CN101720365A - 带涂层的切削工具 - Google Patents

带涂层的切削工具 Download PDF

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CN101720365A
CN101720365A CN200880016247A CN200880016247A CN101720365A CN 101720365 A CN101720365 A CN 101720365A CN 200880016247 A CN200880016247 A CN 200880016247A CN 200880016247 A CN200880016247 A CN 200880016247A CN 101720365 A CN101720365 A CN 101720365A
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cutting tool
layer
coating
thickness
rake face
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CN101720365B (zh
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D·奎因托
C·沃尔拉布
J·拉姆
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Oerlikon Surface Solutions AG Pfaeffikon
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OC Oerlikon Balzers AG Truebbach
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B27/00Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14Cutting tools of which the bits or tips or cutting inserts are of special material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B5/00Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor
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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
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  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Physical Vapour Deposition (AREA)
  • Chemical Vapour Deposition (AREA)
  • Drilling Tools (AREA)

Abstract

本发明提供了带有单层或多层PVD涂层的尖锐切削刃切削工具,其可以同时表现出令人满意的磨损和热化学抗性以及对刃口剥落的抗性。切削工具包括由烧结碳化物、CBN、金属陶瓷或陶瓷材料制成的烧结体,其具有刃口半径为Re的切削刃、侧刀面和前刀面、以及覆盖至少部分烧结体表面的多层涂层,所述多层涂层由包含至少一层氧化PVD层的PVD涂层构成。在一个实施方案中,刃口半径Re小于40μm,优选小于或等于30μm。所覆盖的部分表面优选包含烧结体的尖锐切削刃的至少某些部分。

Description

带涂层的切削工具
技术领域
本发明涉及由下列制成或包括下列的带涂层锐边切削工具领域:烧结体,其包含至少硬质材料和粘合剂材料,其中所述烧结体已经在形成所述烧结体的温度和压力下被烧结。切削工具包括例如,用于铣削的工具(铣削工具)、车削工具、分度镶刃(indexable insert)、齿轮切削工具、齿轮滚铣刀(hob)、带柄类型工具、螺纹成形工具(tool forthreading)、攻丝工具(tapping tool)。
背景技术
利用过去和目前的粉末冶金学烧结技术,烧结碳化物切削工具已经被用于无涂层条件和CVD(化学气相沉积)和PVD(物理气相沉积)涂层条件。CVD涂层工艺,包括MT-CVD(适温CVD或中温CVD)涂层工艺,需要高温,通常对于HT-CVD(高温CVD)超过950℃,或者对于MT-CVD在800℃和900℃之间,以及化学腐蚀性工艺氛围。尤其是,这具有关于下列方面的缺点:切削工具的横断裂强度(TRS)和低刀口强度,以及无法避免的涂层的热裂纹。
下面以烧结碳化物涂层为例给出了关于HT-CVD缺点的更详细描述:
a)如前所述,基材TRS的降低可能是由于下列事实:在涂层之前表面的状态是由于正确研磨工艺所诱导的残余压应力状态,这是有利的;这种状态被高温所改变,其中高温会释放这种有利的残余压应力。因此,和涂覆无关,高温退火对于碳化物基材具有这种作用。然而,即使基材没有被适当研磨-例如,如果其被进行“过度研磨”,这会留下残余拉伸应力或者甚至某些表面裂纹-高温处理基本上没有有利的效果。
b)带涂层的工具的TRS的进一步减小来自于热裂纹的出现,这是由于在从高CVD温度冷却时涂层和基材之间的热膨胀配合不当所诱导的。裂纹会贯穿涂层的厚度,因此能够引起在某些切割条件下的疲劳失效。
c)在WC-Co硬质金属的情况中,还已知在大约850℃及更高的温度下,钴会朝表面扩散,这同样与CVD工艺过程中的脱碳和η相的形成相关。这类η相可以例如通过在TiC或TiCN CVD第一层的起始形成中基材的外部区的脱碳而形成,其中所述第一层是CVD Al2O3涂层的常用底层。η相区形成高多孔性的脆化层,同样造成了微开裂起始位点以及涂层的分层倾向。HT-CVD的至少该缺点已经被MT-CVD所克服,例如通过在大约850℃施加第一TiCN层,由此使得基材η相形成最小化。
因此,已经采取了不同的措施减少这些不利的影响。US 4,610,931建议使用烧结碳化物体,其在外周表面附近具有粘合剂富集。在US5,266,388和US 5,250,367中已经建议将处于残余拉伸应力状态的CVD涂层,之后是处于残余压应力的PVD涂层应用于所提到的富集粘合剂的工具。
尽管上面已经用烧结碳化物举例说明了CVD涂覆工艺的缺点,但从其他具有烧结体的基材也已经知道了相同或至少相似的问题。金属陶瓷也具有Co、Ni(和其他金属如Mo、Al...)粘合剂,并且经历了与烧结碳化物相似的烧结工艺。TiCN-基金属陶瓷如今例如不是容易进行CVD涂覆的,因为这些基材与涂覆气体物种(species)反应性更强,这造成了在界面的不期望的反应层。超硬的CBN工具使用与用于碳化物和金属陶瓷所不同的高温高压烧结技术。然而,它们也可具有金属粘合剂例如Co、Ni...,其倾向于在CVD涂覆工艺过程中的高温反应。这些基材有时被PVD涂覆以TiN、TiAlN、CrAlN或其他主要用于在切削刃口处指示磨损的涂层***。然而,这些涂层仅能够提供有限的对抗高温和高氧化应力的保护,其中所述高温和高氧化应力例如是由于现有技术中车床所采用高切削速度造成的。
引入玻璃相作为粘合剂的基于固体Al2O3、Al2O3-TiC或者Al2O3-Si3N4(SiAlON)的陶瓷工具材料,代表另一种工具类型:这些工具是电绝缘的,并因此同样难以利用传统PVD进行涂覆。这些材料是被烧结-HIP的(HIP:热等静压),这与低压烧结的碳化物不同。这些陶瓷镶刃同样不能进行CVD涂覆,因为高温能够造成Si3N4基材的软化,或者使其由于非晶态玻璃粘合剂相变成晶体而损失一些韧性。然而,无涂层材料能够允许在金属切削过程中在它们粘合剂相和工件材料之间发生相互作用,因此易于形成磨损凹陷(cratering wear),这将这类工具的用途限制到了有限的适当应用。
因此,对于高度需要工具韧性或对几何形状有特殊需求的许多操作,PVD涂层已经部分甚至完全替代了CVD涂层。这些工具的例子是用于断续切削应用如铣削工具或特别是锐边螺纹形成工具和攻丝工具。然而,由于突出的热化学抗性和热硬度,氧化CVD涂层例如α-和/或γ-晶体结构Al2O3或者包含这些涂层的厚多层仍然被广泛应用,特别是用于所有类型材料的中车削-粗车削、分型和开槽应用,并且在铸铁的车削上几乎是独用。直到近来,这些涂层都不能通过PVD工艺产生,这是因为与电绝缘材料特别是氧化涂层相关的主要工艺限制。
正如本领域技术人员公知的,上述所有问题都倾向于出现和集中于随着切削刃半径越小切削刃变得越尖锐。因此,为了避免带CVD涂层的工具出现刃口剥落或破裂,对于切削刃和工具尖端必需考虑额外的几何限制,其中例如,对于烧结碳化物而言切削刃限制为最小半径为40μm。另外,通常使用进一步的措施例如将倒角(chamfer)、水帘(waterfall)、擦拭器或其他特殊的几何形状应用到切削刃的间隙侧刀面(clearance flank)、前刀面或者两面,但通常为生产烧结工具基材增添了另外的处理起来复杂的生产步骤。
发明内容
因此,本发明的目标是提供带单层或多层PVD涂层的锐边切削工具,其可以同时表现令人满意的耐磨性和热化学抗性,以及对刃口剥落的抗性。切削工具包括由烧结碳化物、CBN、金属陶瓷或陶瓷材料制成的烧结体,其具有刃口半径(edge radius)Re的切削刃、侧刀面和前刀面;和单层或多层涂层,所述单层或多层涂层由包含至少一个氧化性PVD层的PVD涂层构成并覆盖所述烧结体表面的至少部分。
在一个实施方案中,刃口半径Re小于40μm,优选小于或等于30μm。所覆盖的表面部分包含烧结体的锐边的至少一些部分。需要提到的是,如果在工具锐化之后不应用任何后处理如搪磨(honing)或钝化等,则等于或者甚至小于20μm的刃口半径Re可以在烧结工具上被构建。同样,这些工具可以被有利地涂覆上氧化PVD涂层,因为对涂覆工艺没有任何有害影响并且不会发生切削刃的弱化。
该涂层不存在热裂纹并且不含任何卤化物或者其他源自CVD工艺气体的污染。另外,涂层或至少氧化PVD层可以不含惰性元素例如He、Ar、Kr等。这可以通过在纯活性气体氛围中的真空电弧沉积(vacuumarc deposition)而实现。作为多层涂层的例子,粘附层和或硬、磨损保护层的沉积可以在氮气氛围中开始,接着是特征在于不断增加的氧气流的工艺步骤以产生朝向氧化涂层的梯度,其伴随或者之后是氮气流的下降或关闭。在阴极电弧靶的表面面积上施加小垂直磁场可能在高度绝缘靶表面(例如通过在纯氧气氛围下由电弧工艺形成的)的情况下是有利的。如何进行这类涂层工艺的详细指导可见于申请WO 2006-099758、WO 2006-099760、WO 2006-099754以及在CH 1166/03中,通过引用将它们并入作为本文实际公开内容的一部分。
优选所述氧化层引入了电绝缘氧化物,其包含选自元素周期表中IV、V、VI族过渡金属和Al、Si、Fe、Co、Ni、Y、La的组的至少一种元素。(Al1-xCrx)2O3和Al2O3是这类材料的两种重要的例子。这类氧化物的晶体结构可以变化,并且可以包含立方或六方晶格如阿尔法(α)、贝塔(β)、伽马(γ)、德尔塔(δ)相或尖晶石结构。例如,包含不同氧化物膜的氧化物层可以被施加于所述工具。尽管多层式涂层可以包含在不同元素或化学计量组成的所限定层之间具有尖锐或梯度转移区的所提到元素的氮化物、碳氮化物、氧氮化物(oxinitrides)、硼化物等,但需要提到的是针对高温和/或高氧化应力的最佳保护可以仅仅通过包含由基本上纯的氧化物组成的至少一层的涂层来确保。
就形成热动力学稳定相而言,刚玉型结构将是氧化层的优选实施方案,其中所述刚玉型结构例如可以是Al2O3、(AlCr)2O3、(AlV)2O3型的,或者更通常是(Me11-xMe2x)2O3型的,其中0.2≤x≤0.98,Me1和Me2是选自Al、Cr、Fe、Li、Mg、Mn、Nb、Ti、Sb、V组的不同元素。关于如何形成这类刚玉型单层或多层结构的详细指导可以见于申请CH01614/06,通过引用将该申请并入本文。
在本发明的实施方案中,涂层包括直接位于体表面上的粘附层,和/或位于所述体和氧化层之间或者位于两层或更多层连续氧化层之间和/或位于涂层顶部的至少一层硬质磨损保护层。其中的粘附层以及磨损保护层优选包含选自元素周期表中IV、V、VI族过渡金属和Al、Si、Fe、Co、Ni、Y、La的组的至少一种元素。磨损保护层的化合物将进一步包含N、C、O、B或其混合物,其中优选N、C和CN。这些磨损保护层的例子是TiN、TiC、CrN、CrC、TiAlN、CrAlN、TiCrAlN以及TiCN、CrCN、TiAlCN、CrAlCN和TiCrAlCN。
粘附层的化合物可以包含N、C、O或其混合物,其中优选N和O。这类粘附层的例子是TiN、CrN、TiAlN、CrAlN、TiCrAlN或TiON、CrON、TiAlON、CrAlON、TiCrAlON。该粘附层的厚度优选是0.1-1.5μm。如果粘附层包含直接位于体表面的薄金属层,则对于最佳的工具-涂层结合而言,金属层的厚度应该是10-200nm。这类金属中间层的例子是Ti、Cr、TiAl或CrAl。涂层的整个厚度应该是2-30μm,而在大多数情况中,由于涂层工艺的经济性原因,该厚度应该是3-10μm。然而,应该指出,原则上能够提供具有甚至更厚涂层的工具,如果对于某些特殊应用需要的话,例如其可以是对铸铁的高速车削。
本发明的另一个实施方案可以包括磨损保护层,其含有至少一种组成偏析膜(composition-segregated film),所述膜包含具有相对高浓度的特定元素(所述元素促进晶体结构发生相偏析)如Si或B的相,以及具有相对低浓度所述特定元素的相。在一个实施方案中,具有相对高浓度所述特定元素的相构成了无定形相或微晶相。所述膜优选包含Cr和Si组合或Ti和Si组合的氮化物或碳氮化物。
根据实际需要,所有层都可以被沉积上形成尖锐的或梯度的层间过渡区的涂层,所述涂层显示出离散的或梯度的层结构。层的厚度可以从数微米至数纳米中选择,如果这些结构对于特定应用应该是优选的话。
与包含氧化性CVD层的切削工具不同,这些PVD涂层的工具不需要富含粘合剂的基材以最小化CVD工艺对烧结体TRS(横切断裂强度)的不利影响。PVD工艺的低工艺温度以及施加处于压应力状态的涂层或某些层(特别是前述的磨损保护层)的可能性,证明可以用作抵抗裂纹扩展和刃口剥落风险的措施。因此,对于大部分实际切削应用,不再使用富含粘合剂的基材,这对于碳化物工具生产而言是明显简化的。
然而,在某些切削条件下,甚至PVD涂覆的、富集的碳化物等级也(PVD coated enriched carbide grade)可以是有用的,例如如果切削参数需要被扩展以便施加更高的进给力以及优选甚至更高的TRS。
由于这类PVD涂覆的硬质金属等级的可能的较高TRS,对于特定的精细加工应用,不仅可以生产具有非常小刃口半径的切削工具,而且可以生产具有较小刀尖半径(nose radius)或顶角(point angle)的切削工具。作为例子,与具有最小0.2mm(0.008英寸)至2.4mm(0.094英寸)的常见刀尖半径的传统烧结碳化物镶刃相比,甚至诸如0.15、0.10、0.05和0.01mm的半径可以被涂层并在常见的精细车削条件下进行测试,而没有过早的尖端剥落迹象。
由于PVD工艺的固有“几何”性质,可以仅仅通过使用规定的夹具***(fixturing system)为简单几何形状的某些烧结体(例如镶刃)提供进一步的涂层特征,由此暴露所述体的某些区域至来自电弧或溅射源的“直接”离子和/或中性流(在后面称作粒子流),而其他区域实质上是仅仅被擦边(grazing)或间接入射而碰撞。在本文中,“直接”意味着电弧源所发出的粒子的主要部分或大部分以大约90±15°的角度碰撞表面。因此,这些区域上的层生长大于在暴露于基本上“间接”粒子流的表面上的生长。这种影响可以用以在一个PVD涂层工艺过程中施加不同厚度的涂层;这与CVD工艺完全不同,其中CVD工艺在每个表面上提供了均一的涂层厚度,而不依赖由于不同基材/源定位的几何影响。
例如,使用三重旋转轴(threefold rotating spindle)以固定带中心孔的方形13x13x5mm的镶刃和交替8mm间隔物时,对于所述镶刃而言,在RCS型商业Oerlikon涂覆装置中可以在大约500mm的基材转盘总长度上,或者在市售Oerlikon BAI 1200涂覆装置中可以在大约900mm的基材转盘的长度上,调节侧刀面厚度(d侧刀面)和前刀面厚度(d前刀面)的比例为大约2±0.5。厚度测量是在侧刀面的中部进行的,对于前刀面则是在距离切削刃2mm的等分线(bisecting line)处测量的,其中所述等分线连接所述镶刃的两个相对的刀尖(nose),限定了刀尖的顶角。具有商值QR/F=d前刀面/d侧刀面<1的镶刃(其中d前刀面是前刀面上的整个涂层厚度,d侧刀面是侧刀面上的整个涂层厚度)对于铣削工具是特别便利的,这是由于在铣削操作过程中的冲击应力得益于来自侧刀面上更高PVD涂层厚度。这种效应通过具有高残余应力的PVD涂层得到增强,其可以通过工艺参数如基材偏压(substrate bias)、总压力等而进行控制。
与铣削不同,车削操作的磨损抗性得益于在前刀面上更高的涂层厚度,这是由于正经过的切屑所造成的高摩擦和热化学磨损。因此,在这种情况中,商值QR/F应当高于1:QR/F=d前刀面/d侧刀面>1。对于镶刃而言,这种涂层分布可以通过夹具产生,所述夹具将前刀面相位(rake phase)暴露到电弧或溅射源的直接粒子流。例如双重旋转磁力夹具可以用于将烧结碳化物镶刃的前刀面直接暴露到所述源。这种磁力夹具导致在切削刃上厚度的额外增强,这能受到工艺参数的影响如基材偏压,并且可以用于改善工具性能。对于非磁力切割板,可以根据需要而使用夹持性或挂钩性夹具。此外,对于车削工具,包含磨损保护层的涂层设计被证明是特别有效的,其中所述磨损保护层定位在所述体和氧化层之间,是由TiN、TiC或TiCN、TiAlN或TiAlCN、AlCrN或AlCrCN制成的。
根据本发明的切削工具可以用于多种不同的工件材料,例如所有类型的金属,如有色金属,但尤其是黑色金属、铸铁等。用于铣削或车削这些材料的特殊工具可以如上所述被优化。这使得PVD涂层成为目前CVD涂层的有利竞争者,甚至在直到目前尚未触及的CVD领域,如车削操作中,特别是钢和铸铁的粗制和高速精加工。
在许多切削应用中,具有氧化层作为涂层***最外层的工具被证明是最佳解决方案。特别的,这指的是齿轮切削工具、齿轮滚铣刀(hob)或不同类型的带柄工具包括分度带柄类型工具。
下面的实施例是为了利用某些特定的工具和涂层证明本发明的有益效果,并不以任何方式将本发明的范围限制为这些具体的实施例。需要提到的是,进行了一些测试来和如下公知应用进行比较:在所述公知应用中,很早就知道PVD涂层工具优于CVD涂层,例如在不同类型金属材料的螺纹成形和钻孔中,非铁材料的干铣削和湿铣削,以及对钢或超合金的某些铣削和车削。对于这种钢铣削,已经采用了低速或中速最高达到100m/min,但最高达到0.2~0.4mm/齿的高进给速度。在大多数情况中,根据本发明的工具与公知的TiCN或TiAlN基PVD涂层工具表现一样或者甚至更好。然而,本发明的一个焦点是在高热化学和/或磨蚀应用中替代CVD涂层,例如铁、钢以及硬质材料的高速铣削以及钢、铁如铸铁、超合金和硬质材料的车削。
已经通过阴极电弧工艺沉积了下列实施例的PVD涂层;沉积温度在比较TiCN涂层的500℃和氧化涂层的550℃之间。对于氧化PVD涂层,基材偏压已经被脉冲化(pulsed)并且施加了小垂直磁场,该磁场具有3~50高斯的垂直场分量和实质上较小的水平分量。对于实验25、28、35和37,额外的脉冲信号被叠加到Al0.6Cr0.4(Al0.6V0.4)电弧源的DC电流上。这类或类似可实用氧化物涂层工艺的细节可见于WO 2006-099758以及其他前面所提到的通过引用并入本文的文献中。在基材和顶部氧化物层之间的TiN和TiCN中间层的层厚度是0.5~1.5μm。
通过MT-CVD以及850℃的沉积温度,已经沉积了比较CVD涂层。
实施例A)合金钢AISI 4140(DIN 1.7225)的铣削
工具:可分度平面铣刀,一个镶刃z=1
工具直径:d=98mm
切削速度:vc=152m/min
进给速度:fz=0.25mm/齿
切削深度:dc=2.5mm
工艺:利用冷却剂的向下铣切
镶刃类型:Kennametal SEHW 1204AFTN,12wt%Co;对于PVD涂覆而言是带倒角的尖锐切削刃,对于CVD涂覆而言经过倒角和搪磨至非常小的40μm半径。
表1)
Figure G2008800162475D00081
实施例B)合金钢AISI 4140(DIN 1.7225)的铣削
工具:分度平面铣刀,一个镶刃z=1
工具直径:d=98mm
切削速度:vc=213m/min
进给速度:fz=0.18mm/齿
切削深度:dc=2.5mm
工艺:无冷却剂的向下铣切
镶刃类型:Kennametal SEHW 1204 AFTN,12wt%Co;切削刃制备参见实施例A。
表2)
Figure G2008800162475D00091
实施例C)合金钢AISI 4140(DIN 1.7225)的铣削
工具:分度平面铣刀,一个镶刃z=1
工具直径:d=98mm
切削速度:vc=260m/min
进给速度:fz=0.20mm/齿
切削深度:dc=3.125mm
工艺:向下铣切
镶刃类型:Kennametal SEHW 1204AFTN,
实验13、15、17、19为Co 6.0重量%富集的碳化物等级,10.4重量%立方碳化物。
实验14、16、18、20为Co 6.0重量%未富集的碳化物级别,10.4重量%立方碳化物。
切削刃制备参见实施例A。
表3)
Figure G2008800162475D00101
实施例C,实验14明确显示CVD工艺对未富集的碳化物级别的不利影响,这是由于所提到的工艺效应。另一方面,Co富集的表面区的有利影响表明利用PVD涂覆时仅有有限的影响。如同实施例A和B所述,包括氧化层的PVD涂层的优点是明显的。
实施例D)不锈钢AISI 430F(DIN 1.4104)的车削
切削速度:vc=200m/min
进给速度:fz=0.20mm/齿
切削深度:dc=1.0mm
工艺:外径的连续车削
镶刃类型:金属陶瓷级别,ISO VNMG 160408All,对于PVD涂覆而言是尖锐的切削刃,在CVD涂覆之前进行倒角并搪磨至微小的60μm半径。
表4)
Figure G2008800162475D00111
除了涂覆类型和材料的影响之外,还可以看到氧化PVD涂层厚度的明显有利影响。不过,即使最薄的氧化PVD涂层也显示了比实验22的厚MT-CVD-涂层好的性能。
实施例E)灰口铸铁的车削
切削速度:vc=550m/min
进给速度:fz=0.65mm/齿
切削深度:dc=5.0mm
工艺:外径的连续车削
镶刃类型:陶瓷,Al2O3-TiC 20%,ISO RNGN 120400T,
对于PVD涂覆而言是尖锐的切削刃,在CVD涂覆之前,进行倒角并搪磨至微小的50μm半径。
表5)
Figure G2008800162475D00121
实施例F)锻钢_AISI 4137H(DIN 1.7225)的车削
切削速度:vc=100m/min
进给速度:fz=0.80mm/齿
切削深度:dc=5-15mm
工艺:外径的连续车削
镶刃类型:烧结碳化物,6%未富集,ISO TNMG 330924
对于PVD涂覆而言是尖锐的切削刃,在CVD涂覆之前,进行倒角并搪磨至微小的50μm半径。
表6)
Figure G2008800162475D00122
通过实施例A~F可以证明氧化涂层可以通过PVD涂覆工艺而被有利地施加于尖锐切削刃的工具上。尖锐切削刃是合意的,因为其导致较低的切割力,降低的工具尖端温度,从而得到更精细的工件表面精度,以及得到工具寿命的大大改进。

Claims (27)

1.切削工具,包括:
-烧结碳化物、CBN、金属陶瓷或陶瓷烧结体,其具有刃口半径为Re的切削刃、侧刀面和前刀面,以及
-单层或多层PVD涂层,其覆盖所述烧结体的表面的至少一部分并且含有至少一层氧化层,
其特征在于
所述刃口半径Re小于40μm,优选小于或等于30μm。
2.根据权利要求1的切削工具,其特征在于所述PVD涂层没有热裂纹。
3.根据权利要求1或2的切削工具,其特征在于所述PVD涂层不含卤化物。
4.根据权利要求1~3任一项的切削工具,其特征在于所述氧化层包含电绝缘氧化物,所述电绝缘氧化物包含选自元素周期表中IV、V、VI族过渡金属和Al、Si、Fe、Co、Ni、Y、La的至少一种元素。
5.根据权利要求1~4任一项的切削工具,其特征在于所述氧化层包括立方或六角晶体结构。
6.根据权利要求1~5任一项的切削工具,其特征在于所述氧化层包含(Al1-xCrx)2O3化合物。
7.根据权利要求1~6任一项的切削工具,其特征在于所述氧化层包含刚玉型结构。
8.根据权利要求7的切削工具,其特征在于所述刚玉型结构是刚玉或具有下列组成的多重式氧化物:
(Me11-xMe2x)2O3,其中0.2≤x≤0.98,
其中Me1和Me2是选自组Al、Cr、Fe、Li、Mg、Mn、Nb、Ti、Sb和V的不同元素。
9.根据权利要求7或8的切削工具,其特征在于所述刚玉型结构是(AlCr)2O3或(AlV)2O3
10.根据权利要求1~9任一项的切削工具,其特征在于所述PVD涂层是多层的。
11.根据权利要求10或11的切削工具,其特征在于所述氧化层包含不同氧化物的膜。
12.根据权利要求11的切削工具,其特征在于所述PVD涂层包含:
-粘附层,其直接位于所述烧结体表面上,和/或
-至少一层硬质磨损保护层,其位于所述烧结体和所述氧化层之间,或者两个或者更多个连续氧化层之间,和/或是所述PVD涂层的最外层,
其中所述粘附层和所述硬质保护层分别优选包含元素周期表中IV、V、VI族过渡金属和Al、Si、Fe、Co、Ni、Y、La的至少一种元素。
13.根据权利要求12的切削工具,其特征在于所述磨损保护层的至少一种元素连同N、C、O、B或与它们的混合物,其中优选N、C和CN,被包含在化合物中。
14.根据权利要求12或13的切削工具,其特征在于至少一层磨损保护层包含至少一个组成偏析膜。
15.根据权利要求12~14任一项的切削工具,其特征在于所述粘附层的至少一种元素连同N、C、O或它们的混合物,其中优选N和O,被包含在化合物中。
16.根据权利要求12~15任一项的切削工具,其特征在于所述粘附层的厚度为0.1~1.5μm。
17.根据权利要求12~16任一项的切削工具,其特征在于所述粘附层包含直接位于所述烧结体表面上的薄金属层。
18.根据权利要求1~17任一项的切削工具,其特征在于总涂层厚度是2~30μm,优选3~10μm。
19.根据权利要求1~18任一项的切削工具,其特征在于所述烧结体是未富集粘合剂的。
20.根据权利要求1~18任一项的切削工具,其特征在于所述烧结体是富集粘合剂的。
21.根据权利要求1~20任一项的切削工具,其特征在于所述侧刀面的涂层厚度与所述前刀面的涂层厚度不同。
22.根据权利要求21的切削工具,其特征在于所述工具是铣削工具,并且采用
QR/F=d前刀面/d侧刀面<1,
其中d前刀面是前刀面上的总涂层厚度,d侧刀面是侧刀面上的总涂层厚度。
23.根据权利要求21的切削工具,其特征在于所述工具是车削工具,并且采用
QR/F=d前刀面/d侧刀面>1,
其中d前刀面是前刀面上的总涂层厚度,d侧刀面是侧刀面上的总涂层厚度。
24.根据权利要求1~21任一项的切削工具,其特征在于所述工具包含或是分度镶刃。
25.根据权利要求1~24任一项的切削工具,其特征在于所述工具是用于下列工作材料至少一种的工具:金属、有色金属、黑色金属、铸铁。
26.根据权利要求12~17任一项的切削工具,其特征在于所述工具是齿轮切削工具、齿轮滚铣刀或带柄类型工具,其具有氧化层作为涂层***的最外层。
27.根据权利要求26的切削工具,其特征在于所述磨损保护层是TiN、TiC或TiCN、TiAlN或TiAlCN、AlCrN或AlCrCN类型的层,并且位于所述烧结体和所述氧化层之间。
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US8129040B2 (en) 2012-03-06
KR20100025522A (ko) 2010-03-09

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