Manufacturing of holemaking tools

Abstract

A process for producing a tool having a main body which extends in a longitudinal direction and at least one blade for machining a workpiece includes providing a base coating on the tool; grinding the at least one blade in a manner that removes the base coating in the region of the at least one blade; and providing a second, fine coating, to the at least one ground blade.

Claims

1. A process for producing a tool having a main body which extends in a longitudinal direction, at least one blade for machining a workpiece, and at least one flute associated with the at least one blade, the process comprising: grinding a coated body having a base coating disposed therein in a manner that removes the base coating in a region of the coated body, wherein grinding the coated body comprises one of: a) providing the coated body having at least one preformed blade and at least one preformed flute, each of the preformed blade and the preformed flute having the base coating disposed thereon, and then grinding the at least one preformed blade in a manner that removes the base coating in a region of the at least one preformed blade including a clearance face of the at least one preformed blade and a flute wall of the at least one preformed flute to form at least one ground blade and at least one ground flute; or b) grinding the coated body in a manner which substantially concurrently 1) forms at least one ground blade having a clearance face and at least one ground flute having a flute wall; and 2) removes the base coating in the region of the at least one ground blade the clearance face of the at least one ground blade, and the flute wall of the at least one ground flute; and providing a second coating to the at least one ground blade.

2. The process of claim 1 wherein: grinding the coated body comprises grinding the coated body in a manner which substantially concurrently 1) forms the at least one ground blade having a clearance face and at least one ground flute having a flute wall; and 2) removing the base coating in the region of the at least one ground blade, the clearance face of the at least one ground blade, and the flute wall of the at least one ground flute.

3. The process of claim 1 wherein the second coating has a smaller layer thickness than the base coating.

4. The process of claim 3 wherein the second coating layer has a layer thickness smaller than the base coating by a factor in the range of 2-10.

5. The process of claim 3 wherein the second coating layer has a layer thickness in the range of 1-2 m.

6. The process of claim 1 wherein: the base coating is applied with the aid of physical vapor deposition; and the second coating is applied with the aid of physical vapor deposition.

7. The process of claim 1 wherein the tool is a rotational tool.

8. The process of claim 1 wherein: the tool is a drilling/reaming tool; the at least one blade comprises at least one reaming blade; the coated body comprises on an end face, a drilling tip with at least one main drilling blade; and grinding the coated body removes the base coating in the region of the reaming blade without removing the base coating in a region of the at least one main drilling blade.

9. The process of claim 1 further comprising, prior to grinding the coated body: grinding a blank to a desired size; grinding main drilling blades and main chip flutes in the blank; and providing the base coating on the blank to form the coated body.

10. The process of claim 9, wherein grinding the coated body does not remove the base coating in the region of the main chip flutes.

11. The process of claim 1, wherein the base coating has a hardness that is greater than a hardness of the main body.

12. The process of claim 11, wherein the main body comprises carbide.

13. The process of claim 1, wherein a coating material of the base coating is the same as a coating material of the fine coating.

14. The process of claim 1, wherein a coating material of the base coating differs from a coating material of the fine coating.

15. The process of claim 1, wherein providing the second coating to the at least one ground blade is performed after grinding.

16. The process of claim 3, wherein the base coating layer has a layer thickness in the range of 5-15 m.

17. A process for producing a tool for machining a workpiece, the tool having a main body which extends in a longitudinal direction, the process comprising: grinding at least one drilling blade and at least one main chip flute in a blank to form a body; providing a base coating on the body to provide a coated body, the base coating having a first layer thickness; grinding at least one reamer blade and at least one reamer chip flute in the coated body, thereby removing the base coating in a region of the at least one reamer blade and not removing the base coating in a region of the at least one drilling blade; and providing a second coating to the at least one reamer blade, the second coating having a second layer thickness, wherein the second layer thickness is smaller than the first layer thickness.

18. The process of claim 17 further comprising providing the second coating to the at least one drilling blade such that the at least one drilling blade is provided with the base coating and the second coating disposed on the base coating.

19. A process for producing a tool having a main body which extends in a longitudinal direction, the process comprising: grinding at least one drilling blade and at least one reamer blade into a blank to form a body; providing a base coating on the body to form a coated body, the base coating having a first layer thickness; and grinding the coated body in a region of the at least one reamer blade to remove the base coating from the region of the at least one reamer blade; and providing a second coating to the coated body such that at least the region of the at least one reamer body is coated with the second coating, the second coating having a second layer thickness, wherein the second layer thickness is smaller than the first layer thickness.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Exemplary embodiments of the invention are explained in more detail below on the basis of the figures in which, partly in a simplified representation:

(2) FIG. 1 shows a side view in the form of a detail of a drilling/reaming tool;

(3) FIG. 2 shows a perspective representation in the form of a detail of a drilling/reaming tool;

(4) FIG. 3 shows an end view of a drilling/reaming tool;

(5) FIG. 4 shows a side view in the form of a detail of a second variant of the embodiment of a drilling/reaming tool;

(6) FIG. 5 shows a schematic side view of a further variant of the embodiment;

(7) FIG. 6 shows a schematic sectional view in the region of a drilling blade with an applied base coating and fine coating; and

(8) FIG. 7 shows a schematic sectional view in the region of a reaming blade with an applied fine coating.

(9) In the figures, parts which have the same effect are provided with the same reference numerals.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(10) A drilling/reaming tool 4, which extends in the longitudinal direction 2, hereafter tool for short, has a main body 6, which extends in the longitudinal direction 2 and incorporated in which are main chip flutes 8, two in the exemplary embodiment, which are spiraled at a first twist angle 1. In the forward region, the tool 4 has a reaming head 10. On its end face, the reaming head 10 is formed as a drilling tip 12, which in the exemplary embodiment has two main blades 14 (cf. FIG. 3), which are joined to one another in the drilling center by way of a center line 16. In the circumferential direction, the respective main blade 14 is adjoined by a clearance face 18, which in the exemplary embodiment is formed like the envelope of a cone, respectively extends up to the main chip flute 8 and is assigned to the next following main blade 14. The fluted region of the main body 6 is additionally adjoined by a shank (not represented), by which the tool 4 is clamped in a tool receptacle of a machine tool.

(11) Defined between the main chip flutes 8 is a heel 20, in which a number of reaming blades 22 are formed circumferentially in the forwardmost region, directly adjoining the drilling tip 12, in the region of the reaming head 10. As can be seen in particular from FIGS. 1 and 2, the reaming blades 22 are arranged set back somewhat in the longitudinal direction 2 from the clearance face 18 in the form of an envelope of a cone. The axial offset 1 between the radially outermost end of the main blade 14 and the first reaming blade 22 in this case lies in the range of only a few mm, that is to say a fraction (less than 20%) of a nominal diameter D of the tool 4.

(12) The reaming blades 22 respectively extend substantially in an approximately radial direction and are oriented approximately perpendicularly in relation to the longitudinal direction 2. The reaming blades 22 here define the nominal diameter D of the tool 4. All of the reaming blades 22 lie in this case on the same nominal diameter D. In contrast, the main blades 14 of the drilling tip 12 reach only up to a drilling diameter d, which is slightly less than the nominal diameter D. The nominal diameter D is in this case typically approximately 0.2 to 1 mm greater than the drilling diameter d.

(13) Each reaming blade 22 is assigned a reaming flute 24, which is incorporated in the main body 6 and embodied in a spiraled manner at a second twist angle 2. A respective reaming blade 22 is respectively adjoined by a secondary reaming blade 26, which is made to run along the respective reaming flute 24. Correspondingly, a main secondary blade (not represented any more specifically here) is also provided adjoining a respective main blade 14.

(14) As can be seen in particular from FIG. 1, the two twist angles 1, 2 are formed differently; the chip flutes 8, 24 therefore do not run parallel to one another. In the exemplary embodiment of FIGS. 1 to 3, it is in this respect provided that the first twist angle 1 of the main chip flutes 8 is much greater than the second twist angle 2 of the reaming flutes 24. In the exemplary embodiment, the first twist angle 1 lies approximately in the range of 30 and the second twist angle 2 lies approximately in the range of approximately 10. Generally, the two twist angles differ approximately by a factor in the range of 2-4.

(15) This measure achieves the effect in the case of the exemplary embodiment of FIGS. 1 to 3 of a configuration in which the individual reaming flutes 24 open out into the respective main chip flute 8, and therefore these intersect as it were. On account of the spiraling, this takes place with different axial lengths. The axial length L of the reaming head 10 is in this case defined by the forwardmost region of the drilling tip 12, therefore in the exemplary embodiment the center line 16, and in the rearward part by the end of the longest reaming flute 24, and therefore when the latter goes over into the main chip flute 8. The axial length L of the reaming head 10 in this case preferably lies in the range of 2 to 3 times the nominal diameter D.

(16) As a difference from the one-piece tool 4 according to FIGS. 1 to 3, the second variant of the embodiment according to FIG. 4 is also formed in particular for modular tools 4, in which the reaming head 10 may for example be inserted as an exchangeable wearing part into the main body 6. Alternatively, the reaming head 10 is irreversibly fastened in the main body 6, for example by brazing. In the case of this variant of the embodiment, the reaming flutes 24 all end at an identical axial length, which at the same time defines the axial length L of the reaming head 10.

(17) As can be seen from FIG. 4, the reaming head 10 has a greater diameter than a rearward part of the main body 6 adjoining the reaming head 10. Therefore, a set-back offset 28 is formed between the reaming head 10 and this rearward part. The radial depth t of the offset 28 is in this case greater than or equal to the radial depth of the respective reaming flutes 24. In particular, the radial depth t lies approximately in the range of 0.3 to 2 mm and is generally a fraction of the nominal diameter (for example approximately 2-6% of the nominal diameter D).

(18) In the exemplary embodiment of FIG. 4, it is additionally provided that the second twist angle 2 is greater than the first twist angle 1, and therefore the reaming flutes 24 do not run toward the main chip flutes 8 and therefore do not intersect them either.

(19) Both variants of the embodiment have in common that, during operation in which the tool 4 rotates about the longitudinal direction 2, reaming chips generated by the reaming blades 22 are carried away in the reaming flutes 24 and transferred into the main chip flutes 8. In the case of the exemplary embodiment of FIGS. 1 to 3, this takes place due to the reaming flutes 24 opening out directly into the main chip flutes 8. In the case of the exemplary embodiment of FIG. 4, this takes place indirectly by way of the clearance 30, which is defined by the offset 28 and during operation forms an annular space in relation to the wall of a drilled hole. The reaming chips enter this annular space at the end of the reaming head 10, when they emerge from the reaming flute 24. The continuing rotation of the tool 4 has the effect that they subsequently pass into the respective main chip flute, and therefore are taken along by the latter for further chip removal.

(20) The particular advantage of the configuration described here can be seen in the fact that the reaming chips, which are much smaller in comparison with the main chips generated by the main (drilling) blades 14, are only carried in the reaming flutes 24 over a very short axial length and are subsequently carried away further in the much larger main chip flutes 8 together with the main chips. As a result, an effective transporting away of the chips is achieved. In particular in the case of great axial lengths of the tool, for example in the case of tools with an axial length greater than 4 to 5 times the nominal diameter D, the risk of a chip buildup in the reaming flutes 24 is avoided. Also avoided in particular is the risk that the reaming chips become caught between the secondary reaming blades 22 and the wall of the hole, and consequently damage the machined wall of the hole.

(21) In particular, long tools 4 such as these often have the tendency to chatter, as it is known, i.e. the tool vibrates unwantedly during operation, which results in undesired chatter marks on the wall of the hole.

(22) In order to minimize this chattering tendency as much as possible, an uneven division of the reaming blades 22 is provided. In the exemplary embodiment, one way of achieving this purpose is for the number of reaming blades on the two heels 20 to be different, which is assisted by different lengths (in the circumferential direction) of the heels 20. The angular distance between successive reaming blades 22 is preferably different from one another and reaming blades 22 that are assigned to one another, that is to say for example the first reaming blades 22 in each case following the respective main blade 14, are not arranged exactly opposite one another (at an angle of 180). Another way that is provided in the exemplary embodiment is that of an uneven division of the main blades 14, i.e. these too are arranged in relation to one another at a rotational angle different from 180.

(23) In the exemplary embodiment of FIG. 3, beginning from the respective main blade 14, the heels extend up to the beginning of the chip flute over an angular portion 8. In the exemplary embodiment, the angle 8 for the larger heel 20 is at approximately 115 and that of the smaller heel is at approximately 85. Four reaming blades 22 are provided on the longer heel and three reaming blades 22 are provided on the shorter heel.

(24) In order to achieve a uniform loading of the reaming blades 22, it is also provided that the first reaming blade 22 following the respective main blade 14 is arranged offset rearwardly with respect to the second reaming blade 22 by an axial offset 2 (cf. FIG. 1). This offset 2 with respect to the axial height of the next following reaming blade 22 in this case lies approximately in the range of 0.005 to 2 mm. In FIG. 1, this offset is only indicated for exemplary purposes and is not true to scale. As a result, the machining performance that can be provided when the first reaming blade 22 is used in the way intended is reduced and adapted to that of the next-following reaming blade 22. On account of the main chip flute 8 preceding the first reaming blade 22, the reaming blade 22 would otherwise have to provide a much greater machining performance for a defined advancement. The axial offset 2 is in this case chosen in particular in such a way that, when there is an advancement as intended, for which the tool 4 is designed, the machining performances of the reaming blades 22 are largely identical. The next-following reaming blades 22 are preferably located at the same axial height.

(25) For a high machining performance, a cooling is also provided in the exemplary embodiment. For this purpose, incorporated in the main body 6 are cooling channels 31, which run in the solid material of the respective heel 20. The cooling channels emerge at end-face first openings 32 on the end face of the drill tip 12. In the region of the reaming head 10, branch channels or bores (not represented any more specifically) lead from the cooling channels into the respective reaming flutes 24 and emerge there at second openings 34 in the flute base of the respective reaming flute 24 (cf. FIG. 2).

(26) Schematically represented in FIG. 5 is a further variant of the embodiment, in which the main chip flute 8 and the reaming flutes 24 are oriented oppositely in relation to one another, i.e. the main chip flute 8 is oriented at a positive first twist angle 1 and the reaming flutes 24 are oriented at a negative second twist angle 2. Such a variant of the embodiment is used for workpieces with, for example, precast through-bores. During operation, the reaming chips are conveyed forward toward the drill tip, whereas the drilling chips are carried away rearward in the main chip flute 8.

(27) The tools 4 represented in FIGS. 1 to 5 are preferably provided with a wear coating. By using a special process for this, the wear coating is formed differently in the region of the drilling tip 12 than in the region of the reaming head 10, at least in the region of the reaming blades 22. This is explained in more detail below in conjunction with FIGS. 6 and 7. FIG. 6 shows here a schematic sectional representation in the region of a main blade 14, the sectional plane being defined by a first straight line, which runs parallel to the longitudinal axis 2 and intersects the main blade 14 (center axis), and by a second straight line, which is oriented perpendicularly in relation to the first line and perpendicularly in relation to the main blade 14. FIG. 7 shows a comparable sectional representation in the region of a reaming blade 22. In a way similar to in the case of FIG. 6, the sectional plane is defined by a first straight line, which runs parallel to the longitudinal axis 2 and intersects the reaming blade 22, and by a second straight line, which runs perpendicularly in relation to the first line and in relation to the reaming blade 22.

(28) Both FIGS. 6 and 7 show a cutting wedge 36 of the main body 6 that is formed on the respective blade 14, 22. The region represented in the figures merely serves for illustration of the wear coating and is not a representation of the wedge angle that is true to scale.

(29) As can be seen from FIGS. 6 and 7, the main blade 14 is provided with a layered structure comprising two layers, built up consisting of a base coating 38 and an outer fine coating 40. By contrast, in the region of the reaming blade 22, only the fine coating 40 is provided. The base coating 38 has in this case a first layer thickness g, which preferably lies in the range of 5 to 15 m. By contrast, the fine coating 40 has a much smaller layer thickness f, which lies only in the range of 1 to 2 m. In the region of the main blade 14, the entire layered structure therefore has a layer thickness which is made up of the two layer thicknesses g and f.

(30) On account of the greater layer thickness g in the region of the main blade 14, a rounding formed by the coating 38, 40 has a greater radius R1 than the corresponding radius R2 of the rounding in the case of the reaming blade 22. Usually, in the case of the thicker coating there also additionally forms a thickening in the manner of a lug, which tends to peel off when loading becomes relatively high. This risk would exist in particular in the region of the reaming blades 22.

(31) To form the different layers, the following procedure is preferably followed in production:

(32) Initially, the main body 6 is formed with the main chip flutes 8 and with the drilling tip 12, that is to say with the main blades 14 and the center line 16 and also the clearance faces 18. The drilling tip 12 is in this case generated by grinding from solid material. In the second step, a carbide coating is applied as a base coating 38, with the aid in particular of a PVD process. This base coating 38 has in this casein a way similar to the fine coating 40a hardness that is greater in comparison with the material of the main body 6. The main body 6 preferably consists of solid carbide.

(33) In the subsequent process step, the entire region of the reaming head 10 is formed by grinding. Therefore, both the reaming blades 22 and the reaming flutes 24 and also the assigned secondary reaming blades 26 are formed. In the region of the respective reaming blades 22, therefore, both a reaming flute wall 42 and an assigned reaming clearance face 44 are also ground in particular during the grinding operation (cf. FIG. 7).

(34) The grinding of the complete reaming head 10 has the effect of removing the base coating 38 again. The base coating 38 is also ground away circumferentially in the region of the heels between the individual reaming flutes 24. The base coating 38 is retained in the remaining regions, as is indicated by the hatching in FIG. 2. The hatching therefore indicates in particular the regions with the complete coating, made up of the base coating 38 and the fine coating 40. The base coating 38 therefore remains in the region of the main blade 14, the main secondary blade adjoining thereto, the main chip flute 8, the heel 20, and the clearance face 18. In the region of the face edge, in which the main blade 14 ends and the main secondary blade adjoins, the base coating 38 is likewise also retained in the circumferential region (heel) up to the first reaming flute 24.

(35) In the next step, the fine coating 40 is applied once again with the aid of a PVD process, so that the ground-free areas of the reaming head 10, in particular in the region of the reaming blade 22, are only provided with the fine coating 40. In the case of the PVD application process, preferably the entire main body 6 provided with the main chip flutes 8 is coated, so thatapart from the ground-free areas in the region of the reaming head 10the layered structure represented in FIG. 6 consisting of the base coating 38 and the fine coating 40 is formed everywhere, as is represented by the hatching in FIG. 2. The coating materials of these two coatings may be both identical and different. In the case of identical material, it is usually not possible to distinguish between the two layers, or at least only with difficulty. On account of the production process, an increase in the layer thickness from the layer thickness f to the combined layer thickness f+g is found in the transitional region between the ground-free areas and the adjoining areas. The increase in the layer thickness usually takes place here continuously within a narrowly limited range.

(36) While specific exemplary embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to the details provided herein could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.