Patent Grant
9868161
This application is a National Stage of International Application No. PCT/JP2013/075286 filed Sep. 19, 2013, claiming priority based on Japanese Patent Application No. 2012-224872, filed Oct. 10, 2012 and Japanese Patent Application Number 2012-264058, filed Dec. 3, 2012, the contents of all of which are incorporated herein by reference in their entirety.
The present invention relates to a solid or indexable ball-end mill suitable for three-dimensionally finishing a work, and an insert attached to an indexable ball-end mill.
Ball-end mills have conventionally been used to three-dimensionally cut flat surfaces and curved surfaces of works such as molding dies, etc. To carry out the three-dimensional finishing of works with good surface roughness by ball-end mills, cutting edges should be free from chipping and cracking, with suppressed vibration for improved chip removal. To this end, it is important to adjust rake angles of arcuate cutting edges of ball-end mills. Accordingly, various proposals have been made so far, on the rake angles of arcuate cutting edges.
JP 10-80815 A discloses a ball-end mill suitable for three-dimensional cutting of curved surfaces of molding dies, etc., which has an rake angle of −2° to −20° in peripheral cutting edges for strengthening, and an rake angle of 0° to +10° near an axial center for better chip removal. Specifically, it describes an example in which the rake angle is +3° near a tip end, and −10° near peripheral cutting edges. However, because the rake angle of the cutting edge at the most projecting position is negative, this ball-end mill has poor capability of finishing works with high accuracy.
JP 2008-110437 A proposes a CBN ball-end mill comprising ball-end cutting edges and peripheral cutting edges, a normal rake angle of each ball-end cutting edge being −5° to −15° at R10°, −5° to +3° in a range of R50° to R70° and having a peak, and −10° to 0° at R90°, thereby suppressing chipping in the entire ball-end cutting edges for a long life. A specific example of the normal rake angles of the ball-end cutting edges is −10° at R10°, peak with 0° at R60°, and −5° at R90°, with gradual change in a plus direction in a range from R10° to R60°, and gradual change in a minus direction in a range from R60° to R90°. However, because this ball-end mill has a peak in a normal rake angle in a range from R50° to R70°, with a larger negative normal rake angle at R10° than at R90°, it suffers poor capability of finishing works with high accuracy.
JP 8-118133 A proposes a ball-end mill for cutting relatively soft works such as wood, non-ferrous metals, etc. smoothly with high accuracy, which comprises curved cutting edges, a rake angle of each cutting edge being 10-30° in a tip end portion with end cutting edges, and 20-40° in a peripheral portion, with an intermediate rake angle continuously changing from the rake angle of the end cutting edge to that in the peripheral portion in a corner portion. An example of the rake angles is 10° in the tip end portion and 20° in the peripheral portion, and another example is 20° in the tip end portion and 30° in the peripheral portion. Because the rake angle of each cutting edge is larger in the peripheral portion than in the tip end portion, and intermediate between those of the tip end portion and the peripheral portion in the corner portion, this ball-end mill cannot be used to finish high-hardness works (Rockwell hardness: 40 HRC or more) such as molding dies, etc.
JP 2004-181563 A proposes a ball-end mill comprising ball-end cutting edges whose center cutting edges are formed by rake faces; a clearance angle of each ball-end cutting edge being smaller than that of each center cutting edge; and each ball-end cutting edge having a normal rake angle gradually increasing to the positive side from a center toward a periphery, thereby having improved strength and chip removal. For example, a center cutting edge of each ball-end cutting edge has a normal rake angle of −45° at center, and gradually and positively increasing to −10° toward the periphery. However, because each center cutting edge has a largely negative normal rake angle, this ball-end mill has poor capability of finishing works with high accuracy.
Japanese Utility Model 62-12503 Y2 proposes a ball-end mill comprising ball-end cutting edges looked an S shape when viewed from the tip end side; a normal rake angle of each ball-end cutting edge being negative at a rotation axis center, and positive with gradual increase on the periphery side. However, because the rake angle of each ball-end cutting edge gradually increases on the positive side from the rotation axis center toward the periphery side for improved chip removal and cutting edge strength, this ball-end mill has poor capability of finishing works with high accuracy.
JP 2004-291096 A proposes a throwaway chip having twisted arcuate cutting edges; the thickness of a chip body at a position perpendicular to its rotation axis being in a range of 0.5 D to 0.9 D, wherein D is the thickness (mm) of a flat plate portion of the chip body; and the radial angle being 40-70° at a point most projecting in a rotation direction. However, JP 2004-291096 A never discloses the change of a rake angle depending on the radial angle of the throwaway chip. In addition, this throwaway chip does not have twisted peripheral cutting edges connected to rear ends of arcuate cutting edges. Accordingly, it is not suitable to three-dimensionally finish works having vertical walls with good surface roughness.
Accordingly, the first object of the present invention is to provide a solid or indexable ball-end mill capable of three-dimensionally finishing works having vertical walls with good surface roughness, and an insert attached to such an indexable ball-end mill.
The second object of the present invention is to provide a solid or indexable ball-end mill preventing chips from being bitten into a gap between a cutting edge and a work, and an insert attached to such an indexable ball-end mill.
The third object of the present invention is to provide a solid or indexable ball-end mill with suppressed vibration by reduced cutting resistance and amplitude thereof, and an insert attached to such an indexable ball-end mill.
The ball-end mill of the present invention comprises, in a tip end portion of an end mill body, arcuate cutting edges each extending from a tip end to a peripherally outermost point along a curve in an S shape when viewed from the front side, spirally-shaped, peripheral cutting edges each smoothly connected to each arcuate cutting edge, and a convex rake face of each arcuate cutting edge protruding forward in a rotation direction;
each of the arcuate cutting edges having a radial rake angle meeting the condition of β<α≦γ, wherein α is a radial rake angle at a radial angle of 5°, β is a radial rake angle at a radial angle of 90°, and γ is a radial rake angle at a rotationally most projecting point of the arcuate cutting edge;
the radial rake angle of the arcuate cutting edge having the maximum value in a radial angle range of 12-40°; and
the radial rake angle continuously decreasing in a range from the rotationally most projecting point to the peripherally outermost point.
The insert of the present invention comprises arcuate cutting edges each extending from a tip end to a peripherally outermost point along a curve in an S shape when viewed from the front side, spirally-shaped, peripheral cutting edges each smoothly connected to each arcuate cutting edge, and a convex rake face of each arcuate cutting edge protruding forward in a rotation direction;
each of the arcuate cutting edges having a radial rake angle meeting the condition of β<α≦γ, wherein α is a radial rake angle at a radial angle of 5°, β is a radial rake angle at a radial angle of 90°, and γ is a radial rake angle at a rotationally most projecting point of the arcuate cutting edge;
the radial rake angle of the arcuate cutting edge having the maximum value in a radial angle range of 12-40°; and
the radial rake angle continuously decreasing in a range from the rotationally most projecting point to the peripherally outermost point.
The radial rake angle γ is preferably a positive angle.
The radial rake angle β is preferably a positive angle of 0° or more.
The difference between the radial rake angle α and the radial rake angle β is preferably 2-6°.
The difference between the radial rake angle γ and the radial rake angle α is preferably 0-2°.
The difference between the radial rake angle γ and the radial rake angle β is preferably 2-6°.
The difference between the maximum value of the radial rake angle and the radial rake angle γ is preferably 0.1-1.0°.
The radial rake angles α, β and γ preferably meet the conditions of 2°≦α≦10°, 0°≦β≦6°, and 3°≦γ≦14°, respectively.
The arcuate cutting edge preferably has a rotationally most projecting point at a position at which the radial angle is 30-47°.
The radial rake angle of the arcuate cutting edge preferably meets the relation of θ1<θ2, wherein θ1 is a radial rake angle in a range from the rotationally most projecting point to the peripherally outermost point, and θ2 is a radial rake angle in a range from the rotationally most projecting point to the tip end.
The arcuate cutting edge preferably has a negative axial rake angle in a range from the tip end to the rotationally most projecting point, and a positive axial rake angle in a range exceeding the rotationally most projecting point to the peripherally outermost point.
The insert preferably has a thickness T (mm) in a flat plate portion and a thickness TS (mm) at the peripherally outermost point S, with the condition of 0.4 T≦TS<0.5 T met.
A crossing angle δ1 of a line connecting the rear end point R of the peripheral cutting edge and the rotationally most projecting point Q to the rotation axis is preferably 15-30°, smaller than a crossing angle δ2 of a line connecting the peripherally outermost point S and the rear end point R to the rotation axis.
The peripheral cutting edge preferably has a length meeting the condition of 0.2 T-0.5 T, wherein T is the thickness (mm) of a flat plate portion of the insert.
The indexable ball-end mill of the present invention comprises the above insert fixed to a slit in a semispherical tip end portion of an end mill body.
The embodiments of the present invention will be explained in detail below referring to the attached drawings, of course without intention of restricting the present invention thereto. Various modifications and additions may be made within the technical idea of the present invention. Explanations of each embodiment are applicable to other embodiments unless otherwise mentioned.
Because a solid ball-end mill has a structure in which an end mill body is integrated with an insert having cutting edges, it does not differ in shape from an indexable ball-end mill. Accordingly, explanations of the indexable ball-end mill and the insert are applicable to the solid ball-end mill.
[1] Indexable Ball-End Mill
As shown in
[2] Insert
As shown in
The semicircular portion 51 comprises first flanks 51b1, 51b2 and second flanks 51c1, 51c2 constituting an end surface connecting a pair of side surfaces 51a1, 51a2, convex rake faces 51e1, 51e2, arcuate cutting edges 51d1, 51d2 extending along ridges between the first flanks 51b1, 51b2 and the rake faces 51e1, 51e2, a pair of spirally-shaped, peripheral cutting edges 51k1, 51k2 each connected smoothly (with no inflection point) to each arcuate cutting edge 51d1, 51d2 at each point S, and a penetrating hole 51p having a centerline passing a center point O of the arcuate cutting edges 51d1, 51d2 for receiving a clamp screw 6. The center point O is positioned at a middle point of the centerline of the penetrating hole 51p (middle point of the insert 5 in a thickness direction). The points S are peripherally outermost points of the arcuate cutting edges 51d1, 51d2, at which a straight line M perpendicular to the rotation axis L1 and passing the circle center O crosses the cutting edges. Namely, each arcuate cutting edge 51d1, 51d2 has the maximum diameter at the point S. The arcuate cutting edges 51d1, 51d2 cross the center axis (rotation axis) L1 of the insert 5 at a tip end P. The rotation axis L1 passes the tip end P of the insert 5 and the circle center O. When the insert 5 is attached to the slit 8 of the end mill body 2, the rotation axis L1 of the insert 5 is aligned with the rotation axis L of the end mill body 2, with the tip end P of the insert 5 on the rotation axis L of the end mill body 2.
The triangular portion 52 comprises a pair of parallel and flat triangular side surfaces 52a1, 52a2, and oblique bottom surfaces 52b1, 52b2 connecting the triangular side surfaces 52a1, 52a2. The oblique bottom surfaces 52b1, 52b2 come into close contact with the bottom surface 8c of the slit 8.
As shown in
Each spirally-shaped, peripheral cutting edge 51k1, 51k2 is a straight line parallel with the rotation axis L1 on the plan view of
Because the peripheral cutting edges 51k1, 51k2 are positioned on a cylindrical surface [straight lines in
(A) Conditions of Rake Angle of Each Arcuate Cutting Edge
The rake angle of each arcuate cutting edge 51d1, 51d2 has a radial rake angle and an axial rake angle. The “radial rake angle” is an angle of each rake face 51e1, 51e2 to a straight line radially extending from the circle center O to each arcuate cutting edge 51d1, 51d2 (radial straight line), which may be called “normal rake angle.” The “axial rake angle” is an angle of a tangent line of each arcuate cutting edge 51d1, 51d2 to the rotation axis L1 on a side view of the insert 5 shown in
(1) Radial Rake Angle
At a positive radial rake angle, as shown in
With respect to one cutting edge 51d1,
The purpose of β<α is to reduce cutting resistance near the tip end P of the arcuate cutting edge 51d1 for good biting performance to a work, and to secure sufficient cutting edge strength because chips are thicker at the peripherally outermost point S of the arcuate cutting edge 51d1. The purpose of making the radial rake angle γ at the rotationally most projecting point Q equal to or larger than the rake angle α near the tip end P is to provide small cutting resistance to the arcuate cutting edge at the rotationally most projecting point Q, which comes into contact with a work first, thereby achieving good biting performance to a work.
The radial angle at the rotationally most projecting point Q is preferably in a range of 30-47°. When the radial angle at the rotationally most projecting point Q is 47° or less, a region with a negative axial rake angle is short in a range from the tip end P of the arcuate cutting edge 51d1 to the rotationally most projecting point Q, effective for making chips thinner, thereby reducing cutting resistance. Also, a region with a positive axial rake angle can be long in a range from the rotationally most projecting point Q to the point R, effective for improving chip removal. Thus, chips are discharged outward from a tangent line of a rotation locus of the tool and slantingly upward from a cut work surface (good detachability of chips from the cutting edge), avoiding a trouble that chips are bitten into a gap between the cutting edge and the work.
When the radial angle at the rotationally most projecting point Q is more than 47°, the rotationally most projecting point Q is too distant from the tip end P, an impinging work applies large impact to the arcuate cutting edge at the rotationally most projecting point Q, and thick chips are generated, resulting in poor chip removal. When the radial angle at the rotationally most projecting point Q is less than 30°, an absolute value of a negative axial rake angle in a range from the tip end P to the rotationally most projecting point Q is too large, resulting in increased cutting resistance, and poor chip removal near the rotation center of the cutting edge. The radial angle at the rotationally most projecting point Q is more preferably in a range of 35-40°.
The difference between the radial rake angle α and the radial rake angle β is preferably 2-6°. The difference between the radial rake angle γ and the radial rake angle α is preferably 0-2°. The difference between the radial rake angle γ and the radial rake angle β is preferably 2-6°. The difference between the maximum value of the radial rake angle and the radial rake angle γ is preferably 0.1-1.0°. With the above relations met, the radial rake angle changes along such a smooth curve that the radial rake angle increases relatively largely in a range from near the tip end P to a point of the maximum value, and gradually decreases in a range from the point of the maximum value to the peripherally outermost point S via the rotationally most projecting point Q.
Among the radial rake angles α, β and γ, at least the radial rake angle γ is preferably a positive angle. Other radial rake angles α and β may be negative angles. When a work with good cuttability such as spheroidal graphite cast iron, which has small cutting resistance with small vibration, is finish-cut, all of the radial rake angles α, β and γ are preferably positive angles to achieve good biting performance to a work. Specifically, the conditions of 2°≦α≦10°, 0°≦β≦6°, and 3°≦γ≦14° are preferably met. Though a positive radial rake angle provides the cutting edge with decreased cracking resistance, the cracking resistance does not matter in finishing because of small cutting depth.
With 2°≦α≦10°, cutting resistance near the tip end P (radial angle=5°) is small, securing sufficient cutting edge strength while keeping good biting performance to a work. When α<2°, there is large cutting resistance near the tip end P, resulting in poor biting performance to a work. In addition, the chip removal decreases, so that the tip end portion of the ball-end mill is likely clogged with chips, resulting in the seizure of chips, poor cut surfaces, etc. When α>10°, the arcuate cutting edge has insufficient strength near the tip end P.
With 0°≦β≦6°, good cut surface conditions are obtained by small cutting resistance, while securing sufficient cutting edge strength at the peripherally outermost point S. When β<0°, there is large cutting resistance at the peripherally outermost point S, generating vibration to deteriorate cut surface conditions. When β>6°, the arcuate cutting edge has insufficient strength at the peripherally outermost point S.
With 3°≦γ≦14°, cutting resistance is small at the rotationally most projecting point Q at which the cutting edge comes into contact with a work first, resulting in good biting to a work. When γ<3°, there is large cutting resistance at the rotationally most projecting point Q, resulting in poor biting to a work. When γ>14°, the cutting edge has insufficient strength at the rotationally most projecting point Q.
In the case of cutting a high-hardness work having large cutting resistance, however, the radial rake angle β, the radial rake angle α and the radial rake angle γ are preferably made negative in this order to increase cutting edge strength. In this case, to have good biting to a work, the radial rake angle γ is preferably close to 0° even when it is negative. In the case of cutting a high-hardness work having relatively large cutting resistance, the radial rake angles α, β and γ preferably meet the conditions of −6°≦α≦−0.5°, −10°≦β≦−2°, and −6°≦γ≦−0.5°, in addition to the relation of β<α≦γ.
By making the radial rake angles α, β and γ negative, the entire arcuate cutting edge is strengthened, resulting in improved cracking resistance in cutting a high-hardness work having Rockwell hardness of 45 HRC or more. The negative radial rake angle, which provides the cutting edge with large cutting resistance and poor chip removal, leads to little increase in cutting resistance and little deterioration of chip removal in the finishing of a high-hardness work, because finishing has smaller cutting depth than in roughing and semi-finishing.
With the condition of −6°≦α≦−0.5° met, cutting edge strength necessary for finishing a high-hardness work can be secured with good biting, without excessive cutting resistance at and near the tip end P. In the case of α>−0.5°, cutting edge strength at the tip end P is insufficient, resulting in the cracking, etc. of the cutting edge. In the case of α<−6°, the arcuate cutting edge has excessive cutting resistance at and near the tip end P, resulting in wearing of the cutting edge, the seizure of chips, the deteriorated cut surface conditions of a work, etc.
With the condition of −10°≦β≦−2° met, cutting edge strength necessary for finishing a high-hardness work can be secured at the peripherally outermost point S. In the case of β>−2°, cutting edge strength is insufficient at the peripherally outermost point S. In the case of β<−10°, cutting resistance is excessive at the peripherally outermost point S, resulting in extreme vibration and heat generation, and thus poor cut surface conditions of a work.
With the condition of −6°≦γ≦−0.5° met, cutting edge strength necessary for finishing a high-hardness work can be secured at the rotationally most projecting point Q at which the cutting edge first comes into contact with the work, and the tool can be stably held particularly in finishing a high-hardness material by properly controlling a thrust force component in a longitudinal direction of the tool. In the case of γ>−0.5°, cutting edge strength necessary for finishing a high-hardness work cannot be secured at the rotationally most projecting point Q. In the case of γ<−6°, cutting resistance is excessive at the rotationally most projecting point Q, resulting in insufficient biting to a high-hardness work.
The radial rake angle of the arcuate cutting edge has a peak (maximum) in a range from a point near the tip end P (radial angle=5°) of the arcuate cutting edge to the rotationally most projecting point Q, and continuously decreases in a range from the rotationally most projecting point Q to the peripherally outermost point S. Specifically, the maximum value of the radial rake angle of the arcuate cutting edge is located in a radial angle range of 12-40°, preferably 15-30°. With this structure, good balance is obtained between the biting performance to a work and the cutting edge strength.
The arcuate cutting edge first comes into contact with a work at the rotationally most projecting point Q, and its contact region with the work then expands in both directions on the side of the tip end P and on the side of the peripherally outermost point S, by the rotation of the cutting edge. Accordingly, with the maximum value of the radial rake angle located in a range from a point near the tip end P (radial angle=5°) to the rotationally most projecting point Q, the cutting resistance can be reduced even if the axial rake angle is negative. With a continuously decreasing radial rake angle in a range from the rotationally most projecting point Q to the peripherally outermost point S, sufficient cutting edge strength can be secured with reduced cutting resistance.
The point Q at which the arcuate cutting edge is most projecting forward in a rotation direction R, which is called “rotationally most projecting point,” is preferably in a radial angle range of 30-47°. This expands a region in which the arcuate cutting edge in an S shape when viewed from the front side has a positive axial rake angle (narrows a negative-axial-rake-angle region), thereby securing sufficient strength of the arcuate cutting edge even with high cutting resistance. Also, with an expanded region in which the axial rake angle is positive, good chip removal is achieved while sufficiently keeping the strength of the arcuate cutting edge.
The radial rake angle of the arcuate cutting edge preferably meets the relation of θ1<θ2, wherein θ1 is a radial rake angle in a range from the rotationally most projecting point Q to the peripherally outermost point S, and θ2 is a radial rake angle in a range from the rotationally outermost point Q to near the tip end P (radial angle=5°). As shown in
(2) Axial Rake Angle
In the insert of the present invention, the axial rake angle also changes depending on the radial angle. In an example of one cutting edge 51d1 shown in
The axial rake angle of the arcuate cutting edge is preferably negative in a range from the tip end P to a point just not reaching the rotationally most projecting point Q, 0° at the rotationally most projecting point Q, and positive in a range exceeding the rotationally most projecting point Q and reaching the peripherally outermost point S. In a range from the tip end P to the rotationally most projecting point Q, a negative axial rake angle gradually increases in a positive direction. In a range exceeding the rotationally most projecting point Q and reaching the peripherally outermost point S, a positive axial rake angle gradually increases. As shown in
With the axial rake angle of about +20° at the peripherally outermost point S, chips are removed in a direction perpendicular to a tangent line of a rotation locus of the tool, resulting in good chip removal. On the other hand, the axial rake angle of smaller than +20° near the peripherally outermost point S provides poor chip removal, and the axial rake angle of larger than +20° near the peripherally outermost point S makes a cutting edge too thin, failing to secure its stiffness.
With the axial rake angle of about −70° to about −80° near the tip end P, a work-cutting stress is applied to the end mill body 2 along the rotation axis L, thereby reducing the flexure of the end mill body 2 without making chip removal difficult.
The radial rake angle and axial rake angle of the arcuate cutting edge is measured by a non-contact three-dimensional digitizer, etc. The above explanations of the radial rake angle and the axial rake angle are applicable to both arcuate cutting edges 51d1, 51d2.
(B) Other Conditions
As shown in
The inclination angle δ1 of the line N is preferably 15-30°. This enables chips to be discharged outward from the tool and slantingly upward from a cut surface of the work (good separation of chips from the insert cutting edges) during cutting, thereby avoiding chips from entering a gap between the cutting edge and the work, and thus reducing cutting resistance and its amplitude. Namely, good chip removal from the cutting edges reduces cutting resistance, and decreased cutting resistance amplitude suppresses the vibration of the tool, thereby improving the cut surface conditions of a work.
When the inclination angle δ1 of the line N is less than 15°, the chip removal direction is substantially aligned with a tangent line of a rotation locus of the tool, meaning that the tool follows chips. As a result, chips are bitten into a gap between the cutting edge and the work. This trouble occurs particularly in the contour cutting of a corner. When the inclination angle δ1 of the line N exceeds 30°, the spirally-shaped, peripheral cutting edge cannot be sufficiently long, and the peripheral cutting edge is thin, resulting in low cutting edge strength. Further, because of a large cutting resistance amplitude, vibration occurs during cutting, resulting in deteriorated surface roughness of a work. δ1 is more preferably 20-30°.
To increase the number of regrinding the cutting edges, the length F (mm) of the peripheral cutting edge 51k1 (line H) preferably meets the condition of 0.2 T≦F≦0.5 T. When F is less than 0.2 T, the peripheral cutting edge 51k1 is too short, resulting in a small number of regrinding. When F is more than 0.5 T, the peripheral cutting edge 51k1 is longer than necessary, resulting in drastically increased cutting resistance, and inducing vibration during cutting.
The thickness TS (mm) of the insert 5 at the peripherally outermost point S preferably meets the condition of 0.4 T≦TS<0.5 T. When TS is less than 0.4 T, the cutting edge has too low stiffness. On the other hand, when TS is 0.5 T or more, the cutting edge is too large in cutting resistance and its amplitude, likely resulting in large tool vibration during cutting. TS is more preferably 0.45 T-0.49 T.
The insert 5 having such a shape can be formed, for example, by cemented carbide comprising tungsten carbide (WC) and cobalt (Co).
[3] Production Method of Insert
The insert 5 of WC-based cemented carbide can be produced, for example, by the following process. Granules of a mixture comprising tungsten carbide powder, cobalt powder, and if necessary, additives are first molded by a powder metallurgy method, etc. A screw-penetrating hole is formed at the time of molding. A green body should be formed larger by sintering shrinkage of 20-30%. The green body is sintered at about 1300-1400° C.
The resultant sintered body is subjected to NC-controlled three-dimensional grinding, to form arcuate cutting edges 51d1, 51d2, spirally-shaped, peripheral cutting edges 51k1, 51k2, and oblique bottom surfaces 52b1, 52b2. To provide the arcuate cutting edges with desired radial rake angle and axial rake angle, NC-controlled working using a disc-shaped thin diamond grinder, etc. is carried out.
A surface of the resultant insert 5 except for the screw-penetrating hole is provided with a coating having wear resistance and heat resistance by a PVD method. The coating may be made of, for example, Ti—Al nitride, Ti—Si nitride, Ti—B nitride, etc.
The same coating as described above on the end mill body 2 provides the indexable ball-end mill with a longer life. Particularly to reduce friction resistance with chips, it is preferable to form a Ti—B nitride coating having wear resistance and lubrication on the end mill body 2.
[4] Indexable Ball-End Mill
The tip end P of the insert 5 slightly projects from the slit 8 along the rotation axis L, and the cutting edges comprising a pair of arcuate cutting edges 51d1, 51d2 and a pair of peripheral cutting edges 51k1, 51k2 and the first and second flanks 51b1, 51b2, 51c1, 51c2 also slightly project from the slit 8. The thickness T (mm) of the insert 5 is preferably 0.2 D-0.5 D, wherein D (mm) is an outer diameter of the end mill. With this condition met, sufficiently deep flute grooves are obtained while securing sufficient strength in the arcuate cutting edges. An indexable ball-end mill 1 to which an insert 5 having a pair of cutting edges is attached corresponds to a two-flute ball-end mill.
[5] Solid Ball-End Mill
The present invention is applicable not only to indexable ball-end mills but also to solid (solid-type) ball-end mills. The solid ball-end mill basically does not differ from the indexable ball-end mill, except that the insert is integral with a tip end portion of the end mill. Of course, the solid ball-end mill preferably has the above features with respect to the radial rake angle and axial rake angle of the arcuate cutting edge.
The present invention will be explained in more detail by Examples below without intention of restricting the present invention thereto.
Produced as a cemented carbide insert to be attached to a slit in a tip end portion of a shank-type end mill body having a cutting diameter of 30 mm, a shank diameter of 32 mm, an entire length of 250 mm, and an under-neck length of 180 mm, were three types of inserts 1-3 each having a thickness T of 7.2 mm and a shape shown in
To cut a wall (inclination angle: 85°) of a work of spheroidal graphite cast iron (FCD700), a machining center was controlled to use each arcuate cutting edge near the peripherally outermost point S of the insert attached to the end mill body.
The cutting conditions of a work were as follows:
Cutting method: Dry cutting with air blow,
Cutting speed (Vc): 754 m/minute,
Number of rotation: 8000 rpm,
Feed (Vf): 7500 mm/minute,
Feed per edge (fz): 0.47 mm/tooth,
Radial cutting depth ae: 0.15 mm and 0.3 mm,
Pick feed (pf): 0.5 mm, and
Tool overhang (OH): 180 mm.
The optical photomicrographs (18 times) of
A target surface roughness Ry of finished surfaces of a die for molding exterior automotive body panels is generally 10 μm or less, and surface roughness Ry better than the target was achieved at radial cutting depths ae of 0.15 mm and 0.3 mm as shown in
The cut surface roughness Ry obtained by an indexable ball-end mill having the insert 2 with a radial rake angle β of +3.0° was 4.3 μm when cut at a radial cutting depth ae of 0.3 mm, and 4.4 μm when cut at a radial cutting depth ae of 0.3 mm, smaller than when other inserts 1 and 3 were used. This indicates that the radial rake angle β is preferably about 3° in finishing a slanting wall of a work of FCD700, having in mind a die for molding exterior automotive body panels.
The same insert as in Example 1 except that a radial rake angle at a radial angle of 5°, 30°, 45°, 60°, 85° and 90° was +1.0°, +1.5°, +1.0°, 0°, −2.5° and −3.0°, respectively, was attached to the same end mill body as in Example 1, to cut a wall (inclination angle: 85°) of a hard work of SKD11 having Rockwell hardness of 60 HRC under the following conditions. The resultant cut surface had surface roughness Ry of 2-3 μm, indicating that even a hard work can be cut with high finishing accuracy.
Cutting method: Dry cutting with air blow,
Cutting speed (Vc): 400 m/minute,
Number of rotation: 4244 rpm,
Feed speed (Vf): 2550 mm/minute,
Feed per edge (fz): 0.3 mm/tooth,
Radial cutting depth ae: 0.1 mm,
Pick feed (pf): 0.3 mm, and
Tool overhang (OH): 120 mm.
The same insert as in Example 1 except that a radial rake angle at a radial angle of 5°, 30°, 45°, 60°, 85° and 90° was −2.5°, −2.0°, −2.5°, −3.5°, −6.0° and −6.5°, respectively, was attached to the same end mill body as in Example 1, to cut a wall (inclination angle: 85°) of a hard work of SKD11 having Rockwell hardness of 60 HRC under the following conditions. The resultant cut surface had surface roughness Ry of 2-3 μm, indicating that even a hard work can be cut with high finishing accuracy.
Cutting method: Dry cutting with air blow,
Cutting speed (Vc): 400 m/minute,
Number of rotation: 4244 rpm,
Feed (Vf): 2550 mm/minute,
Feed per edge (fz): 0.3 mm/tooth,
Radial cutting depth ae: 0.1 mm,
Pick feed (pf): 0.3 mm, and
Tool overhang (OH): 120 mm.
Cemented carbide inserts having the same shape as in Example 1 except for the parameters shown in Table 2 were produced.
(1)The radius of an arcuate cutting edge.
(2)The thickness of the insert.
(3)The radial angle at the rotationally most projecting point Q.
Each insert of Example 4, and Comparative Examples 1 and 2 was attached to a slit in a tip end portion of a shank-type end mill body having a cutting diameter of 30 mm, a shank diameter of 32 mm, an entire length of 220 mm, and an under-neck length of 120 mm, to constitute an indexable ball-end mill. With each indexable ball-end mill mounted to a main spindle of a milling machine, shoulder cutting was carried out under the following cutting conditions, to measure the dynamic change of cutting resistance by a cutting dynamometer (available from Kistler). The cutting resistance and the chip shapes are shown in Table 3, and the dynamic change of cutting resistance is shown in
Work: S50C (hardness, 220 HB),
Cutting method: Dry shoulder cutting with air blow,
Cutting speed (Vc): 200 m/minute,
Number of rotation: 2122 rpm,
Feed (Vf): 849 mm/minute,
Feed per edge (fz): 0.2 mm,
Radial cutting depth ae: 0.5 mm,
Cutting depth: 15 mm, and
Tool overhang (OH): 180 mm.
The dynamic change of cutting resistance was smaller in Example 4 than in Comparative Examples 1 and 2. Particularly, the cutting resistance (100 kgf) in an X direction in Example 4 satisfied the target. The cutting resistance in Example 4 was 60% lower than the cutting resistance (250 kgf) in Comparative Example 2.
Because the radial rake angles α, β and γ of each arcuate cutting edge meet the condition of β<α≦γ in the solid or indexable ball-end mill and insert of the present invention, cutting resistance is small in an entire region of the arcuate cutting edge, resulting in good chip removal. Accordingly, vibration is suppressed, suitable for three-dimensional finishing of a work.
With the axial rake angle of each arcuate cutting edge being negative in a range from the tip end P to the rotationally most projecting point Q, 0° at the rotationally most projecting point Q, and positive in a range from the rotationally most projecting point Q to the peripherally outermost point S, the arcuate cutting edge first comes into contact with a work at the rotationally most projecting point Q, and a contact region with the work expands in both directions on the side of the tip end P and on the side of the peripherally outermost point S by the rotation of the cutting edge, resulting in reduced cutting resistance.
With the radial rake angle of the arcuate cutting edge continuously increasing in a range from the tip end P to the rotationally most projecting point Q, cutting resistance is low even with a negative axial rake angle.
By making the axial rake angle of the arcuate cutting edge positive (about +20°) near the peripherally outermost point S, chips are removed in a direction perpendicular to a tangent line of a rotation locus of the arcuate cutting edge. The clogging of chips is thus suppressed by good chip removal, resulting in good surface roughness on the finished oblique surface of a work.
Because chips are discharged outward in a tangential direction of a rotation locus and slantingly upward from the cut surface, it is possible to avoid a trouble that chips are bitten into a gap between the cutting edge and the work. Second, the cutting edge is provided with improved cracking resistance and chipping resistance, resulting in a longer life while avoiding its deterioration. Third, not only cutting resistance but also its amplitude are reduced, resulting in suppressed vibration, and improved surface conditions of the cut work surface.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-224872 | Oct 2012 | JP | national |
| 2012-264058 | Dec 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/075286 | 9/19/2013 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2014/057783 | 4/17/2014 | WO | A |
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