TWI435782B - 具有冷卻劑通道之合構物件及工具製法 - Google Patents

具有冷卻劑通道之合構物件及工具製法 Download PDF

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TWI435782B
TWI435782B TW095122578A TW95122578A TWI435782B TW I435782 B TWI435782 B TW I435782B TW 095122578 A TW095122578 A TW 095122578A TW 95122578 A TW95122578 A TW 95122578A TW I435782 B TWI435782 B TW I435782B
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cemented carbide
composite
article
binder
mold
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TW200726551A (en
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Prakash K Mirchandani
Michale E Waller
Jeffrey L Weigold
Billy D Swearengin
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Tdy Ind Llc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/22—Making metal-coated products; Making products from two or more metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/004—Article comprising helical form elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool
    • Y10T407/1904—Composite body of diverse material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T408/00—Cutting by use of rotating axially moving tool
    • Y10T408/89—Tool or Tool with support
    • Y10T408/907—Tool or Tool with support including detailed shank
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/131—Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/131—Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
    • Y10T428/1317—Multilayer [continuous layer]

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Drilling Tools (AREA)
  • Milling Processes (AREA)

Description

具有冷卻劑通道之合構物件及工具製法
本發明標的大體為各種形成具有包括相異組成及/或顯微結構之複合構造之物件譬如刀胚之方法。本發明額外標的為具有複合構造及至少一冷卻劑通道之旋轉刀具(工具)及旋轉刀具之刀胚。本發明之方法適用於旋轉刀具生產方面之一般應用，且可應用於例如材料移除作業譬如鑽孔、絞孔、鑽錐坑、鑽柱坑、及端銑中所用膠結碳化物旋轉刀具之生產。
膠結碳化物旋轉刀具(即受驅動旋轉之刀具)常採用於機製作業，例如鑽孔、絞孔、鑽錐坑、鑽柱坑、端銑、以及攻螺絲。此等刀具典型為屬固體單石構造。此等刀具之製法可涉及將冶金粉末(由粒狀陶瓷及黏結劑金屬組成)壓實以形成粉壓胚。然後將該粉壓胚膠結以形成具有固體單石構造之圓柱形刀胚。如本文中所用，單石構造意指該等刀具為由在該刀具內之任何工作容積時均具有大致相同特性之材料譬如膠結碳化物材料構成。繼膠結之後，該刀胚予適當機製以形成該旋轉刀具特殊幾何形狀之刀刃及其他徵貌。旋轉刀具包括例如鑽頭、端銑刀、絞刀、及螺絲攻。
由膠結碳化物構成之旋轉刀具適合多種工業應用，包括建築材料譬如金屬、木材、及塑膠之切削及製形。膠結碳化物刀具因此類材料抗拉強度、耐磨耗性、及韌性之組合特性而具工業重要性。膠結碳化物材料包含至少二相位：至少一硬質陶瓷成分及一較軟之金屬黏結劑基質。該硬質陶瓷成份可例如為週期表內IVB至VIB族中元素之碳化物。一常見實例為碳化鎢。該黏結劑可為金屬或金屬合金，典型為鈷、鎳、鐵或此等金屬之合金。該黏結劑將該陶瓷成分〝膠結〞於一成三度空間互連之基質內。膠結碳化物可藉由將一由至少一粉狀陶瓷成分及至少一粉狀黏結劑所成冶金粉末壓實予以製成。
膠結碳化物之物理及化學性質部分取決於生產該材料所用冶金粉末之個別成分。該等膠結碳化物材料之性質係由例如該陶瓷成分之化學組成、該陶瓷成分之粒徑、該黏結劑之化學組成、以及黏結劑對陶瓷成分之比率所決定。改變該冶金粉末之成分可生產具有配合特定應用之獨特性質之旋轉刀具，譬如鑽頭及端銑刀。
單石旋轉刀具可額外包含冷卻劑通道，延伸過其主體及柄以允許冷卻劑譬如油或水流至該旋轉刀具之各刀面。該冷卻劑可在柄末端進入該通道並在鑽頭尖點離開。該冷卻劑將該旋轉刀具及工件冷卻並協助將切角及塵屑驅離孔口。在機製作業期間使用冷卻劑除延長刀具壽命外，尚容許該旋轉刀具使用較高之切削速率及較快之進料率。具有冷卻劑通道之旋轉刀具格外適合在硬質材料上鑽挖深孔。
然而，單石構造之旋轉刀具先天限制其等之性能及應用範圍。舉例言之，圖1描繪一具有在建築材料譬如金屬、木材、及塑膠上產生及完成孔口所用典型設計之蔴花鑽10之側面及末端視圖。蔴花鑽10包括一對工件作初始切入之鑿緣11。鑽10之刀尖14跟隨鑿緣11，並於鑽孔時將大部分之材料移除。刀尖14外周邊16將孔口完成。在切削程序期間，切削速率自該鑽中心到該鑽外周邊顯著改變。此現象示於圖2，其以圖表比較一典型蔴花鑽之刀尖上內徑(D1)、外徑(D3)、及中徑(D2)處之切削速率。圖2(b)中，外徑(D3)為1.00吋而直徑D1及D2分別為0.25及0.50吋。圖2(a)顯示該蔴花鑽以每分鐘200轉操作時該三直徑處之切削速率。如圖2(a)及(b)所示，在各旋轉刀具刀刃上各點所測切削速率將隨離開各旋轉軸之距離而增加。
由於此等切削速率變化，具有單石構造之鑽頭及其他旋轉刀具將不在該刀具刀面中心到外側緣範圍內不同點經歷均勻之刀具刀刃磨耗及/或缺損及裂開。又，鑽挖經表面硬化之材料時，該鑿緣通常用以穿刺表皮，而鑽體其餘部分則自該經表面硬化材料之較軟心部移除材料。因此，該應用上所用習用單石構造鑽頭之鑿緣將以遠快於刀刃其餘部分之速率磨耗，造成此等鑽頭之較短使用壽命。在二者情況下，由於習用膠結碳化物鑽頭之單石構造，故頻繁之刀刃再研磨乃屬必要，因而對該尖塊之使用壽命設下顯著之限制。頻繁之再研磨及刀具更換亦造成所用工具機之超量停工時間。
因此，合構物件譬如合構旋轉刀具曾予使用，譬如美國專利6,511,265號中所述各種刀具，其全體係以指述方式納入本文。若經正確設計，合構旋轉刀具相較於具有單石構造之旋轉刀具可增長刀具使用壽命。然則存在對於在刀具不同區域具有不同特性且包含冷卻劑通道之各種鑽頭及其他旋轉刀具之需求。舉例言之，存在對於不管相對於刀具旋轉軸之刀具面上位置為何將經歷大致同一磨耗且容許於刀面冷卻之各種膠結碳化物鑽頭及其他旋轉刀具之需求。有需求一種具有冷卻劑通道之合構旋轉刀具，如此則合構旋轉刀具可擁有相同於單石旋轉刀具之利益。亦有需求一種生產合構旋轉刀具及包含冷卻劑通道之合構旋轉刀具之多用途方法。
本發明之各具體形式包括各種包含至少一第一區域及一第二區域之合構物件。該第一區域可包含一第一合構材料，其中該第一區域包含小於5重量%碳化物方塊，而該第二區域可包含一第二合構材料，其中該第二合構材料至少有一特性不同於該第一合構材料。該合構物件可額外包含至少一冷卻劑通道。在某些具體形式中，該第一及第二合構材料可各自包含在黏結劑中之硬粒子，其中該等硬粒子獨立包含碳化物、氮化物、硼化物、矽化物、氧化物、及其等之固熔體中至少一種，而該黏結劑包含至少一由鈷、鎳、鐵、及其等之合金中選出之金屬。在各種特定具體形式中，該第一合構材料及該第二合構材料可各自包含在黏結劑中之金屬碳化物。
該特性可為至少一由彈性模數、硬度、耐磨耗性、破裂韌性、抗拉強度、抗腐蝕性、熱膨脹係數、以及熱傳導係數所成群組中選出之特性。該合構物件可為例如旋轉刀具、旋轉刀具刀胚、鑽頭、端銑刀、絞刀、螺絲攻、桿、及棒中之一。在一些具體形式中，該合構物件尚可包含二或更多冷卻劑通道，而該等冷卻劑通道可為大致筆直或大致螺旋形。
本發明之各具體形式包括一種形成物件之方法，包含共同擠製至少二包含金屬碳化物之合構材料，以形成一生壓胚。該共同擠製至少二合構材料之工作可經由模子執行，而在某些具體形式中，該模子可包含在該生壓胚上製成內通道之裝置。該模子可包含至少一絲線以於該生壓胚上形成一內通道，其中該金屬線可為剛性或撓性。
該等具體形式亦包括一種生產一具有複合結構之旋轉刀具之方法，包含將一擠製之第一金屬粉置於一鑄模空隙之一第一區域內，將一第二冶金金屬粉置於該空隙之一第二區域內而該擠製之第一金屬粉異於該第二冶金粉，以及壓縮該鑄模將該擠製之第一金屬粉及該第二金屬粉壓實以形成生壓胚。該生壓胚可予燒結以形成物件。可在燒結前或之後自該生壓胚移除材料以提供至少一刀刃。
閱讀者將在斟酌下文中本發明各具體形式之詳述時認知本發明之前述以及其他細節及優點。閱讀者亦可在使用本發明時領會本發明之此等額外細節及優點。
10‧‧‧蔴花鑽
11‧‧‧鑿緣
14‧‧‧刀尖
16‧‧‧外周邊
410、441‧‧‧外部區域
415‧‧‧界面
420‧‧‧心部區域
430‧‧‧冷卻劑通道
440‧‧‧桿
442、443‧‧‧內部區域
450‧‧‧集合
451、620‧‧‧管
452、453、610‧‧‧桿
600‧‧‧進料室
630‧‧‧漏斗
640、645‧‧‧模子
650‧‧‧通道模子
660‧‧‧絲線
670‧‧‧臂
680‧‧‧擠製材料
本發明之各項特色及優點可藉參考各後附圖式予更清楚了解，其中：圖1(a)及1(b)分別為一具有冷卻劑通道之習用蔴花鑽之平面及末端視圖；圖2(a)為一圖表，指示在圖2(b)中所示習用蔴花鑽三種直徑D1、D2及D3處之切削速率；圖3(a)及3(b)包括以本發明各種方法具體形式生產之桿之橫斷面(圖3(a))及縱斷面(圖3(b))，包含中央B等級碳化物心部及A等級膠結碳化物殼部；圖4(a)－(d)為一合構膠結碳化物具體形式之橫斷面視圖；圖5(a)－(d)為胚之具體形式，顯示不同構型之冷卻劑通道實例，譬如單一筆直冷卻劑通道(圖5(a))；二筆直冷卻劑通道(圖5(b))；二螺旋形通道(圖5(c))；及三螺旋形通道(圖5(d))；圖6(a)為一A等級管及一B等級桿經由具有內螺旋形鋸齒之模子生產具有螺旋形通道之胚之共同擠製中所用共同擠製加壓裝置之圖示；圖6(b)為一通道模子之圖示；圖6(c)為具有內通道之共同擠製型合構膠結碳化物桿離開具有螺旋形鋸齒之模子時之照片；圖7為一包括用A等級膠結碳化物所製具有內通道之擠製桿將B等級膠結碳化物壓實之本發明方法具體形式中所用乾袋等力加壓裝置之圖示；圖8(a)為本發明具有內冷卻劑通道之合構桿之縱斷面照片，該照片中之耐綸線已經***各通道內以更清楚顯示其等位置及各冷卻劑通道之路徑；而圖8(b)為一由具有內冷卻劑通道之合構膠結碳化物所製鑽頭之縱斷面照片。
本發明提供各種刀具、刀具胚、桿、及其他具有複合構造之物件，以及此等物件之製法。若有需要，該等物件尚可包含內通道，譬如冷卻劑通道。如本文中所用，旋轉刀具乃一具有至少一刀刃之受驅動旋轉之刀具。本文中所用〝複合〞構造係指一具有相異化學組成及/或顯微結構之區域之物件。此等差異造成各區域具有在至少一特性方面相異之性質。該特性可為例如硬度、抗拉強度、耐磨耗性、破裂韌性、彈性模數、抗腐蝕性、熱膨脹係數、以及熱傳導係數中至少一項。可如本發明所提供予以構作之合構旋轉刀具包括鑽頭及端銑刀，以及其他可用於例如材料之鑽孔、絞孔、鑽錐坑、鑽柱坑、端銑、及攻螺絲。
本發明更明確為提供一具有至少一刀刃、至少二個在至少一特性方面相異之膠結碳化物材料區域、及至少一冷卻劑通道之合構旋轉刀具。該等相異特性可藉改變該二膠結碳化物材料區域內化學組成及/或顯微結構中至少一項予以提供。一區域之化學組成為例如該區域之陶瓷成分及/或黏結劑之化學組成以及該區域之碳化物對黏結劑比率之函數。舉例言之，該旋轉刀具二膠結碳化物材料區域中之一可較該二區域中另一個呈現較大之耐磨耗性、提升之硬度、及/或較大之彈性模數。
本發明之各方面可相關於圖4(a)中以橫過該軸之橫斷面視圖所示刀胚加以說明。刀胚為具有二個共軸置放之 膠結碳化物區域410、420及冷卻劑通道430之大體圓柱形膠結粉壓胚。然而，業界熟練人士均將明白，以下對本發明之論述亦可適用於製作具有複雜幾何形狀及/或多於二個區域之合構旋轉刀具及刀胚。因此，以下論述無意拘束本發明，但僅例示其各種具體形式。
在圖4(a)之具體形式中，圓柱形旋轉刀胚係由二相異膠結碳化物區域構成，一為心部區域420而一為外部區域410。心部區域420及外部區域410二者均為將陶瓷粒子包括在連續黏結劑基質內之膠結碳化物材質。在心部區域420及在外部區域410內之膠結碳化物材料較佳為包括由一或更多週期表內IVB至VIB族中元素之碳化物組成之陶瓷成分，包括小於5重量%之碳化物方塊，或在一些應用上為小於3重量%之碳化物方塊。本發明之各具體形式可包含小於5重量%之碳化物方塊，因該等碳化物方塊可能減小該物件之橫向破裂強度，增加生產成本，及減小破裂韌性。此對用以機製硬質工件之刀具尤其重要，其中機製工作造成剪切作用，故鑽頭之強度應為最大。
該陶瓷成分較佳為約佔各區域內膠結碳化物材料總重之60至98重量%。該等碳化物粒子係埋置於該黏結劑物質之基質內，後者較佳為約構成各區域內總體物料之2至40重量%。該黏結劑較佳為鈷、鎳、鐵、及此等元素之合金中一或多種。該黏結劑亦可含有例如鎢、鉻、鈦、鉭、釩、鉬、鈮、鋯、鉿、及碳等元素，而高達此等元素在該黏結劑內之溶解度限值。此外，該黏結劑可含有高達5重 量%之各種譬如銅、錳、銀、鋁、及釕之元素。業界熟練人士將認知，任一或所有該膠結碳化物材料之成分可以元素形式、化合物、及/或母合金予引進。
刀胚之心部區域420係在一界面415處以自生方式黏接於外部區域410。圖4(b)中所示之界面440為圓筒形，但一般均將了解，本發明合構旋轉刀具各膠結碳化物材料區域之界面形狀不限於圓筒構形。各區域間界面415處之自生性黏接可由例如一以三度空間自心部區域420延伸至外部區域410(反之亦然)之黏結劑基質予以形成。該二區域內之黏結劑對陶瓷成分比率可相同或不同，且可在該等區域間予以改變以影響各區域之相對特性。僅屬舉例，該合構刀胚各毗鄰區域內之黏結劑對陶瓷成分比率可相差1至10重量%。本發明合構旋轉刀具不同區域內之膠結碳化物材料特性可對特定應用加以裁修。
業界熟練人士在已斟酌本發明說明後將了解，本發明之改良旋轉刀具可用若干層之不同膠結碳化物材料構作，以自該刀具中心區域到其週邊產生一或更多特性之連續級數。因此，舉例言之，可提供一具有多個共軸置放之膠結碳化物材料區域之蔴花鑽，其中每一此等區域具有連續大於置於較中心之毗鄰區域之硬度及/或耐磨耗性。冷卻劑通道可提供於任一該等區域內或與二或三個區域交叉。本發明之各方法在擠製物件之設計上提供大量之設計彈性。另法，本發明之旋轉刀具可製成具有其他複合構形，其中一特定特性上之差一出現於刀具之不同區域。
本發明合構膠結碳化物旋轉刀具之主要優點為可供刀具設計者利用以裁修各刀具區域性質以適合不同應用之彈性。舉例言之，本發明特定合構胚之個別膠結碳化物材料區域之尺寸、位置、厚度、幾何形狀、及/或物理性質可選擇以適合該胚所製旋轉刀具之特定應用。此外，該等冷卻劑通道可置於所需之位置且為螺旋形、直線形、或此等形狀之組合形。因此，舉例言之，使用期間經歷顯著彎曲之旋轉刀具之一或更多膠結碳化物區域之剛性可為具有提升彈性模數之膠結碳化物材料之剛性；具有刀面且經歷大於其他區域之切削速率之一或更多膠結碳化物區域之硬度及/或耐磨耗性可予增高；且/或使用期間受到化學物接觸之膠結碳化物區域之抗腐蝕性可予提升。
圖4(b)及4(c)顯示本發明之額外具體形式。此等具體形式可額外包含各種通道，譬如冷卻劑通道。圖4(b)之具體形式包含一具有不同等級膠結碳化物之內部區域之管。此實例中，桿440包含一第一膠結碳化物之外部區域441、一第二膠結碳化物之第一內部區域442、以及一可包含相同或不同膠結碳化物之額外內部區域443。桿440可例如藉由共同擠製一包含填裝以桿452及453之管451之集合450予以生產。桿452可例如由具有至少一不同於桿453之特性之膠結碳化物予以形成。
僅屬舉例，本發明旋轉刀具之額外具體形式包括一階段鑽頭，包含一刀部，包括若干螺旋形定向刀刃。該鑽頭亦包括一安裝部，由一夾頭接納以將該鑽頭安裝於工具機 (未示出)。該鑽頭包括彼此相對在至少一特性上相異之三個膠結碳化物材料區域。一第一區域位於該鑽頭之刀尖。該第一區域所由構成之膠結碳化物材料相對於一形成該鑽頭心部之一中心區域呈現提升之耐磨耗性及硬度。該心部區域為相對於其餘二區域呈現提升之彈性模數之膠結碳化物材質。提升之彈性模數減少該鑽頭在其受迫與工件接觸時彎曲之傾向。該鑽頭亦包括一外部區域界定若干螺旋形定向刀刃。該外部區域包圍該心部區域並相對其共軸置放。該外部區域係由相對於該心部區域及該尖部區域二者呈現提升之硬度及耐磨耗性之膠結碳化物材料構成。由該外部區域界定之各刀面經歷快於該鑽頭中心軸附近各切削區域之切削速率。因此，該外部區域之提升耐磨耗性及硬度可加以選擇俾獲致均一之刀面磨耗。
本發明之各具體形式亦包括額外之膠結碳化物合構物件製法。該等具體形式包括藉由共同擠製至少二包含膠結碳化物之合構材料以形成生壓胚之合構物件形成方法。該共同擠製工作可以直接或間接擠製程序執行。擠製機之進料室予填裝二種等級之材料，譬如二種等級之碳化物粉及與一塑膠黏結劑混合之黏結劑粉。該塑膠黏結劑物質可以約33重量%至67重量%之濃度存在，而將該金屬粉混合物之黏滯度減小以容許擠製。膠結碳化物之擠製程序詳知於業界。在一典型擠製程序中，各金屬粉係與一塑膠黏結劑混合。任何典型塑膠黏結劑均可使用，譬如以苯甲基醇、纖維素、聚合物、或石油產物為基底之塑膠黏結劑。典型為使用高光澤混合程序以確保該等金屬粉與該塑膠黏結劑間之親密接觸。
然後，該金屬/黏結劑混合物可藉螺旋式進料機泵唧過該擠製機以生成一擠製產物。本發明方法之各具體形式包括至少二種膠結碳化物等級之共同擠製。本文中所用共同擠製一詞意指該二種材料予同時擠製以形成一併有二者材料之單一物件。任何擠製程序均可用於本發明方法，譬如將二種等級之膠結碳化物泵唧至單獨之漏斗或模區位，其中該二等即以彼此親密接觸方式離開模子。
該擠製程序之一具體形式示於圖6(a)。進料室600予填裝一第一等級膠結碳化物粉製之桿610及一第二等級膠結碳化物粉製之管620。桿610及管620係各自以業界所知之單獨擠製程序形成。在某些具體形式中，管620可直接擠入進料室600。然後，可將一單獨擠製程序中形成之桿610***已在進料室600內之管620內部。
在此擠製程序具體形式中，一柱塞(未示出)將桿610及管620推過該進料室並進入漏斗630。漏斗630自該進料室到模子640之橫斷面積減小。漏斗630導致膠結碳化物粉緊密及壓實，造成桿610與管620間之親密接觸及生壓胚(〝擠製材料〞)之形成。
在某些具體形式中，該擠製程序亦可包括一併入漏斗630與模子640間之通道模子650。該通道模子包含二絲線660，或者該通道模子可包含其他用以在該生壓胚上製成內通道之裝置。絲線660予連接於將絲線660固定之臂670，故彼等可接觸該擠製材料。絲線660造成通道之形成於該擠製材料內。絲線660可由任何能在該擠製材料上形成通道之材料製成，譬如但不限於耐綸、聚合物塗面金屬線、聚乙烯、高密度聚乙烯、聚酯、聚氯乙烯、聚丙烯、芳香聚醯胺、Kevlar、聚醚酮、天然物質、棉花、***、以及黃麻。在某些應用譬如螺旋形定向通道之形成中，該絲線較佳為撓性絲線。然而，對於直線定向通道及在一些螺旋應用上，剛性絲線可予使用。該等通道可用作旋轉刀具內之冷卻劑通道。絲線660可用以形成螺旋形定向通道、直線形定向通道、以及其等之組合形式。該絲線或其他通道製成用組件之橫斷面可為任何形狀，譬如圓形、橢圓形、三角形、正方形、及六邊形。
螺旋形定向通道可在該擠製材料相對於通道模子650旋轉之具體形式中形成於該擠製材料上。該擠製材料可藉由將螺旋形鋸齒併入模子640內予以旋轉。在圖6(c)中，擠製材料680離開模子645，而模子645內表面上包括螺旋形鋸齒。當該擠製材料在螺旋形鋸齒上方通過時，即導使該擠製材料相對於該通道模子(未示出)旋轉。另法，該模子可旋轉以導致該擠製材料相對於該通道模子(未示出)旋轉。可使用其他通道模子譬如包含固定式螺圈之通道模子，其中導使該擠製材料以相同於螺圈之旋轉方式相對於該通道模子旋轉，或使用任何其他通道形成用裝置。
該通道模子可為單獨之組件，或者可與該漏斗、模子、或該擠製系統內之其他組件連成一體。該通道模子可為能在該擠製材料上製成至少一通道。通道之數量及尺寸可能受限於該擠製材料之尺寸、該等通道之尺寸、以及該擠製材料之最終用途應用。在包含一內含絲線之通道之具體形式中，絲線之數量將與該擠製材料上所形成通道之數量對應。對旋轉刀具應用而言，因將有例如槽道之緣故，可能以具有等數量之通道為屬較佳。
本發明各具體形式尚可包括用至少二種膠結碳化物等級裝載該進料室。該進料室內所裝載之至少一種膠結碳化物等級可為桿、管、棒、條、長方體、齒輪形、星形、或任何其他可在擠製程序形成之形狀。在旋轉刀具或輥子應用中，可能較佳為該二膠結碳化物等級中至少有一為桿型之形式且至少一種膠結碳化物為管形。在其他應用中，該進料室可填裝多支不同膠結碳化物等級之管及/或桿。若使用複數之桿，則該擠製材料可用特定等級之膠結碳化物形成於特定區域內或與隨機分布於該擠製材料之整個橫斷面。
本發明之進一步具體形式可包含將一膠結碳化物等級擠出以形成一擠製生壓胚，並將該擠製生壓胚與一第二膠結碳化物等級加壓以形成一壓製生壓胚。該擠製生壓胚可隨意包含例如如上述所形成之內通道。
以下為前述依據本發明提供合構旋轉刀具之方法之實際應用範例。
雖然本發明已相關於某些具體形式加以說明，但業界之普通技術人士在斟酌前列說明時均將認知本發明之各種修改及變化形式均可以採用。本發明之所有此等變化及修改形式均意圖由前列說明及後附申請專利範圍予以涵蓋。
410．．．外部區域
415．．．界面
420．．．心部區域
430．．．冷卻劑通道

Claims (61)

  1. 一種合構物件，包含：至少一外部區域及一共軸置放之心部區域，其中該外部區域包含一第一合構材料及小於5重量%碳化物方塊，該心部區域包含一第二合構材料，且其中該第一合構材料至少有一特性異於該第二合構材料；以及至少一縱向置於該合構物件內部之冷卻劑通道，其中該冷卻劑通道係設置於該外部區域與該心部區域間之界面處以及在該外部區域及該心部區域二者範圍內延伸。
  2. 如申請專利範圍第1項之合構物件，其中該第一合構材料及該第二合構材料各自包含在黏結劑中之硬粒子，該等硬粒子獨立包含碳化物、氮化物、硼化物、矽化物、氧化物、及其等之固熔體中至少一種，而該黏結劑包含至少一由鈷、鎳、鐵、鈷合金、鎳合金、及鐵合金所組成群組中選出之材料。
  3. 如申請專利範圍第1項之合構物件，其中該特性為至少一由彈性模數、硬度、耐磨耗性、破裂韌性、抗拉強度、抗腐蝕性、熱膨脹係數、以及熱傳導係數所組成群組中選出之特性。
  4. 如申請專利範圍第1項之合構物件，其中該第一合構材料及該第二合構材料各自包含一在黏結劑中之金屬碳化物。
  5. 如申請專利範圍第4項之合構物件，其中該第一合構材料之金屬碳化物中之金屬及該第二合構材料之金屬碳 化物中之金屬各自由IVB族、VB族及VIB族元素所組成群組中選出。
  6. 如申請專利範圍第4項之合構物件，其中該外部區域藉該等黏結劑之一自該心部區域至該外部區域或自該外部區域至該心部區域延伸之基質黏接於該心部區域。
  7. 如申請專利範圍第4項之合構物件，其中該第一合構材料之黏結劑及該第二合構材料之黏結劑各自包含一由鈷、鈷合金、鎳、鎳合金、鐵、及鐵合金所組成群組中選出之材料。
  8. 如申請專利範圍第4項之合構物件，其中該第一合構材料之黏結劑在化學組成上異於該第二合構材料之黏結劑。
  9. 如申請專利範圍第4項之合構物件，其中該第一合構材料之黏結劑重量百分比異於該第二合構材料之黏結劑重量百分比。
  10. 如申請專利範圍第4項之合構物件，其中該第一合構材料之金屬碳化物在化學組成及平均晶粒尺寸中至少一項上異於該第二合構材料之金屬碳化物。
  11. 如申請專利範圍第4項之合構物件，其中該第一合構材料及該第二合構材料各自包含2至40重量%之該黏結劑及60至98重量%之該金屬碳化物。
  12. 如申請專利範圍第11項之合構物件，其中該第一合構材料及該第二合構材料中之一較該第一合構材料及該第二合構材料中另一種多包括1至10重量%之該黏結劑。
  13. 如申請專利範圍第1項之合構物件，其中該合構物件為旋轉刀具、旋轉刀具胚、鑽頭、端銑刀、螺絲攻、桿、及棒中之一。
  14. 如申請專利範圍第3項之合構物件，其中在該外部區域內之該第一合構材料之彈性模數異於在該心部區域內之該第二合構材料之彈性模數。
  15. 如申請專利範圍第3項之合構物件，其中在該外部區域內之該第一合構材料之硬度及耐磨耗性中至少一項異於在該心部區域內之該第二合構材料。
  16. 如申請專利範圍第1項之合構物件，包含二冷卻劑通道。
  17. 如申請專利範圍第1項之合構物件，其中該至少一冷卻劑通道為大致筆直。
  18. 如申請專利範圍第1項之合構物件，其中該至少一冷卻劑通道為大致螺旋形。
  19. 如申請專利範圍第18項之合構物件，包含二冷卻劑通道。
  20. 如申請專利範圍第1項之合構物件，其中該第一合構材料及該第二合構材料為膠結碳化物。
  21. 一種形成申請專利範圍第1項之合構物件之方法，包含：共同擠製至少二包含金屬碳化物之合構材料，以形成一生壓胚，其中該至少二合構材料為不同之膠結碳化物等級。
  22. 如申請專利範圍第21項之方法，其中該共同擠製至少二合構材料之工作係經由一模子予以執行。
  23. 如申請專利範圍第22項之方法，其中該模子包含在該生壓胚上製成內通道之裝置。
  24. 如申請專利範圍第22項之方法，其中該模子包含至少一絲線。
  25. 如申請專利範圍第24項之方法，其中該至少一絲線在該生壓胚內形成一內通道。
  26. 如申請專利範圍第24項之方法，其中該模子包含至少二絲線。
  27. 如申請專利範圍第26項之方法，其中該模子包含三絲線。
  28. 如申請專利範圍第24項之方法，其中該至少一絲線為撓性絲線。
  29. 如申請專利範圍第28項之方法，其中該撓性絲線包含耐綸、聚合物塗面金屬線、聚乙烯、高密度聚乙烯、聚酯、聚氯乙烯、聚丙烯、芳香聚醯胺、Kevlar、聚醚酮、棉花、動物腸線、***、以及黃麻中至少一種。
  30. 如申請專利範圍第24項之方法，其中該絲線為非撓性物。
  31. 如申請專利範圍第30項之方法，其中該絲線包含金屬。
  32. 如申請專利範圍第21項之方法，其中至少一種膠結碳化物等級為擠製形式。
  33. 如申請專利範圍第32項之方法，其中該擠製形式為桿、棒、及管中至少一種。
  34. 如申請專利範圍第21項之方法，其中至少一膠結碳化物為桿形且至少一膠結碳化物為管形。
  35. 如申請專利範圍第32項之方法，其中至少二膠結碳化物為管形。
  36. 如申請專利範圍第34項之方法，其中該為桿形式之膠結碳化物係直接擠入一共同擠製機之進料室內。
  37. 如申請專利範圍第21項之方法，其中該生壓胚包含二種膠結碳化物等級而該等膠結碳化物等級係共軸置放。
  38. 如申請專利範圍第22項之方法，其中該模子包括一通道模子。
  39. 如申請專利範圍第22項之方法，其中該至少二合構材料為至少二種類型之膠結碳化物，而該模子包含內螺旋鋸齒。
  40. 如申請專利範圍第22項之方法，其中該至少二合構材料為至少二種類型之膠結碳化物，而該模子係一旋轉模子。
  41. 如申請專利範圍第22項之方法，其中該生壓胚包含至少一通道。
  42. 如申請專利範圍第22項之方法，其中該生壓胚包含二螺旋通道。
  43. 如申請專利範圍第1項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第 二膠結碳化物材料，且該第一膠結碳化物材料及該第二膠結碳化物材料中至少一種包含平均晶粒尺寸為0.3至10微米之碳化鎢粒子。
  44. 如申請專利範圍第1項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第二膠結碳化物材料，且該第一膠結碳化物材料及該第二膠結碳化物材料中之一包含平均晶粒尺寸為0.5至10微米之碳化鎢粒子，而該第一膠結碳化物材料及該第二膠結碳化物材料中另一種包含平均晶粒尺寸為0.3至1.5微米之碳化鎢粒子。
  45. 如申請專利範圍第1項之合構物件，其中該合構物件為鑽頭、端銑刀、及螺絲攻中之一。
  46. 如申請專利範圍第5項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第二膠結碳化物材料，且該第一膠結碳化物材料及該第二膠結碳化物材料中之一較該第一膠結碳化物材料及該第二膠結碳化物材料中另一種多包括1至10重量%之該黏結劑。
  47. 如申請專利範圍第1項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第二膠結碳化物材料，且在該外部區域內之該第一膠結碳化物材料之彈性模數異於在該心部區域內之該第二膠結碳化物材料之彈性模數。
  48. 如申請專利範圍第20項之合構物件，其中每一膠結碳化物材料具有一彈性模數，且其中在該外部區域內之該 第一膠結碳化物材料之彈性模數為90×106 至95×106 psi，而在該心部區域內之該第二膠結碳化物材料之彈性模數為69×106 至92×106 psi。
  49. 如申請專利範圍第1項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第二膠結碳化物材料，且在該外部區域內之該第一膠結碳化物材料之硬度及耐磨耗性中至少一項異於在該心部區域內之該第二膠結碳化物材料之硬度及耐磨耗性。
  50. 如申請專利範圍第1項之合構物件，其中該第一合構材料係一第一膠結碳化物材料，該第二合構材料係一第二膠結碳化物材料，且該第一膠結碳化物材料包含6至15重量%鈷合金，而該第二膠結碳化物材料包含10至15重量%鈷合金。
  51. 一種生產具有複合結構之旋轉刀具之方法，該方法包含：將一擠製之包含一第一冶金粉之生壓胚置於一乾袋式橡膠鑄模之一第一區域內；將一第二冶金粉置於該乾袋式橡膠鑄模之一第二區域內，該第一冶金粉異於該第二冶金粉；等力壓縮該乾袋式橡膠鑄模將該擠製之生壓胚及該第二冶金粉壓實以形成一具有至少一外部區域及一共軸置放之心部區域之壓製生壓胚；以及超壓燒結該生壓胚；其中該壓製生壓胚包含至少一縱向置於該壓製生壓 胚內部之冷卻劑通道，其中該冷卻劑通道與該外部及心部二區域相交。
  52. 如申請專利範圍第51項之方法，尚包含：自該生壓胚移除材料以提供至少一刀刃。
  53. 如申請專利範圍第52項之方法，其中自該生壓胚移除材料之工作包含機製該壓胚以形成界定至少一螺旋形定向刀刃之至少一螺旋形定向槽道。
  54. 如申請專利範圍第51項之方法，其中該第一冶金粉及該第二冶金粉二者均包含一粉狀黏結劑及一由IVB族、VB族及VIB族所組成群組中選出之元素之至少一碳化物所成之多個粒子。
  55. 如申請專利範圍第54項之方法，其中該第一冶金粉及該第二冶金粉之黏結劑各自包含至少一由鈷、鈷合金、鎳、鎳合金、鐵、及鐵合金所組成群組中選出之金屬。
  56. 如申請專利範圍第55項之方法，其中該第一冶金粉及該第二冶金粉各自包含2至40重量%之該粉狀黏結劑及60至98重量%之該碳化物粒子。
  57. 如申請專利範圍第51項之方法，其中該第一冶金粉及該第二冶金粉中至少一種包含平均粒徑為0.3至10微米之碳化鎢粒子。
  58. 如申請專利範圍第51項之方法，其中超壓燒結該壓胚之工作包含在300-2000psi之壓力以1350至1500℃之溫度將該壓胚加熱。
  59. 如申請專利範圍第51項之方法，其中壓縮該鑄模之 工作包含以5,000至50,000psi之壓力等力壓縮該鑄模。
  60. 如申請專利範圍第51項之方法，其中該藉由壓縮該鑄模所形成之生壓胚包含：一外部區域，包含一藉由壓實該第一冶金粉所提供之第一膠結碳化物材料；以及一心部區域，包含一藉由壓實該第二冶金粉所提供之第二膠結碳化物材料，該外部區域與該心部區域在至少一特性方面相異。
  61. 如申請專利範圍第60項之方法，其中該特性為由彈性模數、硬度、耐磨耗性、破裂韌性、抗拉強度、抗腐蝕性、熱膨脹係數、以及熱傳導係數所組成群組中選出之至少一項。
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BRPI0607065A2 (pt) 2009-08-04
CN103551581A (zh) 2014-02-05
KR20080016812A (ko) 2008-02-22
US20070108650A1 (en) 2007-05-17
WO2007001870A2 (en) 2007-01-04
CN101166597A (zh) 2008-04-23
US8808591B2 (en) 2014-08-19
UA95912C2 (ru) 2011-09-26
JP2008546554A (ja) 2008-12-25
KR101353171B1 (ko) 2014-01-17
KR20130088900A (ko) 2013-08-08
EP1907154A2 (en) 2008-04-09
KR101317017B1 (ko) 2013-10-11
CA2596309A1 (en) 2007-01-04
US20140097553A1 (en) 2014-04-10
TW200726551A (en) 2007-07-16
US8637127B2 (en) 2014-01-28
US20130043615A1 (en) 2013-02-21
JP5288309B2 (ja) 2013-09-11
US8318063B2 (en) 2012-11-27
US20060288820A1 (en) 2006-12-28
WO2007001870A3 (en) 2007-05-10

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