CN114222643A - 处理涂层切削工具的方法 - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 32
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- 239000011248 coating agent Substances 0.000 claims abstract description 21
- 239000000758 substrate Substances 0.000 claims abstract description 20
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- 238000005422 blasting Methods 0.000 claims description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 7
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- 239000003973 paint Substances 0.000 claims description 5
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- 229910033181 TiB2 Inorganic materials 0.000 claims description 2
- 229910008482 TiSiN Inorganic materials 0.000 claims description 2
- QRXWMOHMRWLFEY-UHFFFAOYSA-N isoniazide Chemical compound NNC(=O)C1=CC=NC=C1 QRXWMOHMRWLFEY-UHFFFAOYSA-N 0.000 claims description 2
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- 229910052804 chromium Inorganic materials 0.000 description 2
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- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及一种使用激光冲击强化(LSP)处理涂层切削工具的方法,所述涂层切削工具由基材和涂层组成,其中所述基材为硬质合金或金属陶瓷,优选硬质合金,并且其中所述涂层包含CVD层和/或PVD层。所述方法包括将LSP施加于所述切削工具的至少一部分的步骤,其中所述LSP能量密度在0.4J/mm2至1.6J/mm2内,并且其中所述LSP包括将激光脉冲施加至所述切削工具的所述至少一部分。
Description
技术领域
本发明涉及涂层切削工具的激光冲击强化(laser shock peening)处理,其中所述切削工具具有金属陶瓷或硬质合金的基材以及包含由CVD和/或PVD制成的层的涂层。
背景技术
金属陶瓷和硬质合金是由金属粘结剂中的硬质成分构成的材料。这些材料是切削工具中常见的基材,具有高硬度、高耐磨性、高韧性等特性。这些基材通常涂有耐磨涂层,诸如例如TiCN和氧化铝层的CVD涂层或者是例如TiN和TiAlN层的PVD涂层。
所述涂层切削工具通常被表面处理,以进一步改善其切削寿命。常用的表面处理方法是刷光以使外表面光滑或使切削刃成形,喷丸处理(shot blasting)以使表面光滑,并影响硬质合金表面区域或涂层中的残余应力水平。
激光冲击强化是一种利用激光影响表面区域特性的方法。短持续时间和高强度的激光脉冲在表面上扫描。每一个激光脉冲产生在表面形成的局部等离子体,从而产生传播到被处理的对象物内的冲击波。所述冲击波影响表面区域的材料,从而增加硬度、韧性,并改变残余应力水平。
WO 2018/215996 A1公开了一种用激光冲击强化处理硬质合金切削工具的方法。
发明内容
本发明的目的是提供一种改善的处理涂层切削工具的方法,该涂层切削工具包含金属陶瓷或硬质合金的基材。
根据项1的方法实现了这些目的中的至少一个。优选实施方式列举在从属项中。
本发明涉及一种使用激光冲击强化(LSP)处理涂层切削工具的方法,所述涂层切削工具由基材和涂层组成,其中所述基材为硬质合金或金属陶瓷,优选硬质合金,并且其中所述涂层包含CVD层和/或PVD层,其中,所述方法包括将LSP施加于所述切削工具的至少一部分的步骤,其中所述LSP能量密度在0.4J/mm2至1.6J/mm2内,优选在0.9J/mm2至1.4J/mm2内,更优选在1.1J/mm2至1.3J/mm2内。
令人惊讶地发现,如果在所述LSP能量密度设置在0.4J/mm2至1.6J/mm2内(优选在0.9J/mm2至1.4J/mm2内)进行激光冲击强化,则切削工具的性能最佳。如果所述LSP能量密度过低,则LSP的冲击力过低,无法得到改善的刃线(edge line)韧性或耐磨性。如果所述LSP能量密度过高,则表面区域应力降低的风险更高,从而刃线抗崩裂性(chippingresistance)降低。
在本发明的一个实施方式中,所述LSP包括向所述切削工具的所述至少一部分施加激光脉冲,并且其中激光脉冲能量密度为0.04J/mm2至1.0J/mm2,优选0.04J/mm2-0.5J/mm2,更优选0.04J/mm2-0.1J/mm2,甚至更优选0.05J/mm2-0.07J/mm2。
在本发明的一个实施方式中,在施加LSP之前,将黑色漆料或黑色胶带施加至涂层切削工具上。使用黑色漆料或黑色胶带的一个优点在于能够在没有任何厚度减少或外观改变的情况下保持下方的涂层。
在本发明的一个实施方式中,所述涂层包含TiN、TiCN、TiC、TiB2、ZrCN、TiAlN或TiSiN中的一种以上的外层。这些层能够用作吸收层,代替漆料或胶带。这些层的优点在于它们能够作为CVD或PVD涂层的一部分沉积,由此能够避免施加黑色胶带或漆料的额外步骤。另一个优点是,使用这些层使得LSP的效果似乎更明显,从而在基材的表面区域中诱导更高水平的残余应力。
在本发明的一个实施方式中,所述外层的厚度优选为2μm-5μm。如果所述外层的厚度过薄,则在所述LSP期间,下方的耐磨层的厚度将减小。如果厚度大于5μm,则在基材中引起的残余应力较小,因此所述LSP对工具寿命的改善不太明显。
在本发明的一个实施方式中,所述涂层切削工具还包含位于所述基材和所述外层之间的Al2O3层。该Al2O3层优选为α-Al2O3层。这是有利的,因为它是非常耐磨的层。
在本发明的一个实施方式中,所述涂层切削工具还包含位于所述基材和所述外层之间的TiCN层。
在本发明的一个实施方式中,所述涂层切削工具还包含位于所述基材和所述外层之间的TiAlN层。
在本发明的一个实施方式中,所述涂层的总厚度为2μm-20μm。
在本发明的一个实施方式中,所述涂层的总厚度为2μm-10μm。
在本发明的一个实施方式中,所述切削工具包含前刀面和后刀面以及它们之间的切削刃,并且其中所述LSP施加于切削刃的一部分和前刀面的至少一部分上。
在本发明的一个实施方式中,在所述LSP步骤之后进行喷砂、抛光和/或刷光步骤,优选喷砂步骤,例如喷丸。喷砂、抛光和刷光的优点在于切削工具的表面能够通过这些技术中的任意者进行精整,从而能够改善切削工具的切削性能。喷丸是有利的,因为涂层中的表面粗糙度和残余应力水平都能够被影响,在涂层中能够实现较低的表面粗糙度和降低的拉伸应力水平或较高的压缩应力水平,从而能够延长切削工具寿命。
在本发明的一个实施方式中,所述切削工具包含前刀面和后刀面以及它们之间的切削刃,并且其中所述LSP仅施加于所述切削工具的切削刃的一部分以及前刀面和/或后刀面的一部分,其中所述区域的宽度(b)为从切削刃起至多5mm,优选地,所述区域的宽度(b)为从切削刃起1mm-5mm。至少在涉及切削的区域上施加LSP是有利的。在施加中,从刃起在前刀面上的延伸应至少为切削深度ap。
在本发明的一个实施方式中,沿着所述切削工具的整个切削刃施加LSP。
在本发明的一个实施方式中,所述LSP施加于所述切削工具的整个前刀面上。
在本发明的一个实施方式中,所述LSP施加于所述切削工具的整个前刀面、整个刃以及整个后刀面上。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的波长在1000nm至1100nm内,优选在1050nm至1070nm内,更优选约1064nm。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的频率在150 000Hz至250 000Hz内,优选约200 000Hz。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的脉冲持续时间在0.005ns至0.02ns内,优选约0.01ns至0.02ns。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的平均效应(averageeffect)在13W至16W内,优选约15W。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的光斑尺寸在0.03mm至0.05mm内,优选约0.04mm。
在本发明的一个实施方式中,在所述LSP步骤期间所述激光的峰值功率密度在3GW/mm2到7GW/mm2内,优选约6GW/mm2。峰值功率密度水平可以通过改变频率、脉冲长度、激光效应或光斑尺寸来改变。峰值功率密度在3GW/mm2到7GW/mm2内是有利的,因为产生的峰值压力高,从而改善了所述切削工具的使用寿命。
在本发明的一个实施方式中,所述LSP在所述涂层切削工具浸入水中时施加于所述涂层切削工具。
由结合附图考虑的以下实施例,本发明的其它目的和特征将变得显而易见。
附图说明
图1是根据本发明能够处理的切削工具(1)的图,其中指示了前刀面(2)、后刀面(4)和切削刃(3)。该切削工具的几何形状与以下实施例中使用的几何形状相对应。
图2是根据本发明一个实施方式的所述LSP区域的位置和延伸的示意图,显示了切削工具(1)的前刀面(2)和切削刃(3)。
图3是以脉冲步长x在区域上扫描的激光脉冲(圆)的示意图。脉冲彼此重叠,使得整个区域或部分被用LSP处理。
定义
本文中的“切削工具”是指用于金属切削应用的切削工具,例如刀片、立铣刀或钻头。例如,应用领域可以是车削、铣削或钻孔。
本文中的“硬质合金”是指包含至少50重量%WC、在制造硬质合金领域中常见的其它可能的硬质成分以及优选为选自Fe、Co和Ni中的一种以上的金属粘结相的材料。
本文中的“金属陶瓷”是指包含硬质成分和金属粘结相的材料,其中硬质成分为碳氮化钛、碳化钛和氮化钛中的一种以上。所述金属陶瓷中的金属粘结相优选为选自Fe、Co和Ni中的一种以上,优选为Co。金属陶瓷领域中常见的其它硬质成分选自Ti、Ta、Nb、Zr、V和Cr的碳化物、氮化物或碳氮化物。所述金属陶瓷材料不含游离六方WC。基于碳氮化钛的金属陶瓷材料是当今最常见的金属陶瓷材料。
本文中的“LSP能量密度”是指施加于切削工具的LSP处理部分或区域中的平均能量密度。脉冲重叠增加或激光脉冲能量密度增加导致LSP能量密度增加。
本文中的“激光脉冲能量密度”是指单个激光脉冲的平均能量密度。脉冲持续时间增加或效应增加导致激光脉冲能量密度的增加。
本文中的“喷丸”是指使用磨料颗粒的方法,其中通常通过磨料磨损(abrasivewear)从处理表面去除材料。喷丸在切削工具领域是众所周知的,并且例如已知会在切削工具的涂层中引入残余应力。
实施例
现在将更详细地公开本发明的示例性实施方式,并与比较实施方式进行比较。涂层切削工具(刀片)被制备、分析并且在切削试验中评价。
基材
制造了ISO R390-11T308M-PM型铣削用硬质合金基材,见图1。
制造了两种不同的硬质合金组合物。基材A由组成为约13.50重量%Co、0.57重量%Cr和余量WC的粉末混合物制成。基材B由组成为约9.14重量%Co、1.15重量%Ta、0.27重量%Nb、0.05重量%Ti和余量WC的粉末混合物制成。将所述粉末混合物研磨、干燥、压制成生坯并在1450℃下烧结,以形成烧结硬质合金基材。
涂层
在所述两种硬质合金组合物上沉积了CVD涂层。所述CVD涂层由厚度为0.5μm的内部TiN层、厚度为3.5μm的后续耐磨TiCN层和其上的厚度为3μm的耐磨α-Al2O3层组成。此后,沉积厚度为2μm的外部TiN层。所述涂层总厚度约为9μm。
LSP工序
LSP施加于涂层切削工具的前刀面区域,并且也覆盖刃。垂直于切削工具的切削刃测量的区域宽度b约为3mm。沿主切削刃的延伸部分a约为6mm,沿辅助切削刃的延伸部分c约为3mm。参见图2中LSP区域的示意图。
所述LSP工序利用6mm的水在表面上施加。在LSP工序期间,所述切削工具浸没在水中。
LSP期间激光的设置如下:
波长:1064nm
频率:200kHz
脉冲持续时间:0.01ns
脉冲直径,d:0.04mm
激光功率:14.8W
峰值功率密度:5.89GW/mm2
激光脉冲能量密度为0.059J/mm2,计算如下:
LSP能量密度通过如下方式调节:改变脉冲距离(即脉冲步长x),从而改变脉冲重叠,使得脉冲距离更小,从而更大的脉冲重叠导致更大的LSP能量密度。激光脉冲重叠与脉冲步长x和脉冲直径d有关:
样品的LSP能量密度如表1所示。
表1
喷丸工序
在所述LSP之后,对所述切削工具进行喷丸处理,以去除外部TiN层。稍微调节喷丸时间,以从经LSP处理的前刀面区域去除所有TiN。使用磨料氧化铝和2.1巴的气压进行该喷丸处理。对样品A0和B0也进行喷丸处理。
切削性能1
然后,在以下参数下,在铣削操作中对具有基材A的刀片进行测试:
工件材料:未硬化Dievar,PL 129 200x200x100,MC P3.0.Z.AN,CMC 03.11,
负载(charge):M10205
vc=200m/分钟
fz=0.15mm
ae=12mm
ap=3.0
z=1
切削长度=12mm
未使用切削液。
刀片型号R390-11T308M-PM
工具寿命标准设定为刃线的至少0.5mm的缺口(chipping)。工具寿命表示为达到该标准所需的切入的平均次数。平均工具寿命如表2所示,所述工具寿命是切削的平均数,是8个平行切削试验的平均值。
表2
切削性能2
然后,在以下参数下,在铣削操作中测试具有基材B的刀片:
工件材料:未硬化Dievar,PL 129 200x200x100,MC P3.0.Z.AN,CMC 03.11,
负载:M10205
vc=160m/分钟
fz=0.2mm
ae=12mm
ap=3.0
z=1
切削长度=12mm
未使用切削液。
刀片型号R390-11T308M-PM
工具寿命标准设定为刃线的至少0.5mm的缺口。工具寿命表示为达到该标准所需的切入的平均次数。该平均工具寿命如表3所示,所述工具寿命是平均切削次数,是8个平行切削试验的平均值。
表3
虽然已经结合各种示例性实施方式描述了本发明,但是应当理解,本发明不限于所公开的示例性实施方式,相反,本发明旨在涵盖所附权利要求书中的各种修改和等价布置。此外,应当认识到,本发明的任何公开形式或实施方式都可作为设计选择的一般事项并入任何其它公开、描述或建议的形式或实施方式中。因此,其旨在仅限于如本文所附权利要求书的范围所示。
Claims (15)
1.一种使用激光冲击强化(LSP)处理涂层切削工具(1)的方法,所述涂层切削工具由基材和涂层组成,其中所述基材为硬质合金或金属陶瓷、优选硬质合金,并且其中所述涂层包含CVD层和/或PVD层,其中所述方法包括将LSP施加于所述切削工具(1)的至少一部分的步骤,其中所述LSP能量密度在0.4J/mm2至1.6J/mm2内,优选在0.9J/mm2至1.4J/mm2内,更优选在1.1J/mm2至1.3J/mm2内。
2.根据权利要求1所述的方法,其中所述LSP包括向所述切削工具的所述至少一部分施加激光脉冲,并且其中所述激光脉冲能量密度为0.04J/mm2至1.0J/mm2,优选0.04J/mm2-0.1J/mm2,更优选0.05J/mm2-0.07J/mm2。
3.根据权利要求1或2所述的方法,其中在所述LSP步骤期间所述激光的波长在1000nm至1100nm、优选1050nm至1070nm内。
4.根据权利要求1至3中的任一项所述的方法,其中在施加LSP之前,将黑色漆料或黑色胶带施加至涂层切削工具(1)上。
5.根据权利要求1至4中的任一项所述的方法,其中所述涂层包含TiN、TiCN、TiC、TiB2、ZrCN、TiAlN或TiSiN中的一种以上的外层,所述外层的厚度优选为2μm-20μm,更优选为2μm-5μm。
6.根据权利要求5所述的方法,其中所述涂层切削工具(1)还包含位于所述基材和所述外层之间的Al2O3层。
7.根据权利要求5或6所述的方法,其中所述涂层切削工具(1)还包含位于所述基材和所述外层之间的TiCN层。
8.根据权利要求5至7中的任一项所述的方法,其中所述涂层切削工具(1)还包含位于所述基材和所述外层之间的TiAlN层。
9.根据前述权利要求中的任一项所述的方法,其中所述涂层的总厚度为2μm-20μm。
10.根据前述权利要求中的任一项所述的方法,其中所述切削工具(1)包含前刀面(2)和后刀面以及它们之间的切削刃(3),其中所述LSP施加于所述切削刃(3)的一部分和所述前刀面(2)的至少一部分上。
11.根据前述权利要求中的任一项所述的方法,其中在所述LSP步骤之后进行喷砂、抛光和/或刷光步骤,优选喷砂步骤例如喷丸。
12.根据前述权利要求中的任一项所述的方法,其中所述切削工具(1)包含前刀面(2)和后刀面以及它们之间的切削刃(3),并且其中所述LSP仅施加于切削工具(1)的切削刃(3)的一部分以及前刀面(2)和/或后刀面(4)的一部分,其中,所述区域的宽度(b)为从所述刃起至多5mm,优选地,所述区域的宽度(b)为从所述切削刃(3)起1mm至5mm。
13.根据前述权利要求中的任一项所述的方法,其中在所述LSP步骤期间所述激光的频率在150 000Hz至250 000Hz内,优选约200000Hz。
14.根据前述权利要求中的任一项所述的方法,其中在所述LSP步骤期间所述激光的平均效应在13W至16W内,优选约15W。
15.根据前述权利要求中的任一项所述的方法,其中在所述LSP步骤期间所述激光的峰值功率密度在3GW/mm2至7GW/mm2内,优选约6GW/mm2。
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