JP2009050997A - 切削工具 - Google Patents
切削工具 Download PDFInfo
- Publication number
- JP2009050997A JP2009050997A JP2007252192A JP2007252192A JP2009050997A JP 2009050997 A JP2009050997 A JP 2009050997A JP 2007252192 A JP2007252192 A JP 2007252192A JP 2007252192 A JP2007252192 A JP 2007252192A JP 2009050997 A JP2009050997 A JP 2009050997A
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- Prior art keywords
- hard phase
- cutting tool
- coating layer
- substrate
- cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
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- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
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- B23B2200/201—Details of the nose radius and immediately surrounding area
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Abstract
【解決手段】 基体の表面に、Ti1−a−b−c−dAlaWbSicMd(CxN1−x)(ただし、MはNb、Mo、Ta、Hf、Yから選ばれる1種以上、0.45≦a≦0.55、0.01≦b≦0.1、0.01≦c≦0.05、0.01≦d≦0.1、0≦x≦1)からなる被覆層を被覆している切削工具であり、優れた耐摩耗性と耐欠損性を有するものである。
【選択図】 図1
Description
本発明の切削工具(以下、単に工具と略す)は、すくい面と逃げ面との交差稜線が切刃である形状をなし、かつ基体の表面に被覆層を成膜した構成となっている。
次に、本発明の(第1の実施形態における)切削工具の製造方法について説明する。
この実施形態においては、基体が、粒度分布において粒度0.1〜0.8μmの微粒側のピークトップと粒度1.5〜3.0μmの粗粒側のピークトップとの2つのピークトップを有する炭化タングステン相を、5〜7質量%の結合相で結合した超硬合金からなる。
次に、本発明の第2の実施形態における表面被覆切削工具の製造方法について説明する。
この実施形態の切削工具について、図1の(a)概略斜視図および(b)概略断面図、および図2の(a)表面付近および(b)内部についての走査型電子顕微鏡写真を基に説明する。
次に、上述した第3の実施形態における切削工具の製造方法について説明する。
本発明の切削工具の一例について、図3の(a)概略斜視図および(b)概略断面図を基に説明する。
次に、上述した第4の実施形態における切削工具の製造方法について説明する。
本発明の切削工具の一例について、前記した図1の(a)概略斜視図および(b)概略断面図を基に説明する。
次に、上述した第5の実施形態についての切削工具の製造方法について説明する。
平均粒径0.8μmの炭化タングステン(WC)粉末に対して、平均粒径1.2μmの金属コバルト(Co)粉末を10質量%、平均粒径1.0μmの炭化チタン(TiC)粉末を0.5質量%、炭化バナジウム(VC)粉末と炭化クロム(Cr3C2)粉末を合計で5質量%の割合で添加、混合して、プレス成形によりスローアウェイインサート形状(CNMA120408)に成形した後、脱バインダ処理を施し、0.01Paの真空中、1450℃で1時間焼成して超硬合金製の基体を作製した。さらに、作製した超硬合金製の基体にブラシ加工にて刃先処理(ホーニングR)を施した。
被削材 :SCM450
切削速度:150m/min
送り :0.25mm/rev
切り込み:1.5mm
切削状態:乾式
評価方法:20分間切削後のチッピングの有無、逃げ面摩耗幅、先端摩耗幅
平均粒径0.5μmの炭化タングステン(WC)粉末に対して、金属コバルト(Co)粉末を10質量%、炭化バナジウム(VC)粉末と炭化クロム(Cr3C2)粉末を合計で1質量%の割合で添加、混合し、成型、焼成および研削工程により外径16mmの4枚刃エンドミルを作製した。上記基体に実施例I−aと同様のアークイオンプレーティング法により表1に示す種々の組成にて被覆層を成膜した。
被削材 :SCM440
切削速度:80m/min
送り :0.08mm/刃
切り込み:切り込み深さd=18mm×横切込みw=1.5mm
切削状態:エアブロー
評価方法:90分間切削後のチッピングの有無、逃げ面摩耗幅測定
表1より、実施例I−aのインサート(切削工具)の評価結果と同様に、M(Nb、Mo、Ta、Hf、Yから選ばれる少なくとも1種)を含有しない試料No.I−1とNo.I−16、およびAlとM(Nb、Mo、Ta、Hf、Yから選ばれる少なくとも1種)とを含有しないNo.I−17、さらにa(Al含有量)が0.45よりも小さい試料No.I−18では、エンドミルの摩耗量が大きくて耐摩耗性が悪いものであった。a(Al含有量)が0.55よりも大きい試料No.I−19、b(W含有量)が0.1を超える試料No.I−20、c(Si含有量)が0.05を超える試料No.I−21では工具の耐摩耗性が悪くなった。また、d(M含有量)が0.1を超える試料No.I−22では被覆層の耐摩耗性が低下した。
実施例I−aの基体に対して、実施例I−aと同じ条件で表2に記載した被覆層を成膜し、実施例I−aおよび実施例I−bと同じ切削条件で工具性能を評価した。結果は表2に示した。
平均粒径0.5μmの微粒炭化タングステン(WC)粉末と平均粒径2.5μmの粗粒炭化タングステン粉末(WC)とを用い、これに対して平均粒径1.2μmの金属コバルト(Co)粉末を6質量%、炭化クロム(Cr3C2)を0.4質量%の割合で添加し、アトライタミルを用いて表3に示す時間混合し、スプレードライヤを用いて顆粒を作製した。次に、この顆粒を用いて、表3に記載した超硬合金基体を準備した。
実施例I−dの顆粒を用いて、プレス成形によりスローアウェイインサート形状(DCET11T301)に成形した後、脱バインダ処理を施し、0.01Paの真空中、表5の条件で焼成して超硬合金製の基体を作製した。
被削材 :快削鋼(SUM23L)
切削速度:100m/min
送り :0.08mm/rev
切り込み:0.5mm
切削状態:乾式
評価方法:100分間切削後のチッピングの有無、被削材の面粗度(Rz)
マイクロトラック法による測定にて平均粒径0.7μmのTiCN粉末、平均粒径1.5μmのTiN粉末、平均粒径2μmのTaC粉末、平均粒径1.5μmのNbC粉末、平均粒径1.1μmのWC粉末、平均粒径1.8μmのZrC粉末、平均粒径1.0μmのVC粉末、平均粒径2.4μmのNi粉末、および平均粒径1.9μmのCo粉末を表6に示す割合で混合した。得られた混合粉末をステンレス製ボールミルと超硬ボールを用いて、イソプロピルアルコール(IPA)にて湿式混合した。ついで、パラフィンを3質量%添加、混合した後、200MPaでDCET11T301の工具形状にプレス成形し、表6に示す焼成条件で焼成した。なお、昇温工程(b)、(c)においてはN2ガスを表1に示す量だけ注入した。
切削速度:120m/min
送り:0.05mm/rev
切込み:0.5mm
切削状態:湿式(油性切削油使用)
評価方法:φ20mmからφ10mmまで切削長20mmで外径切削
600分加工後の切削加工面の面粗度
実施例III−aで作製した試料No.III−7の切削工具に対して、工具形状をCNMG120408とし、被覆層の層厚を3.0μmとする以外は実施例III−aの試料No.III−7と同じ条件で切削工具(試料No.III−27)を作製した。この試料を用いて以下の条件で切削試験を行った。
切削速度:300m/min
送り:0.20mm/rev
切込み:1.0mm
切削状態:湿式(水性切削液)
評価方法:外径連続切削(加工時間30分後の逃げ面摩耗幅)
また、比較例として実施例III−aの試料No.III−14の切削工具に対して、切削工具の形状をCNMG120408とし、被覆層の層厚を3.0μmとする以外は実施例III−aの試料No.III−14と同じ条件で切削工具(試料No.III−28)を作製し、上記と同様に切削評価した。
実施例III−aの試料No.III−7に対して、基体のサーメット原料のTiCN粉末とCo粉末を、平均粒径0.7μmのTiCN粉末(試料No.III−7と同じ)を30質量%、平均粒径1.0μmの10質量%Co含有TiCN粉末を22質量%、平均粒径1.9μmのCo粉末(試料No.7と同じ)を7質量%にそれぞれ代えた以外は、試料No.III−7と同じ条件で切削工具(試料No.III−29)を作製した。
平均粒径0.8μmのcBN原料粉末50体積%、平均粒径1.2μmのTiN原料粉末40体積%、1.5μmの金属Al原料粉末10体積%を調合し、この粉体を、アルミナ製ボールを用いたボールミルで15時間混合した。次に混合した粉体を圧力98MPaで加圧成形した。この成形体を、超高圧装置を用いて、50℃/分で昇温し、圧力5.0GPaで、1500℃で15分保持することにより焼成した後、50℃/分で降温することにより焼成してcBN質焼結体を得た。また、作製した焼結体からワイヤ放電加工によって所定の寸法に切り出し、超硬合金基体の切刃先端部に形成した切り込み段部にろう付けした。そして、このcBN焼結体の切刃に対してダイヤモンドホイールを用いて刃先処理(チャンファホーニング)を施した。
被削材 :SCM435(浸炭焼入鋼:cスケールのロックウェル硬度(HRC)58〜62)、3個穴付き
切削速度:150m/min
送り :0.15mm/rev
切り込み:肩切り込み0.2mm、深さ切り込み0.4mm
切削状態:乾式
評価方法:欠損するまで加工を実施し、欠損までの衝撃回数により優劣を判断した。また、衝撃回数300回毎にチッピングなどの有無を顕微鏡にて確認した。
平均粒径0.8μmのcBN原料粉末、平均粒径1.0μmのTiC原料粉末、平均粒径1.2μmのTiN原料粉末、平均粒径1.5μmのTiCN原料粉末、平均粒径1.2μmのZrC原料粉末、平均粒径1.2μmのZrN原料粉末、平均粒径0.9μmのWC原料粉末、平均粒径1.0μmのHfC原料粉末平均粒径1.5μmの金属Al原料粉末、平均粒径0.8μmの金属Co原料粉末を用いて、表10に示す組成となるように調合し、この粉体を、アルミナ製ボールを用いたボールミルで15時間混合した。次に混合した粉体を圧力98MPaでプレス成形した。この成形体を、超高圧、高温装置を用いて、表10に示す速度で昇温し、圧力5.0GPaで、表10に示す温度、時間で焼成した後、表10に示す降温速度で降温することにより、焼成されたcBN質焼結体を得た。これを用いて実施例IV−aと同様の工程で切削工具とし、次に、被覆層の層厚を3.0μmとした以外は実施例IV−aの試料No.7と同じ条件で被覆層を成膜した(試料No.IV−22〜31)。この試料を用いて上記と同様に切削評価した。結果は表11に示した。
被削材 :SKD11
切削速度:150m/分
送り :0.5mm/rev
切り込み:0.5mm
切削状態:乾式
評価方法:フランク摩耗が0.3mm以上となる時間またはフレーキングまたは欠損が起こるまでの時間
2、22 すくい面
3、23 逃げ面
4、24 切刃
6、26 基体
7、27 被覆層
8、28 被覆層
9 他の被覆層
10 硬質相
10a 第1硬質相
10b 第2硬質相
10c 第3硬質相
11 表面層領域
12 芯部
13 周辺部
14 極表面領域
15 結合相
Claims (18)
- 基体と、この基体の表面を被覆する被覆層とからなる切削工具であって、前記被覆層が、Ti1−a−b−c−dAlaWbSicMd(CxN1−x)(ただし、MはNb、Mo、Ta、Hf、Yから選ばれる少なくとも1種、0.45≦a≦0.55、0.01≦b≦0.1、0.01≦c≦0.05、0.01≦d≦0.1、0≦x≦1)からなることを特徴とする切削工具。
- 前記被覆層に加えて、Alおよび周期律表4、5、6族元素の炭化物、窒化物および炭窒化物からなる群より選ばれる少なくとも1つからなる層を具備することを特徴とする請求項1記載の切削工具。
- 前記基体が、硬質相と結合相とからなる超硬合金基体であり、前記硬質層は、粒度分布において粒度0.1〜0.8μmの微粒側のピークトップと粒度1.5〜3.0μmの粗粒側のピークトップとの2つのピークトップを有する炭化タングステン相からなり、該炭化タングステン相を、5〜7質量%の結合相で結合していることを特徴とする請求項1記載の切削工具。
- 前記炭化タングステン相の平均粒径が0.5〜1.0μmであることを特徴とする請求項3記載の切削工具。
- 前記基体が、鉄族金属で構成される結合相と、TiおよびWを必須として、Tiを最も多く含有する周期表第4、5および6族金属の炭窒化物にて構成される硬質相とからなるサーメット基体であって、前記サーメット基体の内部における前記硬質相の平均粒径dinが0.1〜1.5μmであるとともに、前記サーメット基体の内部から表面に向かってWの濃度が増加する表面層領域が存在していることを特徴とする請求項1記載の切削工具。
- 走査型電子顕微鏡写真によって観察される前記サーメット基体の断面において、前記硬質相が、黒色の芯部の周辺に灰白色の周辺部が存在する有芯構造からなる第1硬質相と、灰白色の単一構造からなる第2硬質相とから構成されるか、または前記第1硬質相と、前記第2硬質相と、黒色の単一構造からなる第3硬質相とから構成され、前記サーメット基体の内部における前記第1硬質相の平均粒径d1inが0.1〜1.3μmであり、前記第2硬質相の平均粒径d2inが0.2〜1.5μmであり、前記第3硬質相の平均粒径d3inが0.2〜2.0μmであることを特徴とする請求項5記載の切削工具。
- 走査型電子顕微鏡写真によって観察される前記サーメット基体の内部組織において、組織全体に占める前記第1硬質相の面積比率S1inが40〜80面積%であり、前記第2硬質相の面積比率S2inが5〜40面積%であり、前記第3硬質相の面積比率S3inが0〜30面積%であることを特徴とする請求項6記載の切削工具。
- 前記硬質相において、黒色の芯部および前記第3硬質相がTiを80質量%以上含有するとともに、前記第1硬質相の前記灰白色の周辺部および前記第2硬質相が前記第1硬質相の黒色の部分よりもTi以外の周期表第4、5および6族金属を多く含有することを特徴とする請求項6または7記載の切削工具。
- 前記第1硬質相の芯部の一部が鉄族金属を含有していることを特徴とする請求項6乃至8のいずれか記載の切削工具。
- 前記表面層領域における前記硬質相の平均粒径dsfと前記平均粒径dinとの比(dsf/din)が1.1〜1.8であることを特徴とする請求項6乃至9のいずれか記載の切削工具。
- 前記表面層領域に占める前記第1硬質相の面積比率S1sfと前記面積比率S1inとの比(S1sf/S1in)が0.3〜0.7であり、前記表面層領域に占める前記第2硬質相の面積比率S2sfと前記面積比率S2inとの比(S2sf/S2in)が1.5〜4であることを特徴とする請求項7記載の切削工具。
- 走査型電子顕微鏡写真によって観察される前記サーメット基体の断面において、前記表面層領域のうちの表面部分に、前記第1硬質相の面積比率S1ssが80面積%以上の極表面領域が5μm以下の深さ領域で存在することを特徴とする請求項6乃至12のいずれか記載の切削工具。
- 前記基体がcBN焼結体からなることを特徴とする請求項1記載の切削工具。
- 前記cBN焼結体中の結合相がTiNおよびTiCを含むことを特徴とする請求項13記載の切削工具。
- 前記基体がアルミナ粒子のマトリックス中にチタンまたは珪素の炭化物、窒化物、炭窒化物および炭窒酸化物のいずれか少なくとも1種を10〜90質量%の割合で含有したアルミナ質セラミックスからなることを特徴とする請求項1記載の切削工具。
- 前記アルミナ質セラミックスが、さらにコバルトおよびニッケルの少なくとも1種を0.05〜10質量%の割合で含有することを特徴とする請求項15記載の切削工具。
- 前記基体と前記被覆層との界面の粗さが0.01〜0.2μmであることを特徴とする請求項15または16記載の切削工具。
- 前記被覆層の厚みが0.5〜10μmであることを特徴とする請求項15記載の切削工具。
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US7811683B2 (en) | 2010-10-12 |
DE102007046380B9 (de) | 2012-12-06 |
DE102007046380A1 (de) | 2008-04-03 |
JP5188133B2 (ja) | 2013-04-24 |
DE102007046380B4 (de) | 2010-09-30 |
US20080075543A1 (en) | 2008-03-27 |
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