瑞典专利SE539610C2 Tools and process for machining a profile in a cylindrical surface

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专利摘要:
AB STRACT A cutting tool (300) is disclosed. The cutting tool includes a cylindrical body (302) and oneor more axial roWs of cutting elements (318, 336, 363), Which project outwardly from and aresituated radially to the circumference of the cylindrical body. Each cutting element of each roWincludes one or more pocket cutting elements and one or more groove cutting elements. Each pocketcutting element includes a cutting surface. Each groove cutting element includes a cutting surface having groove cutting teeth. _17_
公开号:SE539610C2
申请号:SE1450695
申请日:2014-06-09
公开日:2017-10-17
发明作者:G Whitbeck Rodney；alan stephenson David；Raymond Bartle Keith；Garrett Coffman David
申请人:Ford Global Tech Llc；
IPC主号:

专利说明:

[1] The present invention relates to a cutting tool for cylindrical surfaces and a process.
[2] Car engine blocks include a number of cylindrical motor boreholes. The inner surface of each motor borehole is machined so that the surface is suitable for use in automotive applications, eg exhibiting suitable abrasion resistance and strength. The machining process may include roughening the inner surface and then applying a metal coating to that coarse surface and then henna / honing the metal coating to achieve a polished / smoothed inner surface. Various surface roughening techniques are known in the art but suffer from one or more disadvantages or disadvantages. SUMMARY OF THE INVENTION
[3] A cutting tool is described here. The cutting tool comprises a cylindrical body and one or more axial rows of cutting elements, which project in the outward direction and are located radially towards the circumference of the cylindrical body. Each cutting element in each row comprises one or more pocket / depression cutting elements and one or more groove cutting elements. Each pocket / depression cutting element comprises a cutting surface. Each groove cutting element includes a cutting surface having groove cutting teeth.
[4] In one or more embodiments, the height of the groove cutting teeth is higher than the height of the pocket / recess cutting teeth with a non-zero offset h ("anonzero offset h"). The axial cutting elements may be substantially evenly distributed radially on The one or more axial rows of cutting elements may comprise two or more axial rows of cutting elements.The width of each of the two or more axial rows of cutting elements may overlap adjacent axial rows of cutting elements.In one or more embodiments, two or more axial rows of cutting elements first and second 2axial rows of cutting elements, each row having the same order of groove and pocket / recess cutting elements, which are axially offset by a cutting element.
[5] In one or more embodiments, the axial rows of cutting elements may comprise three or more cutting elements. The three or more cutting elements may comprise a pocket / recess cutting element and two groove cutting cutting elements. The two groove cutting cutting elements may be adjacent to each other. The groove-cutting surface may comprise plate valley portions between the pocket / recess-cutting teeth. The top surfaces of the groove cutting teeth may be offset radially from the top surface of the pocket / recess cutting member with a non-zero value h ("a nonzero offset h"). The groove cutting teeth may comprise a pair of side walls which are mainly parallel to each other and a top surface which is substantially perpendicular to the pair of side walls. The cutting elements may be made of a material having a stiffness higher than an aluminum or magnesium alloy. The pocket / recess and groove cutting surfaces may be tangential to the surface of the The diameter of the inner surface of a one-cylinder bore cut by the cutting tool can be considerably larger than the diameter of the cutting tool.
[6] A cutting element of a cutting tool is described here. The cutting element comprises a body having a cutting surface and a tapered / conical surface extending away from the cutting edge. The cutting edge comprises a series of rectangular cutting teeth. The body is made of a material that has a stiffness that is higher than an aluminum or magnesium alloy. The body is made of a tool material that is suitable for machining an aluminum or magnesium alloy. The series of rectangular cutting teeth cuts grooves in the aluminum or magnesium alloy.
[7] A cylindrical borehole is also described here. The cylindrical borehole includes an inner surface comprising an axial displacement region and an axial non-displacement region, and a plurality of annular grooves formed in the axial non-displacement region. The nominal diameter of the axial displacement region may be larger than the diameter of the detaxial non-displacement region. The axial non-displacement region may comprise two discontinuous axial widths of the cylindrical borehole and the axial displacement region 3 may extend therebetween. The width / height ratio of the depth of the annular grooves in relation to the width of the annular grooves may be 0.5 or less.
[8] Figure 1A shows a top view of an assembly or joint surface for an example of an engine block for an internal combustion engine;
[9] Figure 1B shows a single cross-sectional view of a cylinder borehole along line 1b-1B. Figure 1A; Figure 2A shows a pre-drilling step in which an unprocessed inner cylinder borehole surface is drilled to a diameter;
[11] Figure 2B shows an interpolation step in which a displacement area is machined by using a cutting tool to provide a grooved inner surface with a pocket / recess and annular surface grooves;
[12] Figure 2C shows a deformation step in which flat peaks between adjacent grooves are deformed to produce deformed peaks;
[13] Figure 2D shows an interpolation step in which one or more of the non-displacement regions is machined using a cutting tool to produce annular grooves;
[14] Figure 2E shows an enlarged schematic view of annular grooves formed in the non-displacement areas of a motor borehole;
[15] Figure 3A shows a perspective view of a cutting tool according to an embodiment; Figure 3B shows a top view of a cutting tool having an upper axial row of cutting elements;
[17] Figures 3C, 3D and 3E show schematic cross-sectional views of first and second cutting elements and pocket / recess cutting elements taken along lines 3C-3C, 3D-3D and 3E-3E in Figure 3A; Figure 3F shows a cylindrical shaft for mounting a cutting tool in a tool holder according to an embodiment;
[19] Figure 4A is a schematic top view of a cylinder borehole in accordance with one embodiment;
[20] Figure 4B is a schematic side view of the cylinder bore of Figure 4A in accordance with an embodiment;
[21] Figure 5 shows a fragmentary exploded view of the inner surface of the cylinder bore before, during and after an interpolation step;
[22] Figures 6A, 6B and 6C illustrate a sweeping / spinning tool according to an embodiment; and
[23] Figure 7 illustrates an enlarged cross-sectional view of the inner surface of a cylinder bore. DETAILED DESCRIPTION
[24] Reference will now be made in detail to embodiments known to the inventors. It will be appreciated, however, that the described embodiments are merely examples of the present invention, which may be embodied in various and alternative forms. Specific details herein are, therefore, not to be construed as limiting but merely as representative points of departure for teaching those skilled in the art to practice the present invention in various ways.
[25] Except where expressly described, all numerical quantities in this specification indicating amounts of materials are, of course, to be defined by the word "approximately" in describing the broadest scope of the present invention.
[26] Car engine blocks include a number of cylindrical motor boreholes. The inner surface of each motor borehole is machined so that the surface is suitable for use in automotive applications, eg exhibiting the appropriate wear resistance and strength. The machining process may include roughening the inner surface and then applying a metal coating to the coarse surface and then henna / the female coating to achieve a polished / smoothed inner surface with the required strength and abrasion resistance. Alternatively, a liner material having the necessary strength and abrasion resistance properties can be applied to the unpolished / unpaved inner surface of the motor borehole.
[27] Embodiments described herein provide cutting tools and processes for grooving the inner surface of cylindrical boreholes, e.g. motor boreholes, to improve the adhesion and adhesion of a subsequently applied metal coating, e.g. thermal spray application, on the inner surface. Accordingly, the polished / smoothed inner surface may have improved strength and improved abrasion resistance.
[28] Figure 1A shows a horizontal projection seen from above of a mounting surface for an example of an engine block 100 for an internal combustion engine. The engine block includes cylinder bore 102. Figure 1B shows a single cross-sectional view of the cylinder bore 102 taken along line 1B-1B of Figure 1A. The cylinder bore 102 includes an inner surface portion 104, which may be formed of a metallic material, such as, but not limited to, aluminum, magnesium or iron or a single alloy thereof or steel. In some applications, aluminum or magnesium alloys can be used due to their relatively low weight compared to steel or iron. The relatively light aluminum or magnesium alloy materials can enable a reduction in engine size and weight, which can improve engine output and fuel economy.
[29] Figures 2A, 2B, 2C, 2D and 2E show cross-sectional views of an inner cylinder borehole surface as process engineering steps for applying a profile to the inner surface of the cylinder borehole. Figure 2A shows a pre-drilling step in which an unprocessed inner cylinder borehole surface 200 is drilled into a smaller bore. than the diameter of the finished, eg smoothed / henna / honed, the diameter of the inner surface. In some variants, the difference in diameter is 150 to 250 microns (pm). In other variants, the difference in diameter is 175 to 225 microns (μm). In one variant, the difference in diameter is 200 microns.
[30] Figure 2B shows an interpolation step in which a displacement region 202 is machined into the pre-drilled inner surface 200 using a cutting tool. Interpolation-based grouting can be accomplished with a cutting tool suitable for cylinder boreholes of varying diameter. The cutting tool can be used to groove only the selected area of the borehole, such as the ring displacement area in the borehole. Roughening can reduce the coating cycle time, only the ring displacement area of the borehole can the material consumption, the hening / honey time and the over-spraying of the crankcase. The length of the travel area corresponds to the distance that a piston moves siginuti the motor borehole. In some variants, the length of the displacement area 202 is 90 to 150 millimeters. In one variant, the length of the displacement area 202 is 117 millimeters. The displacement area is made to resist abrasion caused by piston stroke / displacement. The cutting tool creates annular grooves 204 (as shown in the enlarged area 208 in Figure 2B) and a pocket / recess 206 into the displacement area. 202. It should be appreciated that number traces displayed in the magnified area 208 are only an example. Dimension 210 shows the depth of the pocket / depression 206. Dimension 212 shows the depth of the annular grooves 204. In some variants, the groove depth is 100 to 140 microns. In another variant, the groove depth is 120 microns. In some variants, the depth of the pocket is 200 to 300 microns. In another variant, the depression is 250 microns.
[32] The pre-drilled inner surface 200 also includes portions of non-displacement 214 and 216. These areas are outside the axial travel distance / stroke of the piston. Dimensions 218 and 220 show the length of the non-displacement portions 214 and 216. In some variants, the length of the non-displacement portion 214 is 2 to 7 millimeters. In one variant, the length of the non-moving portion 214 is 3.5 millimeters. In some variants, the length of the non-moving portion 216 is 5 to 25 millimeters. In one variant, the length of the non-moving portion 216 is 17 millimeters.
[33] Figure 2C shows a deformation step in which the flat peaks between adjacent grooves 204 are deformed to provide deformed peaks 222 in which each peak 222 includes a pair of undercuts 224, as shown in the enlarged area 226 in Figure 2C. It should be understood that the number of deformed peaks shown in the enlarged area 226 are quite simply an example. The deformation step can be performed by using a spinning / sweeping tool. The spinning / sweeping tool and the deformation step are described in greater detail below.
[34] Figure 2D shows an interpolation step in which one or more of the non-displacement areas 214 and 216 are machined using a cutting tool to create grooves 228, as shown in the enlarged area 230 in Figure 2E. Flat peaks 232 extend between annular grooves 228. It should be appreciated that the number of grooves shown in the enlarged area 230 is only an example. In one embodiment, the grooves form a 7 square wave shape with a uniform / uniform dimension. In some variants, the dimension is 25 to 100 microns. In a variant, the dimension is 50 microns. As described in more detail below, the cutting tool may form a profile of grooves within one or more of the non-displacement regions 214 and 216.
[35] Figure 3A shows a perspective view of a cutting tool 300 in accordance with one embodiment. The cutting tool 300 includes a cylindrical body 302 and first, second, third and fourth axial rows 304, 306, 308 and 310 of cutting elements. The cylindrical body 302 is edge-made of steel or sintered tungsten carbide. The cutting elements can be made of a cutting tool material which is suitable for machining aluminum or magnesium alloys. The considerations for selecting such materials include, without limitation, chemical compatibility and / or hardness. Non-limiting examples of such materials include, without limitation, high speed steel, sintered tungsten carbide or polycrystalline diamond. Each axial row 304, 306, 308 and 310 comprises 6 cutting elements. As shown in Figure 3A, the 6 cutting elements are evenly distributed radially at a distance from adjacent cutting elements. In other words, the six cutting elements are located at 0, 60, 120, 180, 240 and 300 degrees around the circumference of the cylindrical body 302. While 6 cutting elements are shown in Figure 3A, any number of cutting elements may be used in accordance with one or more embodiments. In some variants, 2 to 24 cutting elements are used.
[36] Figure 3B shows a horizontal projection seen from above of the cutting tool 300 showing the first, axial row 304 of cutting elements. As shown in Figure 3B, the 0-degree cutting element includes a cutting surface 312 and a deflection / clearance surface 314. The second element cutting elements include similar cutting and deflection / clearance surfaces. In the embodiment shown, each of the notch elements is one of three types of cutting elements, i.e. a first type of groove cutting element (G1), a second type of groove cutting element (G2) and a pocket / recess cutting element (P). In the embodiment shown in Figure 3B, the 60- and 240-degree cutting elements are the first type of groove-cutting elements; the 120- and 300-degree cutting elements are the second type of groove cutting elements; and the 0 and 180 degree cutting elements are the pocket / recess cutting element. Accordingly, the sequence of cutting elements is from 0 to 300 degrees G1, G2, P, G1, G2 and P, as shown in Figure 3B. It will be appreciated, however, that any cutting element arrangement is within the scope of protection for one or more embodiments. In some variants, the order is G1, P, G2, 8G1, P and G2 or P, G1, G1, P G2 and G2. In the embodiment shown, two groove cutting elements are necessary depending on the width and the number of valleys between the peaks, which exceed the number and widths which can be cut with one element. For other groove geometries, one or three groove cutting elements may be used. The sequence of cutting is not significant as long as all the elements used are in the axial row.
[37] In some variants there is at least one of G1 and G2 and at least one of P. As shown in Figure 3A, the cutting elements in each row are offset / offset or zigzagged circumferentially from each other between each row, e.g. each cutting element of the 0-, 60-, 120-, 180-, 240-, and 300-degree cutting elements is offset by 60 degrees in adjacent rows. The displacement improves the service life of the cutting tool by smoothing / smoothing the initial insert of the inner surface profile . If the cutting elements are aligned between adjacent rows, a greater force would be necessary to initiate the cutting operation and may cause more wear on the cutting elements or deflection and vibration of the tool.
[38] Figures 3C, 3D and 3E show schematic cross-sectional views of G1, G2 and P cutting elements taken along lines 3C-3C, 3D-3D and 3E-3E in Figure 3B. Referring to Figure 3, a G1 cutting element 318 having cutting surface 320, clearance surface 322 and guide surface 324 is shown. The cutting surface 320 schematically includes a number of teeth 326. It should be understood that the number of teeth shown is merely an example. In some variants, the number of teeth is 1 to 2 per millimeter axial length. In one variant, the number of teeth is 1.25 per axial length. Each tooth is rectangular in shape, although other shapes, e.g. square shapes, are intended in one or more embodiments. Each tooth has a top surface 328 and side surfaces 330. As shown in Figure 3C, the length of the top surface 328 is 250 microns and the length of the side surfaces 330 is 300 microns. In other variants, the length of the top surface is 200 to 400 microns and the length of the side surfaces is 200 to 500 microns. Plate tops 358 extend between adjacent teeth 326. As shown in Figure 3C, the widths of the valley 358 are 550 microns. In other variants, the width of the valley is 450 to 1000 microns. Cutting element 318 also includes a chamfer 334. In the embodiment shown, the bevel 334 has a 15 degree angle. The chamfer provides stress relief / equalization and facilitator assembly of the cutting elements. In the embodiment shown, the cutting elements are interchangeable, other embodiments are brazed polycrystalline diamond elements. Interchangeable tungsten carbide elements mounted adjustable holders / sleeves can be used. Referring to Figure 3D, a G2 cutting element 336 is shown having a cutting surface 338, a clearance surface 340 and a guide surface 342. The cutting surface 338 schematically includes a number of teeth 344. It should be understood that the number of teeth shown is merely an example. In some variants, the number of teeth is 1 to 2 teeth per millimeter axial length. In a variant, the number of teeth is 1.25 per millimeter axial length. Each tooth is rectangular in shape, although other shapes, such as square shapes, are possible in one or more embodiments. Each tooth has a top surface 346 and side surfaces 348. As shown in Figure 3D, the length of the top surface 346 is 250 microns and the length of the side surfaces 348 is 300 microns. In other variants, the length of the upper surface is 200 to 400 microns and the length of the side surfaces is 200 to 500 microns. A tooth 350, which is closest to the clearance surface 340, has a side surface at the outermost offset / offset from the clearance surface 340. As shown in Figure 3D, the displacement is 400 microns. In other variants, the displacement can be 0 to 500 microns. Flat valleys 358 extend between adjacent teeth 344. As shown in Figure 3, the width of the valley 358 is 550 microns. In other variants, the width of the valley is 400 to 1000 microns. The cutting element 336 also includes a chamfer 352. In the embodiment shown, the phase 352 has an angle of 15 degrees. This chamfering provides stress relief / equalization and facilitates the assembly of the cutting elements. In the embodiment shown, the cutting elements are replaceable, brazed polycrystalline diamond elements. In other embodiments, replaceable tungsten carbide elements mounted adjustable holders / sleeves may be used.
[40] In the embodiment shown, the arrangement of teeth on the G1 and G2 cutting elements is dimensioned differently. In the case of G1 shown in Figure 3C, tooth 332, which is closest to the leading edge 322, has an outermost side wall which is flush with the clearance surface 322. In the case of the G2 shown in Figure 3D, the tooth 350, which is closest to the leading edge 340, has an outermost side wall which is offset / offset from the clearance surface 340. As shown in Figure 3, the displacement is 400 microns. In other variants, the displacement can be 0 to 500 microns. Accordingly, there is an offset of 400 microns between the release edge tooth for G1 and the release edge tooth for G2. The side facing the release surface of the sixth tooth 354 of the G1 cutting element 318 and the side facing the release surface of the fifth tooth 356 of the G2 cutting element 336 are offset from each other by 550 microns. These deviating dimensions are so utilized that within each row of the cutting elements the G1 and G2 cutting elements can be axially offset from each other. The axial displacement can be, for example, 550 microns. In this embodiment it is possible for the edges to cut two separate rows of grooves, one for each displaced element, with acceptable load on the teeth.
[41] Referring to Figure 3E, there is shown a P-cutting member 362 having a cutting surface 364, a clearance surface 366 and a guide surface 368. The cutting surface 364 is flat or substantially flat, and has no teeth, unlike the cutting surfaces of G1 and G2. the cutting elements, which are shown with dashed phantom lines. The teeth shown by phantom lines in Figure 3E indicate the tooth geometry of the G1 and / or G2 cutting elements and how the cutting surface 364 is radially offset from the tooth top surfaces 328 and 346. The P cutting element 362 removes a portion of the peaks between the grooves and provides the pocket / recess. The size of the radial displacement regulates the depth of the grooves cut into the bottom of the pocket / depression shown in Figure 2B. In the illustrated embodiment, the dimension is 120 microns in Figure 3. The depth of the grooves intersected when the G1, G2 and P elements are used in combination.
[42] Figure 3F shows a cylindrical shaft 380 for mounting the cutting tool 300 in a tool holder for mounting in a machine spindle. In other embodiments, the shaft can be replaced with a direct spindle connection, such as a CAT-V or HSK cone connection.
[43] Having described the construction of the cutting tool 300 in accordance with one embodiment, the use of the cutting tool 300 for machining a profile in an inner surface of a cylinder borehole is described below. Figure 4A is a schematic horizontal projection set from above of a cylinder bore 400 in accordance with one embodiment. Figure 4B is a schematic side view of the cylinder bore 400 in accordance with one embodiment. As shown in Figure 4A, the cutting tool 300 is mounted in a machine tool spindle with a rotation axis AT parallel to the cylinder bore axis AB. The tool shaft AT is offset from the borehole shaft AB. The spindle can be either a box / packing box or a motorized spindle. The tool rotates the ice spindle around its own axis AT at an angular velocity 01 and precedes around the borehole axis AB at an angular velocity 02. This precession is referred to as circular interpolation. The interpolation motion allows the formation of a pocket / depression and annular, parallel grooves within the inner surface of a cylinder borehole. 11
[44] In one embodiment, the width / height ratio between the diameter DT of the cutting tool and the inner diameter DB of the cylinder bore is taken into account. In some variants, the inner diameter is substantially larger than the diameter of the cutting tool. In some variants, the diameter of the cutting tool is 40 to 60 millimeters. In some variants, the inner diameter of the pre-cylinder borehole is 70 to 150 millimeters. Given these dimensional differences, these cutting tools can be utilized with a significant variation in borehole diameter. In other words, the use of the cutting tools in one or more embodiments does not require a separate set of tools for each borehole diameter.
[45] With respect to the pre-drilling step of Figure 2A as identified above, a single bar / drill rod (not shown) may be connected to a machine spindle to drill a diameter smaller than the diameter of the finished / polished diameter of the inner surface. In some variants, the feed rate of the spider, i.e. the speed at which the drill rod is fed radially outwards into the inner surface, 0.1 to 0.3 mm / revolution. In one or more embodiments, the spindle is telescopic / displaceable. In other embodiments, the spindle may be fixed and the borehole may move. In another variant, the feed rate is 0.2 mm / revolution. In some variants, the rotational speed of the drill rod is 1000 to 3000 rpm. In another variant, the rotational speed of the drill rod is 2000 rpm.
[46] Regarding the interpolation step in Figure 2B as identified above, the cutting tool 300 is used to machine a profile in the inner surface of the cylinder bore 400. In some variants, the interpolation feed rate (radially outward) for the spindle during this step is 0.1 to 0.3 mm / revolution. In another variant, the feed speed is 0.2 mm / revolution. In some variants, the rotational speed of the cutting tool 300 is 3000 to 10000 rpm. In another variant, the rotational speed of the cutting tool 300 is 6000 rpm.
[47] As described above, the cutting tool 300 includes the cylindrical body 302 which includes four rows of cutting elements. According to this embodiment, the axial length of the insert is 35 mm. Accordingly, if the length of the displacement area is 105 m, three axial steps are used to complete the interpolation of the displacement area. In other words, the axial position of the spindle is set at an upper, a middle and a lower position before the cutting tool is rotated at each of the positions. Although 4 cutting element rows are shown in one embodiment, it is understood that additional rows 12 may be used. For example, 6 rows can be used to cut a similar displacement area in 2 axial steps instead of 3. Furthermore, 12 rows can be used to cut a similar displacement area in 1 axial step.
[48] Referring to Figure 4B, a fragmented portion of the cylindrical body 302 of the cutting tool 300 and cutting elements from the axial rows 304, 306, 308 and 310 are shown schematically in overlapping relationship. As described above and shown in this Figure 4B, there are overlaps 406, 408 and 410 between adjacent rows of cutting elements. This overlap helps to achieve uniform and even profile cutting in boundary areas.
[49] Figure 5 shows a fragmentary exploded view of the inner surface 500 of the cylinder bore before, during and after the interpolation step. The cutting tool 300 is fed radially outward into the inner surface of the cylinder bore at a feed speed of 0.2 mm per revolution. While the cutting tool 300 is fed into the inner surface, it is rotated at a speed of 6000 revolutions per minute. The P-pocket cutting elements cut the pocket 502 into the inner surface 500. The height of the pocket is H and the width is Wv. The H-value corresponds to the axial displacement between the valleys 358 for the G1 and G2 cutting elements 318 and 336 and the cutting surface 364 for the P-cutting element 362. In a non-limiting, specific example, the displacement is 250 microns. H is therefore 250 microns. The WV value corresponds to the length of the tooth surface 328 and 346, 356 of the G1 and G2 cutting elements 318 and 336. In the non-limiting, specific example described above, the tooth surfaces have a length of 250 microns. Accordingly, Wv is 250 microns.
[50] Track cutting elements G1 and G2 remove material 504 to create peaks 506. The height of these peaks is h and the width is WP. In the non-limiting, specific example shown, WP is 150 microns. This h-value is determined by the radial displacement between the upper part of the groove cutting elements G1 and G2 and the pocket cutting element P. In the non-limiting, specific example described above, this shift is 120 microns. Therefore, h is 120 microns. The Wv value corresponds to the length of the flat valleys intermediate groove cutting tooth surface surfaces. In the non-limiting, specific example described above, the length is 250 microns. Accordingly, Wv is 250 microns. Taking into account the rotational speed of the cutting tool 300, the cutting of the pocket and the annular grooves described above takes place simultaneously or substantially simultaneously, e.g. for a 13 time period equal to 1 / 6th of a turn for the cutting tool 300, if the cutting tool comprises six cutting elements and adjacent elements are groove and pocket cutting elements.
[51] With respect to the deformation step in Figure 2C above, a spinning tool is used to sweep over the flat peaks of selected areas between grooves. As used herein, in some embodiments, "swipe" is a means of deforming the selected areas. In one embodiment, deformation does not involve cutting or grinding selected areas. These types of processes normally involve complete or at least partial material removal. It should be appreciated that other deformation methods may be used in this step. Non-limiting examples of other secondary processes include roll / roll polishing, diamond lettering or a smoothing process in which the flank of the pocket cutting tool is used as a wiper insert. In some variants, the feed rate of the spindle during this step is 0.1 to 0.3 mm / revolution. In another variant, the feed speed is 0.2 mm / revolution. In some variants, the rotational speed of the rotating / sweeping tool 300 is 5,000 to 7,000 revolutions per minute. In another variant, a rotating / sweeping tool 300 rotational speed is 6000 rpm.
[52] Figures 6A, 6B and 6C illustrate a sweeping / spinning tool 600 in accordance with one embodiment. Figure 6A shows a horizontal projection seen from above of the sweeping / spinning tool 600. Figure 6B shows an enlarged view of area 602 of the sweeping / spinning tool 600. Figure 6C shows a side view of the sweeping / spinning tool 600 including a cylindrical shaft 604. The sweeping / spinning tool 604. The spinning tool 600 includes 4 sweeping projections 606, 608, 610 and 612. Each sweeping projection 606, 608, 610 and 612 projects outwardly from the center 614 of the sweeping / spinning tool 600. In one embodiment, the sweeping / spinning tool has the same diameter as the cutting tool and the sweeping elements have the same axial length as the cutting elements, so that the sweeping tool and the cutting tool can be moved over the same tool path to simplify programming and reduce motion errors. Each sweeping protrusion includes a clearing surface 616, a rear surface 618 and a shaving surface 620. A bevel 622 extends between the shaving surface 620 and the clearing surface 616. The phase or similar edge preparation, such as a hinge / fine grinding, is used to ensure that the tool deforms the tips instead to cut them. In one variant, the angle is 15 degrees for the chamfer 622 relative to the overlap / release surface 616. In other variants, the angle is 10 to 20 degrees or a hinge with a radius 14 of 25 to 100 microns. In one embodiment, the angle is 110 degrees between the shaving surface and the clearance surface for adjacent sweeping projections.
[53] The sweeping / spinning tool 600 is blunt enough not to cut into the inner surface of the cylinder bore. The sweeping / spinning tool 600 deforms mechanical grooves formed in the inner surface of the cylinder bore. Looking at Figure 5 again, the spinning tool 600 used in accordance with the methods identified above produced undercuts 508 and elongate the upper surface 510. As shown in Figure 5, the difference between h (the height of the non-deformed tip) and the height of the deformed tip is Ah. In one variant, Ah is 10 microns, while in other variants, Ah can be 5 to 60 microns. The undercuts increase the adhesion of a subsequent thermal spray coating on the roughened inner surface of the cylinder bore.
[54] The machined surface after the non-tracing step and the sweeping step has one or more advantages over other roughening processes. First, the adhesion strength of the metal spray can be improved by using the sweeping step instead of other secondary processes, such as diamond lettering, roller press polishing. The adhesion strength was tested using a tensile test. The adhesion strength can range from 40 to 70 MPa. In other variants, the adhesion strength may be 50 to 60 MPa. Compared to the adhesion strength of a diamond lettering process, the adhesion strength of the swiping is at least 20% higher. Furthermore, the applicant has realized that adhesion is dependent on the profile depth of the grooves after the first process step. This can be beneficial for at least two reasons. The sweeping / spinning tool cuts relative to the basic profile depth compared to conventional processes, such as diamond lettering, roller press polishing. In some variants, the reduction in profile depth is 30 to 40%. Accordingly, a smaller amount of metal spray material is to fill the profile without being necessary to simultaneously jeopardize the adhesion strength. Any variation in the depth of the grooves does not affect the adhesion strength either, which makes the sweeping step more robust than conventional processes. As another advantage of one or more embodiments, the sweeping / spinning tool can be operated at much higher operating speeds than other processes, such as roller press polishing.
[55] With respect to the interpolation step of Figure 2D above, the cutting tool 300 is used to machine non-displacement areas 214 and 216 in order to provide annular grooves. In some variants, the feed rate of the spindle during this step is 0.1 to 0.3mm / revolution. In another variant, the feed speed is 0.2 mm / revolution. In some variants, the rotational speed of the 300 cutting tool 300 is 3000 to 10000 rpm. In another variant, the rotational speed of the cutting tool 300 is 6000 rpm.
[56] These non-displacement ranges do not require a subsequent metal spray. However, single sprayers for metal spraying are normally running during the entire spraying process. If these non-ring displacement areas are not roughened, then spray metal that is accidentally sprayed on these areas will not adhere and cause delamination. This delamination can fall into the borehole during hinge and get stuck between the grindstones and borehole walls and cause unacceptable scratching. The delamination can also fall into the crankcase, which would then require removal. As such, by applying the annular grooves identified herein to the non-ring displacement areas, the thermal spray material adheres to the sub-spray process and limits the contamination of the intended spray surface and crankcase. The easily sprayed ones are easily removed during the non-ring movement areas can subsequent hinge operation.
[57] Figure 7 illustrates an enlarged cross-sectional view of the inner surface of the cylinder bore200. The non-moving surface 214 includes annular square grooves 228. The moving surface 202 includes the grooves 204 and the pocket 206.
[58] This application is related to the application having serial number 13/461 160, filed May 1, 2012, and incorporated herein in its entirety by reference. This is also related to the application that has serial number _ /, submitted. and incorporated in its entirety herein by reference.
[59] Although the best mode of practicing the invention has been described in detail, those skilled in the art to which this invention pertains will understand various alternative embodiments and embodiments for practicing the invention as defined in the following claims. Various aspects of the invention are also defined by the following. Aspect 1: a cutting tool 300 comprising a cylindrical body 302, and one or more axial rows of cutting elements 318, 336, 362 projecting in the outward direction and located radially towards the circumference of the cylindrical body, each cutting element in each row comprising a or several pocket / recess cutting elements and one or more groove cutting 16 elements, each pocket / recess cutting element comprising a cutting surface, and each groove cutting element comprising a cutting surface having groove cutting teeth. Aspect 2: the cutting tool 300 according to aspect 1, wherein the height of the groove cutting teeth is higher than the height of the pocket / recess cutting teeth with a non-zero offset h ("nonzero offset h"). Aspect 3: the cutting tool 300 according to aspect 1, wherein the axial cutting elements are substantially evenly distributed radially spaced apart. Aspect 4: the cutting tool 300 according to aspect 1, wherein the one or more axial rows of cutting elements comprise two or more axial rows of cutting elements. Aspect 5: the cutting tool 300 according to aspect 4, the width of each of the two or more axial rows of cutting elements overlapping adjacent axial rows of cutting elements. Aspect 6: the cutting tool 300 according to aspect 4, wherein the two or more axial rows of cutting elements comprise first and second axial rows of cutting elements, each row having an array of groove and pocket / recess cutting elements axially offset by a cutting element. Aspect 7: the cutting tool 300 according to aspect 1, wherein the axial rows of cutting elements comprise three or more cutting elements. Aspect 8: the cutting tool 300 in accordance with aspect 7, the three or more cutting elements comprising a pocket / recess cutting element 362 and two groove cutting cutting elements 318, 336. Aspect 9: the cutting tool 300 according to aspect 8, the two groove cutting cutting elements 318, 336 are close to each other. Aspect 10: the cutting tool 300 according to aspect 1, the groove cutting surface comprising flat valley portions between the pocket / recess cutting teeth. Aspect 11: the cutting tool 300 according to aspect 1, the upper surfaces of the groove cutting teeth being offset radially from the top surface of the groove. the pocket / recess cutting element with a non-zero value h ("nonzero value h"). Aspect 12: the cutting tool 300 according to aspect 1, wherein the groove cutting teeth comprise a pair of side walls which are substantially parallel to each other and a top surface which is substantially perpendicular to the pair of side walls. Aspect 13: the cutting tool 300 according to aspect 1, wherein the cutting elements are made of a material having a stiffness higher than an aluminum or magnesium alloy. Aspect 14: the cutting tool 300 according to aspect 1, wherein the pocket / recess and groove cutting surfaces are tangential to the surface of the cylindrical body. Aspect 15: the cutting tool 300 according to aspect 1, wherein the diameter of the inner surface of a cylinder bore cut by the cutting tool is considerably larger than the diameter of the cutting tool. Aspect 16: a cutting element of a cutting tool 300 and 17 comprising a body having a cutting surface and a tapered / conical surface extending inwardly from the cutting edge, the cutting edge comprising a series of rectangular cutting teeth, the body being made of a tool material suitable for machining an aluminum or magnesium alloy and the series of rectangular cutting teeth cut grooves in the aluminum or magnesium alloy. Aspect 17: a cylindrical borehole comprising an inner surface comprising an axial displacement region and an axial non-displacement region; and a plurality of annular grooves 204, 228 formed in the axial non-displacement region. Aspect 18: cylindrical borehole according to aspect 17, wherein the nominal diameter of the axial displacement region is larger than the diameter of the axial non-displacement region. Aspect 19: cylindrical borehole according to aspect 17, wherein the axial non-displacement region includes two discontinuous axial widths of the cylindrical borehole and the axial displacement region extends therebetween. Aspect 20: cylindrical borehole according to co-aspect 17, wherein the width / height ratio of the depth of the annular grooves 204, 228 relative to the width of the annular grooves is 0.5 or less.

权利要求:
Claims (10)
[1] 1. l. A cutting tool (300) comprising: a cylindrical body (302) having a cvlindrical surfaatle and a longitudinzil axis =".;='ï¿~.¿_)¿~__; and one or more axial rows__( outwardly from and situated radially to the t". > ~ . >. (cyligjgdgjiggalnsgriagggof the cylindrical body each of the axial rovvs intersecting the circumference of a circle along the cvlindrical hodv *._ .~ -, =,>.=_.~_.,= surface and normal to the longitudihal axis of tlie cvflindrical bodv, each cutting element of each M * row including one or more pocket cutting elements (rg/gwand one or more groove cutting elementsíjgšnsn, each pocket cutting element including a cutting surfacegífš; =É=, and each groove cutting element including a cutting surface
[2] 2. The cutting tool (300) of claim l, wherein the height of the groove cutting teethí is greater than the height of the pocket cutting teeth by a nonzero offset w x
[3] 3. The cutting tool (300) of claim l, wherein the axial cutting elements5§;;,jj§' are substantially equally radially spaced apart from each other.4. The cutting tool (300) of claim l, wherein the one or more axial rows of cutting
[4] 4. Ni. elementsjiß ~ . includes two or more axial rows of cutting elements. 'ä*a
[5] 5. The cutting tool (300) of claim 4, wherein the width of each of the two or more axial - rows of cutting elements ~ »f å.. i...- overlaps adjacent axial rows of cutting elements.
[6] 6. The cutting tool (300) of claim 4, wherein the two or more axial rows of cutting q.- elementswí: rg include first and second aXial rows of cutting elements, each having the same sequence of groove and pocket cutting elements, axially offset by one cutting element.
[7] 7. The cutting tool (300) of claim l, wherein the axial rows of cutting elementsjl, _.
[8] 8. The cutting tool (300) of claim 7, wherein the three or more cutting elements ginclude one pocket cutting element (362) and two groove cutting elements (3l8, 336).
[9] 9. The cutting tool (300) of claim 8, wherein the two groove cutting elements are adjacent to each other (3 l 8, 336).
[10] 10. l0. The cutting tool (300) of claim l, wherein the groove cutting surface includes ﬂat valley portions between the pocket cutting teeth.

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法律状态:
2021-10-05| NUG| Patent has lapsed|

优先权:

申请号 | 申请日 | 专利标题

US13/913,865|US9511467B2|2013-06-10|2013-06-10|Cylindrical surface profile cutting tool and process|

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