CN105705281A - 被覆切削工具 - Google Patents
被覆切削工具 Download PDFInfo
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Abstract
本发明提供具有优异的耐磨耗性及耐缺损性、比以往品的寿命还长的被覆切削工具。本发明的被覆切削工具具备基材和形成于基材表面的被覆层。被覆层含有α型氧化铝层。α型氧化铝层的(116)面上的残留应力值大于0。α型氧化铝层的(012)面上的残留应力值小于0。
Description
技术领域
本发明涉及一种被覆切削工具。
背景技术
一直以来,已知有具备由超硬合金形成的基材和形成于基材表面的被覆层的被覆切削工具。被覆层例如含有选自Ti的碳化物、氮化物、碳氮化物、碳氧化物及碳氮氧化物中的至少1种。被覆层还可以含有氧化铝。被覆层可以是单层,也可以含有2个以上的层。被覆层通过化学蒸镀法形成在基材的表面上。被覆层的整体厚度为3~20μm。具备这种被覆层的被覆切削工具被用于钢或铸铁等的切削加工。
通常,在形成于碳化钨基超硬合金的表面上的被膜中残留有拉伸应力。当被膜中残留有拉伸应力时,被覆切削工具的破坏强度降低、同时被覆切削工具变得易于缺损。
作为用于释放残留于被膜的拉伸应力的技术,已知在被膜上通过喷丸加工(shotpeening)使其产生裂纹的技术(例如参照专利文献1)。
已知一种被覆切削工具,其具备基材和形成于基材上的被膜,被膜含有具有拉伸应力的TiCN被膜和具有压缩应力的α型Al2O3被膜,TiCN被膜位于基材与α型Al2O3被膜之间(例如参照专利文献2)。
现有技术文献
专利文献
专利文献1:日本特开平5-116003号公报
专利文献2:国际公开第2006/064724号公报
发明内容
发明所要解决的技术问题
近年,切削加工的高速化、高传送化及切削深度化变得显著,工具寿命较以往也有缩短的倾向。
上述专利文献1公开的工具中,当释放残留于被膜的拉伸应力时,虽然工具的耐缺损性提高,但存在工具的耐磨耗性下降的问题。其原因认为在于,以被膜上发生的裂纹为起点、被膜的一部分发生剥离。
上述专利文献2公开的工具的α型Al2O3被膜整体具有压缩应力。因此,上述专利文献2公开的工具存在耐磨耗性低的问题。
本发明是为了解决这些问题而完成的,其目的在于通过控制被覆切削工具的应力分布、提高被覆切削工具的耐磨耗性及耐缺损性。另外,本发明的目的在于延长工具的寿命。
用于解决课题的方法
本发明者们从上述观点出发,对被覆切削工具进行研究,完成了以下的发明。通过本发明,可以提高工具的耐磨耗性及耐缺损性。另外,通过本发明可以延长工具寿命。
本发明的主旨如下所述。
(1)一种被覆切削工具,其为具备基材和形成于基材表面的被覆层的被覆切削工具,其中,
所述被覆层含有α型氧化铝层,
所述α型氧化铝层的(116)面上的残留应力值大于0,
所述α型氧化铝层的(012)面上的残留应力值小于0。
(2)根据上述(1)所述的被覆切削工具,其中,当将所述α型氧化铝层的(116)面上的残留应力值记为A时,20≤A≤500MPa,
当将所述α型氧化铝层的(012)面上的残留应力值记为B时,-800≤B≤-100MPa。
(3)根据上述(1)或(2)所述的被覆切削工具,其中,所述残留应力值是通过sin2ψ法测定的值。
(4)根据上述(1)~(3)中任一项所述的被覆切削工具,其中,所述α型氧化铝层的平均厚度为1~15μm。
(5)根据上述(1)~(4)中任一项所述的被覆切削工具,其进一步具备含有Ti元素和选自C、N、O及B中的至少1种元素的化合物的Ti化合物层,
所述Ti化合物层形成于所述基材与所述α型氧化铝层之间。
(6)根据上述(1)~(5)中任一项所述的被覆切削工具,其中,所述Ti化合物层含有TiCN层,相对于所述TiCN层所含的C和N的总量的C原子比[C/(C+N)]为0.7≤C/(C+N)≤0.9。
(7)根据上述(1)~(6)中任一项所述的被覆切削工具,其中,所述被覆层的平均厚度为3~30μm,所述Ti化合物层的平均厚度为2~15μm。
(8)根据上述(1)~(7)中任一项所述的被覆切削工具,其中,所述基材为超硬合金、金属陶瓷、陶瓷或立方晶氮化硼烧结体。
<被覆切削工具>
本发明的被覆切削工具包含基材和形成于该基材表面的被覆层。被覆切削工具例如为铣刀加工用刀具、旋削加工用刀具、钻孔机或立铣刀等。
<基材>
本发明的基材例如为超硬合金、金属陶瓷(Cermet)、陶瓷、立方晶氮化硼烧结体、金刚石烧结体或高速度钢。其中,由于耐磨耗性及耐缺损性优异,优选超硬合金、金属陶瓷、陶瓷或立方晶氮化硼烧结体。
另外,基材的表面还可以经过改性。例如,当基材为超硬合金时,还可以在基材的表面上形成脱β层。基材为金属陶瓷时,还可以在基材的表面上形成硬化层。
<被覆层>
本发明的被覆层的平均厚度优选为3~30μm。被覆层的厚度小于3μm时,有被覆层的耐磨耗性降低的情况。被覆层的厚度超过30μm时,有被覆层与基材的密合性及被覆层的耐缺损性降低的情况。被覆层的平均厚度更优选为3~20μm。
<α型氧化铝层>
本发明的被覆层含有氧化铝层。氧化铝层可以是1层、也可以是多层。氧化铝层的晶型为α型。
本发明的α型氧化铝层的(116)面上的残留应力值大于0(MPa)。即,本发明的α型氧化铝层的(116)面上的残留应力为拉伸应力。
本发明的α型氧化铝层的(012)面上的残留应力值比0(MPa)小。即,本发明的α型氧化铝层的(012)面上的残留应力为压缩应力。
当α型氧化铝层的(116)面上的残留应力为拉伸应力且α型氧化铝层的(012)面上的残留应力也为拉伸应力时,在切削加工时被覆层上易于产生龟裂、被覆切削工具的耐缺损性降低。
当α型氧化铝层的(012)面上的残留应力为压缩应力且α型氧化铝层的(116)面上的残留应力也为压缩应力时,对被覆层进行干式喷砂加工(shotblast)等机械处理所需的能量提高。机械处理的能量高时,被覆层上易于产生龟裂。当被覆层上产生龟裂时,由于切削加工时的冲击、被覆层的一部分易于剥离。因此,无法充分地发挥被覆层本来的性能、被覆切削工具的耐磨耗性降低。
这里所说的压缩应力是被覆层的内部应力(固有应变)中的一种,是用“-”(负)的数值表示的应力。压缩应力大是指压缩应力的绝对值大。压缩应力小是指压缩应力的绝对值小。
这里所说的拉伸应力是被覆层的内部应力(固有应变)中的一种,是用“+”(正)的数值表示的应力。本说明书中仅提到残留应力时,包括压缩应力和拉伸应力这两者。
当将本发明的α型氧化铝层的(116)面上的残留应力值记为A时,优选为20≤A≤500MPa。α型氧化铝层的(116)面上的残留应力值A小于20MPa时,有被覆层的耐磨耗性降低的倾向。α型氧化铝层的(116)面上的残留应力值A超过500MPa时,有被覆层的耐缺损性降低的倾向。
当将本发明的α型氧化铝层的(012)面上的残留应力值记为B时,优选为-800≤B≤-100MPa。α型氧化铝层的(012)面上的残留应力值B小于-800MPa时,由于在被覆层上易于发生龟裂或剥离,因此被覆层的耐磨耗性降低。当α型氧化铝层的(012)面上的残留应力值B超过-100MPa时,由于将压缩应力赋予至被覆层所获得的效果减小,因此被覆层的耐缺损性降低。
残留应力值(A、B)可以通过使用了X射线应力测定装置的sin2ψ法测定。优选通过sin2ψ法测定被覆层中的任意10个点的残留应力值,计算这10个点的残留应力值的平均值。成为测定位置的被覆层中的任意10个点优选按照相互间距离0.1mm以上的方式选择。
为了测定α型氧化铝层的(012)面上的残留应力值,选择α型氧化铝层的(012)面。具体而言,利用X射线衍射装置对形成有α型氧化铝层的试样进行分析。进而,研究改变试样面法线与晶格面法线所成角度ψ时的(012)面的衍射角变化。
为了测定α型氧化铝层的(116)面上的残留应力值,选择α型氧化铝层的(116)面。具体而言,利用X射线衍射装置对形成有α型氧化铝层的试样进行分析。进而,研究改变试样面法线与晶格面法线所成角度ψ时的(116)面的衍射角变化。
由于α型氧化铝层的晶体的面不同,X射线的入射角不同。
认为选择α型氧化铝层的(012)面进行测定时的残留应力值B相对地表示α型氧化铝层的表面侧的残留应力。
认为选择α型氧化铝层的(116)面进行测定时的残留应力值A相对地表示α型氧化铝层的内部侧的残留应力。
本发明的α型氧化铝层的平均厚度优选为1~15μm。α型氧化铝层的平均厚度小于1μm时,有前刀面的防缩孔磨耗性降低的情况。α型氧化铝层的平均厚度超过15μm时,有被覆层易于发生剥离、被覆层的耐缺损性降低的情况。
<Ti化合物层>
本发明的被覆层优选含有Ti化合物层。当被覆层含有Ti化合物层时,被覆层的耐磨耗性提高。Ti化合物层可以是1层、也可以是多层。
本发明的Ti化合物层还可形成在基材与α型氧化铝层之间,还可以较α型氧化铝层形成于更外侧。
本发明的Ti化合物层优选形成在基材的表面上。当Ti化合物层形成于基材的表面上时,基材与被覆层的密合性提高。
本发明的Ti化合物层还可以形成在被覆层的最外侧。当Ti化合物层形成于被覆层的最外侧时,易于识别被覆切削工具的使用过的角。
Ti化合物层含有Ti化合物。Ti化合物在作为必须元素含有Ti的同时,含有选自C、N、O及B中的至少1种元素。Ti化合物层还可进一步含有选自Zr、Hf、V、Nb、Ta、Cr、Mo、W、Al及Si中的至少1种。Ti化合物层例如含有选自TiN层、TiCN层、TiC层、TiAlCNO层、TiAlCO层、TiCNO层及TiCO层中的至少1个。
本发明的Ti化合物层的平均厚度优选为2~15μm。Ti化合物层的平均厚度小于2μm时,有被覆层的耐磨耗性降低的倾向。Ti化合物层的平均厚度超过15μm时,有被覆层的耐缺损性降低的倾向。
本发明的Ti化合物层优选含有TiCN层。Ti化合物层含有TiCN层时,Ti化合物层的耐磨耗性提高。相对于TiCN层所含的C和N的总量的C原子比[C/(C+N)]优选为0.7≤C/(C+N)≤0.9。当C/(C+N)小于0.7时,由于被覆层的硬度降低,有被覆层的耐磨耗性降低的情况。当C/(C+N)超过0.9时,由于被覆层的韧性降低,有被覆层的耐崩裂性降低的情况。
相对于本发明的TiCN层所含的C和N的总量的C原子比[C/(C+N)]例如可通过EPMA测定。具体而言,可以通过EPMA对TiCN层中的C和N的量进行定量来算出C/(C+N)。
〔被覆层的形成方法〕
构成本发明的被覆切削工具的被覆层的各层例如可通过以下的方法形成。
例如,TiN层可以通过使原料气体组成为TiCl4:1.0~5.0mol%、N2:20~60mol%、H2:余量、温度:850~920℃、压力:100~350hPa的化学蒸镀法来形成。
例如,TiCN层可以通过使原料气体组成为TiCl4:1.0~4.0mol%、C3H6:1.0~4.0mol%、N2:10~50mol%、H2:余量、温度:700~900℃、压力:50~100hPa的化学蒸镀法来形成。由此,可形成C/(C+N)=0.7~0.9的TiCN层。
TiC层可以通过使原料气体组成为TiCl4:1.0~3.0mol%、CH4:4.0~6.0mol%、H2:余量、温度:990~1030℃、压力:50~100hPa的化学蒸镀法来形成。
α型氧化铝(Al2O3)层可以通过使原料气体组成为AlCl3:1.0~5.0mol%、CO2:2.5~4.0mol%、HCl:2.0~3.0mol%、H2S:0.28~0.45mol%、H2:余量、温度:900~1000℃、压力:60~80hPa的化学蒸镀法来形成。
TiAlCNO层可以利用使原料气体组成为TiCl4:1.0~5.0mol%、AlCl3:1.0~2.0mol%、CO:0.4~1.0mol%、N2:30~40mol%、H2:余量、温度:975~1025℃、压力:90~110hPa的化学蒸镀法来形成。
TiAlCO层可以通过使原料气体组成为TiCl4:0.5~1.5mol%、AlCl3:1.0~5.0mol%、CO:2.0~4.0mol%、H2:余量、温度:975~1025℃、压力:60~100hPa的化学蒸镀法来形成。
TiCNO层可以通过使原料气体组成为TiCl4:1.0~5.0mol%、CO:0.4~1.0mol%、N2:30~40mol%、H2:余量、温度:975~1025℃、压力:90~100hPa的化学蒸镀法来形成。
TiCO层可以通过使原料气体组成为TiCl4:0.5~3.0mol%、CO:2.0~4.0mol%、H2:余量、温度:975~1025℃、压力:60~100hPa的化学蒸镀法来形成。
控制了被覆层的残留应力的被覆切削工具例如利用以下方法获得。
在基材上形成了被覆层之后,使用干式喷砂加工或喷丸加工对被覆层的表面投射投射材料。投射材料的投射角度优选为2~10°。投射材料优选为立方晶氮化硼(cBN)。当对前刀面(rakeface)实施干式喷砂加工或喷丸加工处理时,优选按照投射材料不会触碰后刀面的方式进行遮挡。相反,当对后刀面(flankface)实施干式喷砂加工或喷丸加工处理时,优选对前刀面进行遮挡。投射材料的平均粒径优选为100~150μm。投射材料的投射速度优选为85~150m/秒钟。
被覆层所含各层的厚度例如可以使用光学显微镜、扫描型电子显微镜(SEM)或电场放射型扫描电子显微镜(FE-SEM)进行测定。具体而言,使用光学显微镜、扫描型电子显微镜(SEM)或电场放射型扫描电子显微镜(FE-SEM)对被覆切削工具的截面组织进行观察。另外,被覆层所含各层的厚度优选在从刀尖朝向前刀面为50μm的位置附近进行测定。被覆层所含各层的厚度优选在3处以上进行测定,求出所测定的3处厚度的平均值。
被覆层所含各层的组成可以使用能量分散型X射线分光器(EDS)、波长分散型X射线分光器(WDS)或电子探针微小分析器(EPMA)进行测定。例如,通过利用这些机器对被覆切削工具的截面组织进行分析,可以测定各层的组成。
TiCN层的组成可以使用能量分散型X射线分光器(EDS)、波长分散型X射线分光器(WDS)或电子探针微小分析器(EPMA)进行测定。例如,通过利用这些机器对被覆切削工具的截面组织进行分析,可以测定TiCN层的组成。
发明效果
本发明的被覆切削工具的耐磨耗性高、耐缺损性优异。因此,本发明的被覆切削工具比以往的工具寿命长。
实施例
以下举出实施例来说明本发明,但本发明并不限定于这些。
按照以下顺序制作具备基材和形成于基材表面的被覆层的被覆切削工具(试样)。在从所制作的试样的刀尖朝向前刀面中心部的50μm的位置附近,利用SEM对试样的截面进行观察。在3处对被覆切削工具(试样)的被覆层厚度进行测定,求出所测定的3处厚度的平均值。
通过使用了X射线应力测定装置的sin2ψ法对被覆层所含的α型氧化铝层的残留应力进行测定法,在被覆层中的任意10个点中,测定α型氧化铝层的残留应力,求出该测定的残留应力的平均值。
作为基材使用JIS标准CNMA120408形状的93.6WC-6.0Co-0.4Cr3C2(质量%)组成的超硬合金制切削刀具。在该基材的切削刃脊部用碳化硅刷磨圆之后,对基材的表面进行洗涤。
对基材的表面进行洗涤之后,将基材搬运至外热式化学蒸镀装置。在外热式化学蒸镀装置的内部,在基材的表面形成被覆层。将被覆层的形成条件示于表1。将被覆层的构成和平均厚度示于表2。
表1
表2
对于发明品1~14,在形成被覆层之后,在表3所示的条件下分别对前刀面和后刀面实施干式喷砂加工。此时,对前刀面实施处理时,按照投射材料不接触后刀面的方式进行遮挡。对后刀面实施处理时,对前刀面进行遮挡。
对于比较品1~9,在形成被覆层之后,在表4所示的条件下实施干式喷砂加工或湿式喷砂加工。对于比较品10,未实施干式喷砂加工及湿式喷砂加工中任一项。
表3
表4
通过使用了X射线应力测定装置的sin2ψ法测定α型氧化铝层的残留应力。将α型氧化铝层的残留应力的测定结果示于表5。
表5
使用EPMA测定相对于TiCN层所含的C和N总量的C原子比[C/(C+N)]。具体而言,利用EPMA测定从被覆切削工具刀尖朝向前刀面中心部的50μm位置的原子比。
表6
使用所得的试样(工具)进行切削试验1及切削试验2。切削试验1是评价工具的耐磨耗性的试验。切削试验2是评价工具的耐缺损性的试验。
[切削试验1]
加工材料:FCD600
加工材料的形状:圆盘φ180mm×L20mm(圆盘中心有φ75mm四边形的孔)
切削速度:150m/分钟
传送:0.35mm/rev
刻痕:2.0mm
冷却液:有
在切削试验1中,使用试样对加工材料进行切削,测定试样(工具)的寿命。具体而言,测定至试样后刀面的最大磨耗宽度达到0.3mm的加工时间。
[切削试验2]
加工材料:FC200
加工材料的形状:带有2条15mm宽的沟的圆盘φ180mm×L20mm(圆盘中心有φ65mm的孔)
切削速度:400m/分钟
传送:0.35mm/rev
刻痕:2.0mm
冷却液:有
在切削试验2中,使用试样对加工材料进行切削,测定试样(工具)的寿命。具体而言,测定至试样发生缺损或至试样后刀面的最大磨耗宽度达到0.3mm的冲击次数。冲击次数是指试样与加工材料相接触的次数。冲击次数达到20000次时,结束试验。各试样分别准备5个。对各试样测定5次冲击次数。求出所测定的5次冲击次数的平均值。
表7
如表7所示,发明品的耐磨耗性及耐缺损性提高。发明品与比较品相比,至达到工具寿命的加工时间长、冲击次数多。由此结果可知,发明品的工具寿命较比较品大幅度地长。
产业实用性
本发明的被覆切削工具的耐磨耗性高、耐缺损性优异。本发明的被覆切削工具由于较以往工具的寿命长,因此产业实用性高。
Claims (8)
1.一种被覆切削工具,其为具备基材和形成于基材表面的被覆层的被覆切削工具,其中,
所述被覆层含有α型氧化铝层,
所述α型氧化铝层的(116)面上的残留应力值大于0,
所述α型氧化铝层的(012)面上的残留应力值小于0。
2.根据权利要求1所述的被覆切削工具,其中,当将所述α型氧化铝层的(116)面上的残留应力值记为A时,20≤A≤500MPa,
当将所述α型氧化铝层的(012)面上的残留应力值记为B时,-800≤B≤-100MPa。
3.根据权利要求1或2所述的被覆切削工具,其中,所述残留应力值是通过sin2ψ法测定的值。
4.根据权利要求1~3中任一项所述的被覆切削工具,其中,所述α型氧化铝层的平均厚度为1~15μm。
5.根据权利要求1~4中任一项所述的被覆切削工具,其进一步具备含有Ti元素和选自C、N、O及B中的至少1种元素的化合物的Ti化合物层,
所述Ti化合物层形成于所述基材与所述α型氧化铝层之间。
6.根据权利要求1~5中任一项所述的被覆切削工具,其中,所述Ti化合物层含有TiCN层,相对于所述TiCN层所含的C和N的总量的C原子比[C/(C+N)]为0.7≤C/(C+N)≤0.9。
7.根据权利要求1~6中任一项所述的被覆切削工具,其中,所述被覆层的平均厚度为3~30μm,所述Ti化合物层的平均厚度为2~15μm。
8.根据权利要求1~7中任一项所述的被覆切削工具,其中,所述基材为超硬合金、金属陶瓷、陶瓷或立方晶氮化硼烧结体。
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CN109952169A (zh) * | 2016-11-14 | 2019-06-28 | 株式会社泰珂洛 | 被覆切削工具 |
CN108723400A (zh) * | 2017-04-21 | 2018-11-02 | 株式会社泰珂洛 | 被覆切削工具 |
CN113909573A (zh) * | 2020-07-08 | 2022-01-11 | 株式会社泰珂洛 | 被覆切削工具 |
CN113909573B (zh) * | 2020-07-08 | 2023-12-05 | 株式会社泰珂洛 | 被覆切削工具 |
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CA2929731C (en) | 2018-05-01 |
CA2929731A1 (en) | 2015-05-14 |
JP5994948B2 (ja) | 2016-09-21 |
EP3067133B1 (en) | 2020-05-20 |
EP3067133A4 (en) | 2017-01-18 |
BR112016009492B1 (pt) | 2020-12-01 |
CN105705281B (zh) | 2017-08-15 |
KR101713884B1 (ko) | 2017-03-09 |
RU2016122446A (ru) | 2017-12-11 |
WO2015068792A1 (ja) | 2015-05-14 |
US9993878B2 (en) | 2018-06-12 |
JPWO2015068792A1 (ja) | 2017-03-09 |
EP3067133A1 (en) | 2016-09-14 |
KR20160070833A (ko) | 2016-06-20 |
US20160263659A1 (en) | 2016-09-15 |
EP3067133A9 (en) | 2017-04-19 |
RU2643754C2 (ru) | 2018-02-05 |
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