formed in a straight line.

  Further, as shown in FIG. 5B, the breaker wall surface 4e is formed with a chip breaker inclination angle θb described later with respect to the rake face 4a.

  Further, 4f is a biting cutting blade formed by chamfering a corner portion where the cutting blade 4c and the cutting blade 4d intersect, and the biting cutting blade 4f performs cutting first at the start of cutting processing, Chips can be sent out toward the chip breaker 4b. In the figure, reference numeral 4g denotes a screw hole for inserting the clamp screw 3 (see FIG. 1).

  Next, the chip disposal of the chip breaker 4b will be described with reference to FIGS.

First, symbols used in the description are shown in FIG. 3 and their definitions are summarized below.
Tip breaker arrangement angle θa [°]: Angle of chip breaker 4b arranged in a state inclined with respect to cutting edge 4d Breaker inclination angle θb [°]: Inclined forward with respect to rake face 4a in the direction of arrow W Angle of breaker wall surface 4e arranged in a state Breaker height h [mm]: Height from rake face 4a to chip upper surface 4h Breaker width S [mm]: Maximum distance from chip breaker 4b to outer peripheral cutting edge 4d Nose radius r [mm]: radius of radius at biting cutting edge 4f Lead angle θc [°]: Angle at which chips collide with breaker wall surface 4e and reflect in the direction of arrow E Feed f [mm / rev]: Work material 5 travel per rotation (thickness of the work material cut by the cutting blade)
Radial cutting depth t [mm]: Cutting depth in the radial direction of work material 5

  An object of the present invention is to provide a nonferrous metal machining tip that can be applied in a wide range from roughing to finishing. Therefore, in the following description, a chip with a breaker (see FIG. 4) applied to finishing and a chip with a breaker (see FIG. 5) applied to roughing will be described separately.

  In common with roughing and finishing, the chips flowing out from the biting cutting edge 4f first collide with the breaker wall surface 4e and are reflected to be discharged in the direction of arrow E as shown in FIG. The

  However, in rough machining exceeding the nose radius r (the cut t is large), the work piece is positioned in the chip discharge direction at the breaker arrangement angle θa shown in FIG. 4, and discharge failure occurs.

  Therefore, in rough machining, the breaker arrangement angle θa is set to be smaller as shown in FIG. Then, the chips discharged from the biting cutting blade 4f are reflected in the direction of the arrow F or G, respectively, and the chips sent from the cutting blade portion other than the biting cutting blade 4f, for example, the cutting blade 4d, are also in the direction of the arrow H. As a result, the liquid is smoothly discharged.

  It is known that the chip discharge direction can be controlled by adjusting the breaker arrangement angle θa in this way, but the chip breaker 4b can be applied in a wide range from roughing to finishing. Therefore, it is necessary to set the breaker arrangement angle θa to an appropriate value.

  Therefore, a chip discharge angle was estimated from the geometric shape of the biting cutting edge 4f, and a model formula for determining the shape of the chip breaker was created.

(a) Breaker arrangement angle θa
(a-1) First, in the case of t <r as the finishing process, as shown in FIG. 6, N is the point where the line segment vertically dropped from the center P of the nose radius r intersects the cutting edge 4c, and the biting edge When the point that intersects the workpiece surface in 4f is N ′,
An angle θ sandwiched between the line segment PN and the line segment PN ′ indicates a cutting range, and chips are discharged from the biting cutting blade 4f in this range.

When the average of the angle at which the chips are sent out is θ / 2 (see arrow I in the figure), the breaker arrangement angle θa set for the chips sent out in the direction of arrow I is expressed by the following formula (1). The
θa (°) = 90−cos ⁻¹ [(rt) / r] × 0.5−α ° (1)

In the present embodiment, as shown in FIG. 4, when the chip breaker 4b is arranged so that the angle at which the chips are incident in the arrow D direction and the angle at which the chips are reflected in the arrow E direction are substantially the same, cos ^-1 [ The chip breaker 4b is inclined by θ / 2 which is obtained by (rt) / r] × 0.5.

  In the equation, α is a value determined in consideration of the chip lead angle θc, and the maximum value is 10 °, but in this embodiment, it is set to 4 °. That is, α is reduced as an angle for discharging the chips fed in the direction of arrow D in the direction of arrow E without hitting the work material.

(a-2) Next, when t ≧ r as roughing, it is expressed by the following formula (2).
θa (°) = (r / t) × 45 ° −α ° (2)

  As shown in FIG. 5, since the lead angle θc tends to decrease as the cut t increases, the chip breaker 4b is set up so that chips are easily discharged, that is, the breaker arrangement angle θa is set small.

  In the equation, r / t represents the ratio of chips discharged from the nose radius r portion with respect to the cut t. Therefore, if the breaker arrangement angle θa is increased or decreased according to this r / t, chips can be discharged smoothly.

  As shown in FIG. 5, when t is sufficiently larger than r, the ratio of chips discharged from the nose radius r is as small as 0.5, for example. Therefore, the breaker arrangement angle θa is set to be small by multiplying the average angle 45 ° of the chips fed from the biting cutting blade 4f by 0.5. Note that α is a value similar to that in Equation (1).

  The above formulas (1) and (2) function as the first model formula.

(b) Breaker width S
Next, the breaker width S will be described.

  The breaker width S indicating the distance between the chip breaker 4b and the outer peripheral cutting edge 4d is represented by the following formula (3).

(b-1) When t <r as roughing, it is expressed by the following formula (3).
S = f × 25mm ± 0.3mm (3)

  For example, when the cut thickness f in the finishing process is set to 0.05 mm, if this value is substituted into the expression (3), the breaker width S when the finishing process is performed is set within a range of 0.95 to 1.55 mm. Will do. When the value of the above-mentioned breaker width S exceeds 1.55 mm, the effect of the breaker is lost, and when it is less than 0.95 mm, chip dischargeability is lowered, which is not preferable.

(b-2) When t ≧ r as finishing, it is expressed by the following formula (4).
S = f × 25mm ± 0.3mm (4)

  For example, when the cut thickness f in rough machining is set to 0.1 mm, if this value is substituted into the equation (4), the breaker width S in the case of rough machining is in the range of 2.2 to 2.8 mm. .

  When the value of the above-mentioned breaker width S exceeds 2.8 mm, the effect of the breaker is lost, and when it is less than 2.2 mm, the chip discharge property is lowered and the surface properties of the finished surface are deteriorated, which is not preferable.

  The above equations (3) and (4) function as the second model equation.

(c) Breaker inclination angle θb
The breaker inclination angle θb is set to 40 to 60 ° for both finishing and roughing. When θb is less than 40 ° or exceeds 60 °, clogging of chips occurs or the curl radius of the chips increases. Further, it is most preferable to set the breaker inclination angle θb to 50 ° because not only clogging of the chip is eliminated and the curl radius of the chip becomes appropriate, but also the finished surface becomes good.

  FIG. 7 shows a state where chips are clogged.

(d) Breaker height h
When the breaker height h is less than 1.0 mm, the effect of the breaker cannot be obtained. If the breaker height h is 1.0 mm or more, the breaker height h can be obtained. However, the portion raised to 1.5 mm or more does not contribute to the breaker effect. Therefore, the breaker height h is set to 1.0 to 1.5 mm for both finishing and roughing. FIG. 8 shows a state where the chip breaker effect is not effective.

  In this way, if the shape of the chip breaker is modeled for each finishing process and roughing process, even if the cutting depth t or the cutting thickness f as the cutting conditions fluctuates, the ductile aluminum cutting breakability is satisfactorily maintained, You will be able to control the chips.

  In the above-described embodiment, three-dimensional cutting has been described as an example. However, the present invention is not limited to this, and the non-ferrous metal processing tip of the present invention can also be applied to two-dimensional cutting.

  If the “cut” is larger than the “feed” in the three-dimensional cutting, it can be regarded as the generation of chips by a substantially single straight cutting edge, and therefore it can be considered approximately as a two-dimensional cutting. However, in this case, “radial cut t” and “feed f” in the three-dimensional cutting are regarded as “cut t” and “cut thickness f” in the two-dimensional cutting.

  In the above-described embodiment, aluminum is taken as an example of the work material, but the present invention can also be applied to processing of non-ferrous metals such as copper and titanium alloys in addition to aluminum.

  In the above embodiment, the cutting tool for outer diameter processing is described as an example. However, the present invention is not limited to this, and the chip breaker of the present invention is used for arbitrary processing such as inner diameter processing, grooving, profiling, and thinning. can do.

  In addition, the non-ferrous metal working tip of the present invention can be attached to an end mill, a rotary multi-blade tool or the like.

It is a front view of the cemented carbide tool with a chip breaker concerning the present invention. (a) is a side view of a cemented carbide tool with a chip breaker, (b) is a plan view, and (c) is a front view. It is a perspective view for demonstrating the name of each part of the cemented carbide tool with a chip breaker. It is explanatory drawing which shows the discharge direction of the chip at the time of finishing. It is explanatory drawing which shows the discharge direction of the chip at the time of roughing. It is explanatory drawing for calculating a breaker arrangement angle. It is the schematic diagram which illustrated the state where chips are clogged. It is the schematic diagram which illustrated the state where a chip breaker does not function effectively.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Cutting tool 2 Groove 3 Clamp screw 4 Tip 4a Rake face 4b Chip breaker 4c Cutting blade 4d Cutting blade 4e Breaker wall surface 4f Chamfering cutting blade 4g Screw hole 5 Work material f Feeding h Breaker height S Breaker width r Nose radius t Radial cut

Claims (3)

A chip breaker having a cutting blade (4d) perpendicular to the chip feed direction at the time of cutting and a cutting blade (4c) in the same direction as the chip feed direction, and a chip breaker for chip disposal is the cutting blade (4d) A method for producing a non-ferrous metal processing chip formed with a predetermined arrangement angle θa ,
As the first model formula, the following formula (1) is used when the cutting amount t <nose radius r, and the following formula (2) is used when the cutting amount t ≧ nose radius r, and these formulas (1) or ( The chip breaker arrangement angle θa is obtained from 2),
Using the following formula (3) as the second model formula, the chip breaker width S is obtained from this formula (3),
A method for producing a chip for non-ferrous metal processing, comprising forming a chip breaker on the chip in accordance with the obtained chip breaker arrangement angle θa and chip breaker width S.
θa = 90−cos ⁻¹ [(rt) / r] × 0.5−α (1)
θa = (r / t) × 45 ° −α (2)
θa: Chip breaker arrangement angle [°]
r: Nose radius [mm]
t: Cutting depth [mm]
α: Angle correction value [°] (however, the maximum value is 10 °)
S = f × 25 mm ± 0.3 mm (3)
S: Chip breaker width [mm]
f: Feed [mm / rev]   The manufacturing method of the chip | tip for non-ferrous metal processing of Claim 1 which forms the inclination-angle of the said chip breaker surface in the state inclined at 40-60 degrees with respect to the rake face of the said chip | tip.   The method for producing a chip for nonferrous metal processing according to claim 1 or 2, wherein a height of the chip breaker is 1.0 to 1.5 mm.

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