WO2015182711A1 - 硬質被覆層がすぐれた耐チッピング性を発揮する表面被覆切削工具 - Google Patents
硬質被覆層がすぐれた耐チッピング性を発揮する表面被覆切削工具 Download PDFInfo
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/044—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/36—Carbonitrides
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/34—Nitrides
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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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- 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
- B23B27/148—Composition of the cutting inserts
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/308—Oxynitrides
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/32—Carbides
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/40—Oxides
- C23C16/403—Oxides of aluminium, magnesium or beryllium
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
- C23C16/45523—Pulsed gas flow or change of composition over time
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
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- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
- C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
Definitions
- the present invention is a high-speed intermittent cutting process that involves high heat generation of alloy steel and the like, and an impact load is applied to the cutting edge, and the hard coating layer has excellent chipping resistance, so that it can be used for a long time.
- the present invention relates to a surface-coated cutting tool (hereinafter referred to as a coated tool) that exhibits excellent cutting performance.
- WC tungsten carbide
- TiCN titanium carbonitride
- cBN cubic boron nitride
- the conventional coated tool formed with the Ti—Al composite nitride layer is relatively excellent in wear resistance, but it tends to cause abnormal wear such as chipping when used under high-speed intermittent cutting conditions. Accordingly, various proposals have been made for improving the hard coating layer.
- Patent Document 1 discloses a surface-coated cutting tool in which a hard coating layer is formed on the surface of a tool base, and the hard coating layer is configured by one or a plurality of layers and is cut in a specific plane.
- the hard coating layer when T1 is the thickness of the thinnest part of the edge of the cutting edge and T2 is a thickness 1 mm away from the edge of the cutting edge in the rake face direction, the surface of the hard coating layer satisfies T1 ⁇ T2.
- Patent Document 2 discloses a composite nitriding of Al and Ti that satisfies the composition formula (Al 1-x Ti x ) N (wherein x is 0.35 to 0.60) on the tool base surface.
- the crystal orientation ⁇ 100> is within a range of 0 to 15 degrees from the normal direction of the surface polished surface.
- the area ratio of the crystal grains is 50% or more, and the ratio of the small-angle grain boundaries (0 ⁇ ⁇ 15 °) is 50% or more when the angle formed between adjacent crystal grains is measured. It is disclosed that excellent fracture resistance can be obtained in heavy cutting by forming a hard coating layer with a composite nitride layer of Al and Ti showing a crystal arrangement.
- Patent Document 3 discloses that a chemical vapor deposition is performed in a mixed reaction gas of TiCl 4 , AlCl 3 , and NH 3 in a temperature range of 650 to 900 ° C., so that the value of the Al content ratio x is 0.65 to
- this reference further describes an Al 2 O 3 layer on the (Ti 1-x Al x ) N layer. Therefore, the value of the Al content ratio x is increased from 0.65 to 0.95 to form a (Ti 1-x Al x ) N layer. It is not clear what kind of influence the cutting performance has.
- Patent Document 4 a TiCN layer and an Al 2 O 3 layer are used as an inner layer, and a cubic structure (Ti 1-x Al) having a cubic structure or a hexagonal structure is formed thereon by chemical vapor deposition.
- x ) N layer (wherein x is 0.65 to 0.90 in atomic ratio) is coated as an outer layer, and a compressive stress of 100 to 1100 MPa is applied to the outer layer, whereby the heat resistance and fatigue strength of the coated tool It has been proposed to improve.
- Japanese Unexamined Patent Publication No. 2012-20391 Japanese Unexamined Patent Publication No. 2009-56540 (A) Japan Special Table 2011-516722 Publication (A) Japanese National Table 2011-513594 (A)
- the Al content ratio x can be increased and a cubic structure can be formed. Therefore, although a hard coating layer having a predetermined hardness and excellent wear resistance can be obtained, there is a problem that the toughness is inferior. Furthermore, although the coated tool described in Patent Document 4 has a predetermined hardness and excellent wear resistance, it is inferior in toughness, so when it is used for high-speed intermittent cutting of alloy steel, etc. However, there is a problem that abnormal damage such as chipping, chipping and peeling is likely to occur, and it cannot be said that satisfactory cutting performance is exhibited.
- the technical problem to be solved by the present invention that is, the purpose of the present invention is to provide excellent toughness even when used for high-speed interrupted cutting of alloy steel and the like, over a long-term use.
- the object is to provide a coated tool exhibiting excellent chipping resistance and wear resistance.
- the present inventors have at least a composite nitride or composite carbonitride of Ti and Al (hereinafter referred to as “(Ti, Al) (C, N)” or “(Ti 1-x Al x ) ( CyN 1-y ) ”), a hard coating layer containing a hard coating layer formed by chemical vapor deposition. Results of extensive research to improve chipping resistance and wear resistance. The following findings were obtained.
- the conventional hard coating layer including at least one (Ti 1-x Al x ) (C y N 1-y ) layer and having a predetermined average layer thickness is (Ti 1-x Al x ) (
- the C y N 1-y ) layer When the C y N 1-y ) layer is formed in a columnar shape in the direction perpendicular to the tool base, it has high wear resistance.
- the present inventors have conducted intensive research on the (Ti 1-x Al x ) (C y N 1-y ) layer constituting the hard coating layer, and found that (Ti 1-x Al x ) (C y N 1 ).
- -Y The cubic crystal structure is obtained by a completely new idea that the layer contains crystal grains having a cubic crystal structure, and the average orientation difference within the crystal grains of the crystal grains having the cubic crystal structure is 2 degrees or more.
- the inventors have succeeded in increasing the hardness and toughness by causing distortion in the crystal grains, and as a result, have found a novel finding that the chipping resistance and fracture resistance of the hard coating layer can be improved.
- the hard coating layer includes at least a composite nitride or composite carbonitride layer of Ti and Al formed by chemical vapor deposition, and has a composition formula: (Ti 1-x Al x ) (C y N 1 ⁇ y ), the average content ratio x avg in the total amount of Ti and Al in Al and the average content ratio y avg in the total amount of C and N in C (where x avg and y avg are either Also satisfy 0.60 ⁇ x avg ⁇ 0.95 and 0 ⁇ y avg ⁇ 0.005, respectively, and a cubic structure is formed in the crystal grains constituting the composite nitride or composite carbonitride layer.
- the average orientation within the crystal grain The crystal grains whose difference is 2 degrees or more are 20 in terms of the area ratio of the composite nitride or composite carbonitride layer
- the presence or can cause distortions in the cubic grains Furthermore, wear resistance is improved while maintaining toughness by increasing the ratio of the ⁇ 100 ⁇ orientation on the film surface side compared to the tool substrate surface side of the crystal grains.
- a cutting tool having such a hard coating layer has improved chipping resistance and fracture resistance and exhibits excellent wear resistance over a long period of time.
- the (Ti 1-x Al x ) (C y N 1-y ) layer having the above-described configuration is formed by, for example, the following chemical vapor deposition method that periodically changes the reaction gas composition on the tool base surface. can do.
- the chemical vapor deposition reactor to be used includes a gas group A composed of NH 3 and H 2 and a gas group B composed of TiCl 4 , Al (CH 3 ) 3 , AlCl 3 , N 2 , and H 2, respectively.
- the gas group A and the gas group B are supplied into the reactor from, for example, a constant cycle time interval so that the gas flows for a time shorter than the cycle.
- the reaction gas composition on the tool base surface is changed to the gas group A (first reaction gas), the gas group A and The gas group B can be changed in time with the mixed gas (second reaction gas) and the gas group B (third reaction gas).
- the gas supply port is rotated, the tool base is rotated, the tool base is reciprocated, the reaction gas composition on the surface of the tool base is changed to the gas group A as the main.
- the mixed gas (first reaction gas), the mixed gas of gas group A and gas group B (second reaction gas), and the mixed gas mainly composed of gas group B (third reaction gas) are changed over time. But it can be realized.
- the reaction gas composition (volume% with respect to the total of the gas group A and the gas group B) on the surface of the tool base is, for example, NH 3 : 4.0 to 6.0% as the gas group A, H 2 : 65 to 75.
- reaction atmosphere pressure 4.5 to 5.0 kPa
- reaction atmosphere temperature 700 to 900 ° C
- gas supply time per cycle 0.15 to (Ti 1-x Al x ) having a predetermined target layer thickness by performing a thermal CVD method for a predetermined time with a phase difference of 0.10 to 0.20 seconds between gas supply A and gas supply B for 0.25 seconds
- a (C y N 1-y ) layer is formed.
- the gas group A and the gas group B are supplied so as to have a difference in time to reach the tool base surface, and the nitrogen source gas in the gas group A is set to NH 3 : 4.0 to 6.0%.
- AlCl 3 0.6 to 0.9%
- TiCl 4 0.2 to 0.3%
- Al (CH 3 ) 3 0 to 0.5, which is a metal chloride raw material or carbon raw material in gas group B %
- Local compositional irregularities in the crystal grains, local distortion of the crystal lattice due to the introduction of dislocations and point defects, and the crystal grains on the tool substrate surface side and the film surface side are formed.
- the degree of ⁇ 100 ⁇ orientation can be changed.
- the hard coating layer includes at least a composite nitride or composite carbonitride layer of Ti and Al having an average layer thickness of 2 to 20 ⁇ m formed by chemical vapor deposition, and has a composition formula: (Ti 1-x Al x ) When expressed by (C y N 1-y ), the average content ratio x avg as the atomic ratio of the total amount of Ti and Al in the composite nitride or composite carbonitride layer and the composite nitride or composite The average content ratio y avg as an atomic ratio in the total amount of C and N in the carbonitride layer
- the composite nitride or composite carbonitride layer includes at least a phase of a composite nitride or composite carbonitride of Ti and Al having a NaCl-type face-centered cubic structure
- (C) Further, the crystal orientation of the crystal grains having the NaCl-type face-centered cubic structure in the crystal grains constituting the composite nitride or composite carbonitride layer is determined in the longitudinal section direction using an electron beam backscatter diffractometer. When the average orientation difference in crystal grains of each crystal grain is calculated, the crystal grains showing the average orientation difference in crystal grains of 2 degrees or more are 20% or more in terms of the area ratio of the composite nitride or composite carbonitride layer.
- the inclination angle formed by the normal line of the ⁇ 100 ⁇ plane which is the crystal plane with respect to the normal direction of the surface of the tool base of the crystal grain is equal to the composite nitride or the composite carbonitride layer in the layer thickness direction. Measured separately into the divided interface side area and surface side area, and the measured inclination angle within the range of 0 to 45 degrees with respect to the normal direction among the measured inclination angles is 0.25 degree pitch.
- the surface-coated cutting tool N deg is characterized in that it is a M deg + 10 ⁇ M deg + 30%.
- Ti and Al composite nitride or composite carbonitride having the NaCl type face-centered cubic structure is represented by the above (Ti 1-x Al x ) (C y N 1-y ) Ti and Al
- the composite nitride or the composite carbonitride layer is a cubic crystal in the composite nitride or the composite carbonitride layer when the composite nitride or the composite carbonitride layer is observed from the longitudinal section direction.
- each crystal grain having a structure has a columnar structure having an average grain width W of 0.1 to 2 ⁇ m and an average aspect ratio A of 2 to 10.
- Coated cutting tool (4) Of the carbide layer, nitride layer, carbonitride layer, carbonate layer and carbonitride oxide layer of Ti between the tool base and the composite nitride or composite carbonitride layer of Ti and Al
- the surface-coated cutting tool of the present invention which is an aspect of the present invention
- the surface-coated cutting tool of the present invention provided with a hard coating layer on the surface of the tool base.
- the hard coating layer includes at least a composite nitride or composite carbonitride layer of Ti and Al having an average layer thickness of 2 to 20 ⁇ m formed by chemical vapor deposition, and has a composition formula: (Ti 1-x Al x ) (C y N 1-y ), the average content x avg in the total amount of Ti and Al in Al and the average content y avg in the total amount of C and N in C (where x avg , Y avg are atomic ratios) satisfying 0.60 ⁇ x avg ⁇ 0.95 and 0 ⁇ y avg ⁇ 0.005, respectively, and constituting the composite nitride or composite carbonitride layer Some of them have a cubic structure, and the crystal Is analyzed from the longitudinal cross-sectional direction using an electron beam backscattering diffractometer, and the average orientation difference in each crystal grain is obtained.
- the compound or composite carbonitride layer is present in an area ratio of 20% or more, and the inclination angle formed by the normal of the ⁇ 100 ⁇ plane, which is the crystal plane with respect to the normal direction of the surface of the tool base of the crystal grain, is the composite Measured by dividing the nitride or composite carbonitride layer into an area on the interface side and an area on the surface side which are divided into two in the thickness direction, and 0 to 45 degrees with respect to the normal direction among the measured inclination angles
- a) exists within the range of 0 to 12 degrees in the area on the interface side total power is, to a rate with respect to the entire frequency in the inclination angle frequency distribution and M deg
- M deg is 10-40%, in the region of b) surface, the highest peak is present in the tilt angle sections of the range of 0 to 12 degrees, it exists within the range of the 0-12
- the average grain width W of each crystal grain having a cubic structure in the composite nitride or composite carbonitride layer is 0.1 to 2 ⁇ m, and the average aspect ratio A is 2 to 10.
- the schematic explanatory drawing of the measuring method of the crystal grain average orientation difference of the crystal grain which has the NaCl type face center cubic structure (cubic crystal) of the composite nitride of Ti and Al of this invention coated tool or a composite carbonitride layer is shown.
- the average grain orientation difference (GOS value) of individual grains having a cubic structure An example of the histogram about an area ratio is shown.
- the dotted line in the vertical direction in the histogram indicates a boundary line having an average orientation difference within the grain of 2 °.
- the bar on the right side of the dotted line in the vertical direction has an average orientation difference within the grain of 2 ° or more.
- the average grain orientation difference (GOS value) of individual grains having a cubic structure An example of the histogram about an area ratio is shown.
- the dotted line in the vertical direction in the histogram indicates a boundary line having an average orientation difference within the grain of 2 °, and the bar on the right side of the dotted line in the vertical direction in FIG.
- the count frequency is shown as a relative value normalized with the maximum count frequency as 100. It is an example of the inclination angle number distribution graph of the ⁇ 100 ⁇ plane created in the area
- Average layer thickness of the composite nitride or composite carbonitride layer constituting the hard coating layer Hard layer having a surface-coated cutting tool of the present invention, chemical vapor deposited composition formula: (Ti 1-x Al x ) (C y N 1-y) Ti-Al composite nitride represented by or composite At least a carbonitride layer is included.
- This composite nitride or composite carbonitride layer has high hardness and excellent wear resistance, but the effect is particularly remarkable when the average layer thickness is 2 to 20 ⁇ m.
- the average layer thickness is set to 2 to 20 ⁇ m.
- composition of composite nitride or composite carbonitride layer constituting hard coating layer has an average content ratio x avg in the total amount of Ti and Al in Al and the total amount of C and N in C
- the average content ratio y avg (where x avg and y avg are atomic ratios) is controlled so as to satisfy 0.60 ⁇ x avg ⁇ 0.95 and 0 ⁇ y avg ⁇ 0.005, respectively. To do.
- the average content ratio x avg of Al is less than 0.60, the composite nitride or composite carbonitride layer of Ti and Al is inferior in hardness, so that it was subjected to high-speed intermittent cutting of alloy steel and the like. In some cases, the wear resistance is not sufficient.
- the average content ratio x avg of Al exceeds 0.95, the content ratio of Ti is relatively decreased, so that embrittlement is caused and chipping resistance is deteriorated. Therefore, the average Al content ratio x avg was determined to be 0.60 ⁇ x avg ⁇ 0.95.
- the content ratio (atomic ratio) y avg of the C component contained in the composite nitride or the composite carbonitride layer is a minute amount in the range of 0 ⁇ y avg ⁇ 0.005
- the composite nitride or the composite carbonitride The adhesion between the material layer and the tool base or the lower layer is improved and the lubricity is improved to reduce the impact during cutting. As a result, the fracture resistance and resistance of the composite nitride or composite carbonitride layer are reduced. Chipping property is improved.
- the average content ratio y avg of the component C deviates from the range of 0 ⁇ y avg ⁇ 0.005
- the toughness of the composite nitride or composite carbonitride layer decreases, so that the chipping resistance and chipping resistance are reversed. Since it falls, it is not preferable. Therefore, the average content ratio y avg of the C component was set to 0 ⁇ y avg ⁇ 0.005.
- Mean crystal orientation difference (GOS value) of individual crystal grains of the cubic crystal grains constituting the composite nitride or composite carbonitride layer First, in the present invention, an electron beam backscattering diffraction apparatus is used to analyze at an interval of 0.1 ⁇ m from the longitudinal cross-sectional direction, and as shown in FIG. 1, at least 5 degrees between adjacent measurement points P (hereinafter referred to as pixels). If there is a misorientation, this is defined as the grain boundary B.
- the longitudinal section direction means a direction perpendicular to the longitudinal section.
- a longitudinal section means a section of a tool perpendicular to the tool base surface.
- a region surrounded by the grain boundary is defined as one crystal grain.
- a single pixel that has an orientation difference of 5 degrees or more with all adjacent pixels is not a crystal grain, and a pixel having two or more pixels connected is treated as a crystal grain. Then, an orientation difference is calculated between a certain pixel in the crystal grain and all other pixels in the same crystal grain, and an average of these is defined as a GOS (Grain Orientation Spread) value.
- GOS Gram Orientation Spread
- a schematic diagram is shown in FIG. The GOS value is described in, for example, the document “The Journal of the Japan Society of Mechanical Engineers (A) 71: 712 (2005-12) Paper No. 05-0367 1722-1728”.
- “inside crystal grain average orientation difference” means this GOS value.
- the number of pixels in the same crystal grain is n
- the numbers assigned to different pixels in the crystal grain are i and j (where 1 ⁇ i and j ⁇ n)
- the crystal orientation difference obtained from the crystal orientation at pixel j as ⁇ ij (i ⁇ j) can be written by the following equation.
- Analysis is performed at intervals of 0.1 ⁇ m from the longitudinal cross-section direction using an electron beam back-scattering diffractometer, the width is 10 ⁇ m, and the vertical measurement is performed in the vertical cross-section direction within the measurement range of the film thickness in five fields of view.
- the total number of pixels belonging to the cubic crystal grains constituting the material or the composite carbonitride layer is obtained, the average orientation difference within the crystal grain is divided at intervals of 1 degree, and the average orientation difference within the grain is included within the range of the value.
- the histogram showing the area ratio of the average orientation difference in the crystal grains can be created by counting the crystal grain pixels to be divided by the total number of pixels.
- the crystal orientation within the crystal grains varies, and when the histogram is obtained, the crystal grains showing an average orientation difference within the crystal grains of 2 degrees or more are compared with the composite nitride or composite carbonitride layer of Al and Ti. It was found that the area ratio was 20% or more (see FIGS. 3 and 4).
- the crystal grains constituting the composite nitride or composite carbonitride layer of Al and Ti included in the surface-coated cutting tool of the present invention are compared with the crystal grains constituting the conventional TiAlN layer. In this, the crystal orientation varies greatly, that is, there is distortion, and this contributes to the improvement of hardness and toughness.
- the area ratio of crystal grains having an average orientation difference within the crystal grains of 2 degrees or more with respect to the area of the preferred composite nitride or composite carbonitride layer is 30 to 60%.
- the area ratio of crystal grains having an average orientation difference within the crystal grains of 2 degrees or more with respect to the area of the more preferable composite nitride or composite carbonitride layer is 35 to 55%.
- the area ratio of the crystal grains in which the average orientation difference in the crystal grains is 2 degrees or more with respect to the area of the composite nitride or composite carbonitride layer is 40 to 50%.
- Crystal orientation in the region on the interface side and the region on the surface side when the composite nitride or composite carbonitride layer is divided into two equal parts in the layer thickness direction The crystal grains constituting the composite nitride or composite carbonitride layer are such that the surface side is directed to the normal direction of the tool base surface, that is, the ⁇ 100 ⁇ plane, rather than the tool base surface (interface) side.
- An effect peculiar to the present invention that wear resistance is improved while maintaining toughness is exhibited.
- the increase rate of the ⁇ 100 ⁇ plane orientation degree on the surface side relative to the interface side is less than 10%, the increase rate of the ⁇ 100 ⁇ plane orientation degree is small, and the wear resistance while maintaining the toughness expected in the present invention. The effect of improving is not fully achieved.
- the inclination angle formed by the normal of the ⁇ 100 ⁇ plane which is the crystal plane with respect to the normal direction of the tool substrate surface of the crystal grains, is divided into two in the thickness direction of the composite nitride or composite carbonitride layer.
- the frequencies existing in each section are tabulated, a) In the region on the interface side, the sum of the frequencies existing in the range of 0 to 12 degrees represents the ratio of the total frequencies in the gradient angle frequency distribution to M deg Then, M deg is 10 to 40%, and b) in the region on the surface side, the highest peak exists in the inclination angle section within the range of 0 to 12 degrees, and exists within the range of 0 to 12 degrees.
- the total frequency is the ratio of the total frequency in the tilt angle frequency distribution to N d
- N deg was determined to be M deg +10 to M deg + 30%.
- Ti and Al composite nitride or composite carbonitride layer represented by (Ti 1-x Al x ) (C y N 1-y ) is a composite nitride of Ti and Al having a NaCl type face centered cubic structure.
- excellent wear resistance is exhibited by including at least a composite carbonitride phase, and particularly excellent wear resistance is exhibited when the area ratio exceeds 70%.
- Average grain width W and average aspect ratio A of individual grains having a cubic structure in a composite nitride or composite carbonitride layer of Ti and Al A columnar structure having an average grain width W of 0.1 to 2 ⁇ m and an average aspect ratio A of 2 to 10 for each crystal grain having a cubic structure in the composite nitride or composite carbonitride layer of Ti and Al.
- the average particle width W is set to 0.1 to 2 ⁇ m because, if it is less than 0.1 ⁇ m, the proportion of atoms belonging to the TiAlCN crystal grain boundary in the atoms exposed on the surface of the coating layer is relatively large.
- the average particle width W is preferably 0.1 to 2 ⁇ m.
- the average aspect ratio A is less than 2, since the columnar structure is not sufficient, the equiaxed crystal having a small aspect ratio is dropped, and as a result, sufficient wear resistance cannot be exhibited.
- the average aspect ratio A exceeds 10
- the strength of the crystal grains themselves cannot be maintained, and the chipping resistance is lowered.
- the average aspect ratio A is preferably 2-10.
- the average aspect ratio A means the surface of the tool base when the longitudinal section of the hard coating layer is observed in a range of 100 ⁇ m in width and including the entire hard coating layer using a scanning electron microscope.
- required about each crystal grain was calculated as the average aspect ratio A, and the average value of the particle width w calculated
- the composite nitride or composite carbonitride layer included in the surface-coated cutting tool of the present invention alone has a sufficient effect, but the Ti carbide layer, nitride layer, carbonitride layer, carbonate layer, and carbon
- a lower layer having a total average layer thickness of 0.1 to 20 ⁇ m is provided, or it has an average layer thickness of 1 to 25 ⁇ m.
- an upper layer including an aluminum oxide layer it is possible to create better characteristics in combination with the effects of these layers.
- the total average layer of the lower layer If the thickness is less than 0.1 ⁇ m, the effect of the lower layer is not sufficiently achieved. On the other hand, if it exceeds 20 ⁇ m, the crystal grains are likely to be coarsened and chipping is likely to occur. Further, if the total average layer thickness of the upper layer including the aluminum oxide layer is less than 1 ⁇ m, the effect of the upper layer is not sufficiently achieved. On the other hand, if it exceeds 25 ⁇ m, the crystal grains are likely to be coarsened and chipping is likely to occur. . In addition, the figure which represented typically the cross section of the composite nitride or composite carbonitride layer of Ti and Al which comprises the hard coating layer of this invention is shown in FIG.
- WC powder, TiC powder, TaC powder, NbC powder, Cr 3 C 2 powder and Co powder all having an average particle diameter of 1 to 3 ⁇ m are prepared, and these raw material powders are blended as shown in Table 1. Blended into the composition, added with wax, mixed in a ball mill in acetone for 24 hours, dried under reduced pressure, pressed into a compact of a predetermined shape at a pressure of 98 MPa, and the compact was 1370 in a vacuum of 5 Pa.
- Mo 2 C powder Mo 2 C powder
- ZrC powder ZrC powder
- NbC powder WC powder
- Co powder all having an average particle diameter of 0.5 to 2 ⁇ m.
- Ni powder are prepared, these raw material powders are blended in the blending composition shown in Table 2, wet mixed by a ball mill for 24 hours, dried, and then pressed into a compact at a pressure of 98 MPa.
- the body was sintered in a nitrogen atmosphere of 1.3 kPa at a temperature of 1500 ° C. for 1 hour, and after sintering, a tool base D made of TiCN-based cermet having an ISO standard SEEN1203AFSN insert shape was produced.
- reaction gas composition (capacity% with respect to the total of the gas group A and the gas group B) is set as NH 3 : 4.0 to 6.0% as the gas group A, H 2 : 65 to 75%, gas group B as AlCl 3 : 0.6 to 0.9%, TiCl 4 : 0.2 to 0.3%, Al (CH 3 ) 3 : 0 to 0.5%, N 2 : 12.5 to 15.0%, H 2 : remaining, reaction atmosphere pressure: 4.5 to 5.0 kPa, reaction atmosphere temperature: 700 to 900 ° C., supply cycle 1 to 5 seconds, gas per cycle Supply time 0.15 to 0.25 seconds, phase difference between
- the coated tools 1 to 15 of the present invention were manufactured by forming a hard coating layer composed of a (Ti 1-x Al x ) (C y N 1-y ) layer having a target layer thickness shown in FIG.
- the lower layer shown in Table 6 and / or the upper layer shown in Table 7 were formed under the formation conditions shown in Table 3.
- the surfaces of the tool bases A to D are the same as the coated tools 1 to 15 of the present invention under the conditions shown in Tables 3, 4 and 5 and the target layer thickness ( ⁇ m) shown in Table 8. Then, a hard coating layer including at least a composite nitride or composite carbonitride layer of Ti and Al was formed by vapor deposition. At this time, a comparison is made by forming a hard coating layer so that the reaction gas composition on the surface of the tool base does not change with time during the process of forming the (Ti 1-x Al x ) (C y N 1-y ) layer. Coated tools 1-13 were produced. Similar to the coated tools 6 to 13 of the present invention, the comparative coated tools 6 to 13 are formed with the lower layer shown in Table 6 and / or the upper layer shown in Table 8 under the forming conditions shown in Table 3. did.
- the (Ti 1-x Al x ) (C y N 1-y ) layer of the reference example is formed on the surfaces of the tool base B and the tool base C by arc ion plating using a conventional physical vapor deposition apparatus.
- the reference coated tools 14 and 15 shown in Table 8 were produced by vapor-depositing with a target layer thickness.
- the arc ion plating conditions used for the vapor deposition in the reference example are as follows.
- the tool bases B and C are ultrasonically washed in acetone and dried, and the outer periphery is positioned at a predetermined distance in the radial direction from the central axis on the rotary table in the arc ion plating apparatus.
- an Al—Ti alloy having a predetermined composition is disposed as a cathode electrode (evaporation source),
- B First, the inside of the apparatus is evacuated and kept at a vacuum of 10 ⁇ 2 Pa or less, the inside of the apparatus is heated to 500 ° C. with a heater, and then the tool base that rotates while rotating on the rotary table is set to ⁇ 1000 V. A DC bias voltage is applied and a current of 200 A is passed between a cathode electrode and an anode electrode made of an Al—Ti alloy to generate an arc discharge, and Al and Ti ions are generated in the apparatus.
- the cross sections in the direction perpendicular to the tool base of the constituent layers of the coated tools 1 to 15 of the present invention, the comparative coated tools 1 to 13 and the reference coated tools 14 and 15 are measured using a scanning electron microscope (5000 magnifications).
- 5000 magnifications 5000 magnifications.
- the average Al content x avg of the composite nitride or composite carbonitride layer was measured using an electron beam microanalyzer (Electron-Probe-Micro-Analyzer: EPMA) in a sample whose surface was polished. Irradiation was performed from the sample surface side, and an average Al content ratio x avg was obtained from an average of 10 points of the analysis results of the obtained characteristic X-rays.
- the average C content y avg was determined by secondary ion mass spectrometry (Secondary-Ion-Mass- Spectroscopy: SIMS).
- the ion beam was irradiated in the range of 70 ⁇ m ⁇ 70 ⁇ m from the sample surface side, and the concentration in the depth direction was measured for the components emitted by the sputtering action.
- the average content ratio y avg of C indicates an average value in the depth direction of the composite nitride or composite carbonitride layer of Ti and Al.
- the content ratio of C excludes the inevitable content ratio of C that is included without intentionally using a gas containing C as a gas raw material.
- the content ratio (atomic ratio) of the C component contained in the composite nitride or composite carbonitride layer when the supply amount of Al (CH 3 ) 3 is 0 is determined as the inevitable C content ratio.
- the inevitable C content is subtracted from the C component content (atomic ratio) contained in the composite nitride or composite carbonitride layer obtained when Al (CH 3 ) 3 is intentionally supplied.
- the value was determined as yavg .
- each crystal grain having a cubic structure constituting the composite nitride or composite carbonitride layer of Ti and Al is analyzed from the longitudinal cross-sectional direction using an electron beam backscatter diffraction apparatus, and adjacent pixels are analyzed. If there is a misorientation of 5 degrees or more between them, this is the grain boundary, and the region surrounded by the grain boundary is one crystal grain.
- One pixel in the crystal grain and all other pixels in the same crystal grain The difference in orientation within the grain is calculated between 0 degree and less than 1 degree, 1 degree and less than 2 degree, 2 degree and less than 3 degree, 3 degree and less than 4 degree, and so on. The range of 10 degrees was divided and mapped every 1 degree.
- FIG. 3 shows an example of a histogram of the average orientation difference in crystal grains (that is, the GOS value) measured for the coated tool 2 of the present invention
- FIG. 4 shows the average orientation difference in crystal grains measured for the comparative coated tool 2. An example of the histogram is shown.
- the column of the field emission scanning electron microscope with the cross section of the hard coating layer made of a composite carbonitride layer of Ti and Al having a cubic structure as a polished surface The surface of the tool base (interface) side divided into two layers in the layer thickness direction and the surface side region were analyzed, and an electron beam with an acceleration voltage of 10 kV at an incident angle of 70 degrees was 1 nA.
- the measurement results in the interface-side area and the surface-side area are 10 ⁇ m in the horizontal direction and the tool base in the horizontal direction at a spacing of 0.1 ⁇ m / step for 5 fields of view.
- each crystal grain having a cubic crystal lattice existing within the measurement range Irradiate each crystal grain having a cubic crystal lattice existing within the measurement range, and use the electron beam backscatter diffraction image apparatus to normalize the tool base surface (direction perpendicular to the tool base surface on the cross-section polished surface)
- the crystal plane of the crystal grain Measure the inclination angle formed by the normal of the ⁇ 100 ⁇ plane, and based on the measurement result, the measurement inclination angle within the range of 0 to 45 degrees out of the measurement inclination angles is 0.25 degree pitch.
- the ratio of the frequencies existing in the range of 0 to 12 degrees was obtained by classifying every time and counting the frequencies existing in each section. The results are shown in Table 7 and Table 8.
- analysis was performed at intervals of 0.1 ⁇ m from the longitudinal cross-section direction using an electron beam backscattering diffractometer, the width was 10 ⁇ m, and the vertical measurement within the measurement range of the film thickness was performed in five fields of view.
- the total number of pixels belonging to the cubic crystal grains constituting the nitride or composite carbonitride layer is obtained, and the composite nitride or composite is determined according to the ratio to the total number of measured pixels in the measurement of the hard coating layer in the five fields of view.
- the area ratio of cubic crystal grains constituting the carbonitride layer was determined.
- the coated tools 1 to 15 according to the present invention, the comparative coated tools 1 to 13 and the reference coated tool are used in the state where each of the various coated tools is clamped to the tool steel cutter tip portion having a cutter diameter of 125 mm by a fixing jig. 14 and 15 were subjected to a dry high-speed face milling and center-cut cutting test, which is a kind of high-speed interrupted cutting of alloy steel, and the flank wear width of the cutting edge was measured.
- the results are shown in Table 9.
- Tool substrate Tungsten carbide-based cemented carbide, titanium carbonitride-based cermet, Cutting test: dry high-speed face milling, center cutting, Work material: JIS / SCM440 block material with a width of 100 mm and a length of 400 mm, Rotational speed: 955 min ⁇ 1 Cutting speed: 375 m / min, Cutting depth: 1.2 mm, Single-blade feed rate: 0.15 mm / tooth, Cutting time: 8 minutes.
- WC powder, TiC powder, ZrC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder and Co powder each having an average particle diameter of 1 to 3 ⁇ m are prepared.
- Compounded in the formulation shown in Table 10 added with wax, ball mill mixed in acetone for 24 hours, dried under reduced pressure, press-molded into a green compact of a predetermined shape at a pressure of 98 MPa.
- vacuum sintering is performed at a predetermined temperature within a range of 1370 to 1470 ° C. for 1 hour, and after sintering, the cutting edge is subjected to a honing process of R: 0.07 mm.
- Tool bases ⁇ to ⁇ made of WC-base cemented carbide having the insert shape of CNMG120212 were manufactured.
- NbC powder NbC powder
- WC powder Co powder
- Ni powder Ni powder each having an average particle diameter of 0.5 to 2 ⁇ m
- These raw material powders were blended into the composition shown in Table 11, wet mixed with a ball mill for 24 hours, dried, and then pressed into a green compact at a pressure of 98 MPa.
- a chemical vapor deposition apparatus is used on the surfaces of these tool bases ⁇ to ⁇ and tool base ⁇ , and at least (Ti 1-x Al) under the conditions shown in Tables 3 and 4 by the same method as in Example 1.
- the coated tools 16 to 30 according to the present invention shown in Table 13 were manufactured by vapor-depositing a hard coating layer containing x ) (C y N 1-y ) layer at a target layer thickness.
- the coated tools 34 to 38 of the present invention the lower layer as shown in Table 17 and / or the upper layer as shown in Table 18 were formed under the formation conditions shown in Table 3.
- the coated tools 19 to 28 of the present invention the lower layer shown in Table 12 and / or the upper layer shown in Table 13 were formed under the formation conditions shown in Table 3.
- the present invention was also applied to the tool bases ⁇ to ⁇ and the tool base ⁇ using normal chemical vapor deposition equipment under the conditions shown in Tables 3 and 4 and the target layer thicknesses shown in Table 14.
- Comparative coating tools 16 to 28 shown in Table 14 were manufactured by vapor-depositing a hard coating layer in the same manner as the coating tool.
- the comparative coated tools 19 to 28 are formed with the lower layer shown in Table 12 and / or the upper layer shown in Table 14 under the forming conditions shown in Table 3. did.
- the (Ti 1-x Al x ) (C y N 1-y ) layer of the reference example is formed on the surfaces of the tool base ⁇ and the tool base ⁇ by arc ion plating using a conventional physical vapor deposition apparatus.
- the reference coating tools 29 and 30 shown in Table 14 were manufactured by vapor-depositing with a target layer thickness.
- the conditions similar to the conditions shown in Example 1 were used for the conditions of arc ion plating.
- the cross-sections of the constituent layers of the inventive coated tools 16 to 30, the comparative coated tools 16 to 28 and the reference coated tools 29 and 30 were measured using a scanning electron microscope (magnification 5000 times), and 5 in the observation field of view.
- a scanning electron microscope magnification 5000 times
- 5 in the observation field of view When the layer thicknesses of the points were measured and averaged to determine the average layer thickness, both showed the average layer thickness substantially the same as the target layer thickness shown in Table 13 and Table 14.
- each crystal grain having a cubic structure constituting a composite nitride or composite carbonitride layer of Ti and Al is analyzed from the longitudinal cross-sectional direction using an electron beam backscatter diffraction apparatus, The difference in direction is 0 degree or more, less than 1 degree, 1 degree or more, less than 2 degree, 2 degree or more, less than 3 degree, 3 degree or more, less than 4 degree, and so on. did. From the mapping diagram, the area ratio of the crystal grains having an average orientation difference within the grain and an orientation difference within the grain of 2 degrees or more to the entire composite nitride or composite carbonitride layer of Ti and Al was obtained. The results are shown in Table 13 and Table 14.
- the column of the field emission scanning electron microscope with the cross section of the hard coating layer made of a composite carbonitride layer of Ti and Al having a cubic structure as a polished surface The surface of the tool base (interface) side divided into two layers in the layer thickness direction and the surface side region were analyzed, and an electron beam with an acceleration voltage of 10 kV at an incident angle of 70 degrees was 1 nA.
- the crystal grains having a cubic crystal lattice existing within the measurement range of the interface-side region and the surface-side region are irradiated individually with an irradiation current of the electron beam, and the tool substrate is horizontally aligned with an electron beam backscatter diffraction image apparatus.
- a crystal plane of the crystal grain with respect to the normal of the tool base surface (direction perpendicular to the tool base surface in the cross-section polished surface) at an interval of 0.1 ⁇ m / step with a width of 10 ⁇ m in the direction and five fields of view.
- Measure the tilt angle formed by the normal of ⁇ 100 ⁇ plane Based on the measurement results, the measurement inclination angles within the range of 0 to 45 degrees out of the measurement inclination angles are divided into pitches of 0.25 degrees, and the frequency existing in each division is determined. By counting, the ratio of the frequencies existing in the range of 0 to 12 degrees was obtained. The results are shown in Table 13 and Table 14.
- the coated tools 16 to 30 of the present invention the comparative coated tools 16 to 28, the reference coated tool 29, About 30, the dry high speed intermittent cutting test of the carbon steel and the wet high speed intermittent cutting test of cast iron which were shown below were implemented, and all measured the flank wear width of the cutting edge.
- Cutting condition 1 Work material: JIS ⁇ S45C lengthwise equal 4 round grooved round bars, Cutting speed: 370 m / min, Incision: 1.5mm, Feed: 0.1 mm / rev, Cutting time: 5 minutes (Normal cutting speed is 220 m / min),
- Cutting condition 2 Work material: JIS / FCD700 lengthwise equal length 4 round bar with round groove, Cutting speed: 320 m / min, Cutting depth: 1.2mm, Feed: 0.2mm / rev, Cutting time: 5 minutes (Normal cutting speed is 200 m / min). Table 15 shows the results of the cutting test.
- cBN powder, TiN powder, TiC powder, Al powder, and Al 2 O 3 powder each having an average particle diameter in the range of 0.5 to 4 ⁇ m were prepared. These raw material powders are shown in Table 16. After blending into the blended composition, wet mixing with a ball mill for 80 hours, drying, and press-molding into a green compact with a diameter of 50 mm ⁇ thickness: 1.5 mm at a pressure of 120 MPa, and then this green compact Is sintered in a vacuum atmosphere at a pressure of 1 Pa at a predetermined temperature in the range of 900 to 1300 ° C. for 60 minutes to obtain a presintered body for a cutting edge piece, and this presintered body is separately prepared.
- a normal ultra high pressure sintering apparatus in a state of being superposed on a support piece made of WC base cemented carbide having Co: 8 mass%, WC: remaining composition, and diameter: 50 mm ⁇ thickness: 2 mm
- Normal pressure 4 Pa
- temperature Presence at a predetermined temperature in the range of 1200 to 1400 ° C.
- Holding time 0.8 hours under high pressure sintering, and after sintering, the upper and lower surfaces are polished with a diamond grindstone, and used in a wire electric discharge machine.
- the brazing part (corner part) of the insert body made of a WC-base cemented carbide having a diamond) is Ti- having a composition consisting of Zr: 37.5%, Cu: 25%, Ti: the remainder in mass%.
- the cutting edge is subjected to honing processing with a width of 0.13 mm and an angle of 25 °, and further subjected to final polishing to achieve ISO.
- Standard CNGA12 Tool substrate 2A having the insert shape of 408, 2B was prepared respectively.
- a chemical vapor deposition apparatus is used on the surfaces of these tool bases 2A and 2B, and at least (Ti 1-x Al x ) (C) under the conditions shown in Tables 3 and 4 by the same method as in Example 1.
- the coated tools 31 to 40 of the present invention shown in Table 18 were manufactured by vapor-depositing a hard coating layer including a y N 1-y ) layer with a target layer thickness.
- the coated tools 34 to 38 of the present invention the lower layer as shown in Table 17 and / or the upper layer as shown in Table 18 were formed under the formation conditions shown in Table 3.
- a normal chemical vapor deposition apparatus is used on the surfaces of the tool bases 2A and 2B, and at least (Ti 1-x Al x ) (C y N 1 ) under the conditions shown in Tables 3 and 4.
- Comparative coating tools 31 to 38 shown in Table 19 were manufactured by vapor-depositing a hard coating layer including a -y ) layer at a target layer thickness. Similar to the coated tools 34 to 38 of the present invention, the comparative coated tools 34 to 38 have the formation conditions shown in Table 3 and the lower layer as shown in Table 17 and / or the upper layer as shown in Table 19. Formed.
- the (Ti 1-x Al x ) (C y N 1-y ) layer is formed at the target layer thickness on the surfaces of the tool bases 2A and 2B by arc ion plating using a conventional physical vapor deposition apparatus.
- Reference coating tools 39 and 40 shown in Table 19 were manufactured by vapor deposition.
- the arc ion plating conditions are the same as those shown in Example 1, and the (Al, Ti) N layer having the target composition and target layer thickness shown in Table 19 is formed on the surface of the tool base.
- the reference coating tools 39 and 40 were manufactured by vapor deposition.
- the average content of Al x avg , the average content ratio of C y avg , and the average orientation difference in the crystal grains of the cubic grains constituting the (Ti 1-x Al x ) (C y N 1-y ) layer is 2 degrees or more.
- the area ratio of the crystal grains, the average grain width W, and the average aspect ratio A were calculated. The results are shown in Table 18 and Table 19.
- the inclination angle number distribution of the inclination angle formed by the normal line of the ⁇ 100 ⁇ plane in the interface side region and the surface side region is obtained.
- the ratio of the total frequency existing in the range to the total frequency was determined. The results are shown in Table 18 and Table 19.
- the coated tools 31 to 40 of the present invention, the comparative coated tools 31 to 38, and the reference coated tools 39 and 40 are mounted in a state where all the various coated tools are screwed to the tip of the tool steel tool with a fixing jig.
- the dry high-speed intermittent cutting test of carburized and quenched alloy steel shown below was performed, and the flank wear width of the cutting edge was measured.
- Tool substrate Cubic boron nitride-based ultra-high pressure sintered body
- Cutting test Dry high-speed intermittent cutting of carburized and quenched alloy steel
- Work material JIS ⁇ SCr420 (Hardness: HRC60) lengthwise equidistant four round grooved round bars
- Cutting speed 240 m / min
- Cutting depth 0.12 mm
- Feed 0.12 mm / rev
- Cutting time 4 minutes. Table 20 shows the results of the cutting test.
- the coated tool of the present invention is in the cubic crystal grains constituting the composite nitride or composite carbonitride layer of Al and Ti constituting the hard coating layer,
- the crystal has a predetermined in-grain average orientation difference and the tilt angle formed by the normal of the ⁇ 100 ⁇ plane in the interface side region and the surface side region of the crystal grain has a predetermined tilt angle number distribution.
- Grain distortion improves hardness and improves toughness while maintaining high wear resistance.
- even when used for high-speed intermittent cutting where intermittent and impactful high loads act on the cutting edge, it has excellent chipping resistance and chipping resistance, resulting in excellent wear resistance over a long period of use. It is clear that it will work.
- the coated tool of the present invention can be used not only for high-speed intermittent cutting of alloy steel but also as a coated tool for various work materials, and has excellent chipping resistance over a long period of use. Since it exhibits wear resistance, it can sufficiently satisfy the high performance of the cutting device, the labor saving and energy saving of the cutting work, and the cost reduction.
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Abstract
Description
本願は、2014年5月28日に、日本に出願された特願2014-109881号、および2015年5月21日に、日本に出願された特願2015-104042号に基づき優先権を主張し、その内容をここに援用する。
ただ、前記従来のTi-Al系の複合窒化物層を被覆形成した被覆工具は、比較的耐摩耗性にすぐれるものの、高速断続切削条件で用いた場合にチッピング等の異常損耗を発生しやすいことから、硬質被覆層の改善についての種々の提案がなされている。
このような観点から、化学蒸着法で硬質被覆層を形成することで、Alの含有割合を、0.9程度にまで高める技術も提案されている。
しかし、前記特許文献1、2に記載されている被覆工具は、(Ti1-xAlx)N層からなる硬質被覆層のAlの含有割合xを高めることについて考慮されていないため、合金鋼の高速断続切削に供した場合には、耐摩耗性、耐チッピング性が十分であるとは言えないという課題があった。
一方、前記特許文献3に記載されている化学蒸着法で蒸着形成した(Ti1-xAlx)N層については、Alの含有割合xを高めることができ、また、立方晶構造を形成させることができることから、所定の硬さを有し耐摩耗性にすぐれた硬質被覆層が得られるものの、靭性に劣るという課題があった。
さらに、前記特許文献4に記載されている被覆工具は、所定の硬さを有し耐摩耗性にはすぐれるものの、靭性に劣ることから、合金鋼の高速断続切削加工等に供した場合には、チッピング、欠損、剥離等の異常損傷が発生しやすく、満足できる切削性能を発揮するとは言えないという課題があった。
そこで、本発明者らは、硬質被覆層を構成する(Ti1-xAlx)(CyN1-y)層について鋭意研究したところ、(Ti1-xAlx)(CyN1-y)層が立方晶結晶構造を有する結晶粒を含有し該立方晶結晶構造を有する結晶粒の結晶粒内平均方位差を2度以上とするという全く新規な着想により、立方晶結晶構造を有する結晶粒内に歪みを生じさせ、硬さと靭性の双方を高めることに成功し、その結果、硬質被覆層の耐チッピング性、耐欠損性を向上させることができるという新規な知見を見出した。
用いる化学蒸着反応装置へは、NH3とH2からなるガス群Aと、TiCl4、Al(CH3)3、AlCl3、N2、H2からなるガス群Bがおのおの別々のガス供給管から反応装置内へ供給され、ガス群Aとガス群Bの反応装置内への供給は、例えば、一定の周期の時間間隔で、その周期よりも短い時間だけガスが流れるように供給し、ガス群Aとガス群Bのガス供給にはガス供給時間よりも短い時間の位相差が生じるようにして、工具基体表面における反応ガス組成を、ガス群A(第一反応ガス)、ガス群Aとガス群Bの混合ガス(第二反応ガス)、ガス群B(第三反応ガス)と時間的に変化させることができる。ちなみに、本発明においては、厳密なガス置換を意図した長時間の排気工程を導入する必要は無い。従って、ガス供給方法としては、例えば、ガス供給口を回転させたり、工具基体を回転させたり、工具基体を往復運動させたりして、工具基体表面における反応ガス組成を、ガス群Aを主とする混合ガス(第一反応ガス)、ガス群Aとガス群Bの混合ガス(第二反応ガス)、ガス群Bを主とする混合ガス(第三反応ガス)、と時間的に変化させることでも実現する事が可能である。
工具基体表面に、反応ガス組成(ガス群Aおよびガス群Bを合わせた全体に対する容量%)を、例えば、ガス群AとしてNH3:4.0~6.0%、H2:65~75%、ガス群BとしてAlCl3:0.6~0.9%、TiCl4:0.2~0.3%、Al(CH3)3:0~0.5%、N2:12.5~15.0%、H2:残、反応雰囲気圧力:4.5~5.0kPa、反応雰囲気温度:700~900℃、供給周期1~5秒、1周期当たりのガス供給時間0.15~0.25秒、ガス供給Aとガス供給Bの位相差0.10~0.20秒として、所定時間、熱CVD法を行うことにより、所定の目標層厚の(Ti1-xAlx)(CyN1-y)層を成膜する。
(1)炭化タングステン基超硬合金、炭窒化チタン基サーメットまたは立方晶窒化ホウ素基超高圧焼結体のいずれかで構成された工具基体の表面に、硬質被覆層を設けた表面被覆切削工具において、
(a)前記硬質被覆層は、化学蒸着法により成膜された平均層厚2~20μmのTiとAlの複合窒化物または複合炭窒化物層を少なくとも含み、組成式:(Ti1-xAlx)(CyN1-y)で表した場合、複合窒化物または複合炭窒化物層のAlのTiとAlの合量に占める原子比としての平均含有割合xavgおよび複合窒化物または複合炭窒化物層のCのCとNの合量に占める原子比としての平均含有割合yavgが、それぞれ、0.60≦xavg≦0.95、0≦yavg≦0.005を満足し、
(b)前記複合窒化物または複合炭窒化物層は、NaCl型の面心立方構造を有するTiとAlの複合窒化物または複合炭窒化物の相を少なくとも含み、
(c)また、前記複合窒化物または複合炭窒化物層を構成する結晶粒中のNaCl型の面心立方構造を有する結晶粒の結晶方位を、電子線後方散乱回折装置を用いて縦断面方向から解析し、結晶粒個々の結晶粒内平均方位差を求めた場合該結晶粒内平均方位差が2度以上を示す結晶粒が複合窒化物または複合炭窒化物層の面積割合で20%以上存在し、
(d)さらに、前記結晶粒の工具基体表面の法線方向に対する結晶面である{100}面の法線がなす傾斜角を前記複合窒化物または複合炭窒化物層を層厚方向に二等分した界面側の領域と表面側の領域に分けて測定し、測定された前記傾斜角のうち法線方向に対して0~45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分して各区分内に存在する度数を集計した場合、
界面側の領域において、0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をMdegとすると、Mdegが10~40%であり、
表面側の領域において、0~12度の範囲内の傾斜角区分に最高ピークが存在すると共に、前記0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をNdegとすると、NdegがMdeg+10~Mdeg+30%であることを特徴とする表面被覆切削工具。
(2)前記NaCl型の面心立方構造を有するTiとAlの複合窒化物または複合炭窒化物が前記(Ti1-xAlx)(CyN1-y)で表されるTiとAlの複合窒化物または複合炭窒化物層に占める面積割合は70%以上であることを特徴とする前記(1)に記載の表面被覆切削工具。
(3)前記複合窒化物または複合炭窒化物層は、前記複合窒化物または複合炭窒化物層について、前記縦断面方向から観察した場合に、複合窒化物または複合炭窒化物層内の立方晶構造を有する個々の結晶粒の平均粒子幅Wが0.1~2μm、平均アスペクト比Aが2~10である柱状組織を有することを特徴とする前記(1)または(2)に記載の表面被覆切削工具。
(4)前記工具基体と前記TiとAlの複合窒化物または複合炭窒化物層の間にTiの炭化物層、窒化物層、炭窒化物層、炭酸化物層および炭窒酸化物層のうちの1層または2層以上のTi化合物層からなり、0.1~20μmの合計平均層厚を有する下部層が存在することを特徴とする前記(1)から(3)のいずれかに記載の表面被覆切削工具。
(5)前記複合窒化物または複合炭窒化物層の上部に、少なくとも酸化アルミニウム層を含む上部層が1~25μmの合計平均層厚で形成されていることを特徴とする前記(1)から(4)のいずれかに記載の表面被覆切削工具。
(6)前記複合窒化物または複合炭窒化物層は、少なくとも、トリメチルアルミニウムを反応ガス成分として含有する化学蒸着法により成膜されたものであることを特徴とする前記(1)から(5)のいずれかに記載の表面被覆切削工具。
なお、“結晶粒内平均方位差”とは、後述するGOS(Grain Orientation Spread)値のことを意味する。
本願発明の表面被覆切削工具が有する硬質被覆層は、化学蒸着された組成式:(Ti1-xAlx)(CyN1-y)で表されるTiとAlの複合窒化物または複合炭窒化物層を少なくとも含む。この複合窒化物または複合炭窒化物層は、硬さが高く、すぐれた耐摩耗性を有するが、特に平均層厚が2~20μmのとき、その効果が際立って発揮される。その理由は、平均層厚が2μm未満では、層厚が薄いため長期の使用に亘っての耐摩耗性を十分確保することができず、一方、その平均層厚が20μmを越えると、TiとAlの複合窒化物または複合炭窒化物層の結晶粒が粗大化し易くなり、チッピングを発生しやすくなる。したがって、その平均層厚を2~20μmと定めた。
本願発明の表面被覆切削工具が有する硬質被覆層を構成する複合窒化物または複合炭窒化物層は、AlのTiとAlの合量に占める平均含有割合xavgおよびCのCとNの合量に占める平均含有割合yavg(但し、xavg、yavgはいずれも原子比)が、それぞれ、0.60≦xavg≦0.95、0≦yavg≦0.005を満足するように制御する。
その理由は、Alの平均含有割合xavgが0.60未満であると、TiとAlの複合窒化物または複合炭窒化物層は硬さに劣るため、合金鋼等の高速断続切削に供した場合には、耐摩耗性が十分でない。一方、Alの平均含有割合xavgが0.95を超えると、相対的にTiの含有割合が減少するため、脆化を招き、耐チッピング性が低下する。したがって、Alの平均含有割合xavgは、0.60≦xavg≦0.95と定めた。
また、複合窒化物または複合炭窒化物層に含まれるC成分の含有割合(原子比)yavgは、0≦yavg≦0.005の範囲の微量であるとき、複合窒化物または複合炭窒化物層と工具基体もしくは下部層との密着性が向上し、かつ、潤滑性が向上することによって切削時の衝撃を緩和し、結果として複合窒化物または複合炭窒化物層の耐欠損性および耐チッピング性が向上する。一方、C成分の平均含有割合yavgが0≦yavg≦0.005の範囲を逸脱すると、複合窒化物または複合炭窒化物層の靭性が低下するため耐欠損性および耐チッピング性が逆に低下するため好ましくない。したがって、C成分の平均含有割合yavgは、0≦yavg≦0.005と定めた。
まず、本願発明において電子線後方散乱回折装置を用いて縦断面方向から0.1μm間隔で解析し、図1に示すように、隣接する測定点P(以下、ピクセルという)間で5度以上の方位差がある場合、そこを粒界Bと定義する。縦断面方向とは、縦断面に垂直な方向を意味する。縦断面とは、工具基体表面に垂直な工具の断面を意味する。そして、粒界で囲まれた領域を1つの結晶粒と定義する。ただし、隣接するピクセル全てと5度以上の方位差がある単独に存在するピクセルは結晶粒とせず、2ピクセル以上が連結しているものを結晶粒として取り扱う。
そして、結晶粒内のあるピクセルと、同一結晶粒内の他のすべてのピクセル間で方位差を計算し、これを平均化したものをGOS(Grain Orientation Spread)値として定義する。概略図を図1に示す。GOS値については、例えば文献「日本機械学会論文集(A編) 71巻712号(2005-12) 論文No.05-0367 1722~1728」に説明がなされている。なお、本願発明における“結晶粒内平均方位差”とは、このGOS値を意味する。GOS値を数式で表す場合、同一結晶粒内のピクセル数をn、結晶粒内の異なるピクセルにおのおの付けた番号をiおよびj(ここで 1≦i、j≦nとなる)、ピクセルiでの結晶方位とピクセルjでの結晶方位から求められる結晶方位差をαij(i≠j)として、下記式により書ける。
このように本願発明の表面被覆切削工具が有するAlとTiの複合窒化物または複合炭窒化物層を構成する結晶粒は、従来のTiAlN層を構成している結晶粒と比較して、結晶粒内で結晶方位のばらつきが大きく、すなわち、歪みがあるため、このことが硬さや靭性の向上に寄与している。
好ましい複合窒化物または複合炭窒化物層の面積に対する、結晶粒内平均方位差が2度以上を示す結晶粒の面積割合は30~60%である。より好ましい複合窒化物または複合炭窒化物層の面積に対する、結晶粒内平均方位差が2度以上を示す結晶粒の面積割合は35~55%である。さらにより複合窒化物または複合炭窒化物層の面積に対する、結晶粒内平均方位差が2度以上を示す結晶粒の面積割合は40~50%である。
複合窒化物または複合炭窒化物層を構成する結晶粒は、工具基体表面(界面)側よりも表面側の方が、工具基体表面の法線方向、すなわち{100}面に向いていることにより、靱性を維持しつつ、耐摩耗性が向上するという本発明に特有の効果が奏される。
しかしながら、界面側よりも表面側の{100}面配向度の増加割合が10%未満であると{100}面配向度の増加割合が少なく、本発明において期待する靱性を維持しつつ耐摩耗性を向上するという効果が十分に奏されない。一方、30%を超えると配向の急激な変化により結晶のエピタキシャル成長を阻害し、かえって靭性が低下する。また界面側の{100}面配向度が10%以下では表面側の{100}面配向度の増加割合が30%以上となり、界面側の{100}面配向度が40%以上では表面側の{100}面配向度の増加割合が10%未満となる事が分かった。したがって、結晶粒の工具基体表面の法線方向に対する結晶面である{100}面の法線がなす傾斜角を複合窒化物または複合炭窒化物層を層厚方向に二等分した界面側の領域と表面側の領域に分けて測定し、測定された前記傾斜角のうち法線方向に対して0~45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分して各区分内に存在する度数を集計した場合、a)界面側の領域において、0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をMdegとすると、Mdegが10~40%であり、b)表面側の領域において、0~12度の範囲内の傾斜角区分に最高ピークが存在すると共に、0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をNdegとすると、NdegがMdeg+10~Mdeg+30%であると定めた。
(Ti1-xAlx)(CyN1-y)で表されるTiとAlの複合窒化物または複合炭窒化物層はNaCl型の面心立方構造を有するTiとAlの複合窒化物または複合炭窒化物の相を少なくとも含むことで優れた耐摩耗性を発揮し、その面積割合が70%を超えることで特に優れた耐摩耗性を発揮する。
TiとAlの複合窒化物または複合炭窒化物層内の立方晶構造を有する個々の結晶粒の平均粒子幅Wが0.1~2μm、平均アスペクト比Aが2~10となる柱状組織となるように構成することにより、靭性および耐摩耗性が向上するという前述した効果をより一層、発揮させることができる。
すなわち、平均粒子幅Wを0.1~2μmとしたのは、0.1μm未満では、被覆層表面に露出した原子におけるTiAlCN結晶粒界に属する原子の占める割合が相対的に大きくなることにより、被削材との反応性が増し、その結果、耐摩耗性を十分に発揮することができず、また、2μmを超えると被覆層全体におけるTiAlCN結晶粒界に属する原子の占める割合が相対的に小さくなることにより、靭性が低下し、耐チッピング性を十分に発揮することができなくなる。したがって、平均粒子幅Wを0.1~2μmとすることが好ましい。
また、平均アスペクト比Aが2未満の場合、十分な柱状組織となっていないため、アスペクト比の小さな等軸結晶の脱落を招き、その結果、十分な耐摩耗性を発揮することができない。一方、平均アスペクト比Aが10を超えると結晶粒そのものの強度を保つ事が出来ず、かえって、耐チッピング性が低下するため好ましくない。したがって、平均アスペクト比Aを2~10とすることが好ましい。
なお、本願発明では、平均アスペクト比Aとは、走査型電子顕微鏡を用い、幅100μm、高さが硬質被覆層全体を含む範囲で硬質被覆層の縦断面観察を行った際に、工具基体表面と垂直な皮膜断面側から観察し、基体表面と平行な方向の粒子幅w、基体表面に垂直な方向の粒子長さlを測定し、各結晶粒のアスペクト比a(=l/w)を算出するとともに、個々の結晶粒について求めたアスペクト比aの平均値を平均アスペクト比Aとして算出し、また、個々の結晶粒について求めた粒子幅wの平均値を平均粒子幅Wとして算出した。
また、本願発明の表面被覆切削工具が有する複合窒化物または複合炭窒化物層は、それだけでも十分な効果を奏するが、Tiの炭化物層、窒化物層、炭窒化物層、炭酸化物層および炭窒酸化物層のうちの1層または2層以上のTi化合物層からなり、0.1~20μmの合計平均層厚を有する下部層を設けた場合、あるいは、1~25μmの平均層厚を有する酸化アルミニウム層を含む上部層を設けた場合には、これらの層が奏する効果と相俟って、一層すぐれた特性を創出することができる。Tiの炭化物層、窒化物層、炭窒化物層、炭酸化物層および炭窒酸化物層のうちの1層または2層以上のTi化合物層からなる下部層を設ける場合、下部層の合計平均層厚が0.1μm未満では、下部層の効果が十分に奏されず、一方、20μmを超えると結晶粒が粗大化し易くなり、チッピングを発生しやすくなる。また、酸化アルミニウム層を含む上部層の合計平均層厚が1μm未満では、上部層の効果が十分に奏されず、一方、25μmを超えると結晶粒が粗大化し易くなり、チッピングを発生しやすくなる。
なお、本発明の硬質被覆層を構成するTiとAlの複合窒化物または複合炭窒化物層の断面を模式的に表した図を図2に示す。
(a)表4、表5に示される形成条件A~J、すなわち、NH3とH2からなるガス群Aと、TiCl4、Al(CH3)3、AlCl3、N2、H2からなるガス群B、およびおのおのガスの供給方法として、反応ガス組成(ガス群Aおよびガス群Bを合わせた全体に対する容量%)を、ガス群AとしてNH3:4.0~6.0%、H2:65~75%、ガス群BとしてAlCl3:0.6~0.9%、TiCl4:0.2~0.3%、Al(CH3)3:0~0.5%、N2:12.5~15.0%、H2:残、反応雰囲気圧力:4.5~5.0kPa、反応雰囲気温度:700~900℃、供給周期1~5秒、1周期当たりのガス供給時間0.15~0.25秒、ガス供給Aとガス供給Bの位相差0.10~0.20秒として、所定時間、熱CVD法を行い、表7に示される結晶粒内平均方位差が2度以上を示す立方晶構造を有する結晶粒が表7に示される面積割合存在し、表7に示される目標層厚を有する(Ti1-xAlx)(CyN1-y)層からなる硬質被覆層を形成することにより本発明被覆工具1~15を製造した。
なお、本発明被覆工具6~13については、表3に示される形成条件で、表6に示される下部層および/または表7に示される上部層を形成した。
なお、本発明被覆工具6~13と同様に、比較被覆工具6~13については、表3に示される形成条件で、表6に示される下部層および/または表8に示される上部層を形成した。
なお、参考例の蒸着に用いたアークイオンプレーティングの条件は、次のとおりである。
(a)前記工具基体BおよびCを、アセトン中で超音波洗浄し、乾燥した状態で、アークイオンプレーティング装置内の回転テーブル上の中心軸から半径方向に所定距離離れた位置に外周部に沿って装着し、また、カソード電極(蒸発源)として、所定組成のAl-Ti合金を配置し、
(b)まず、装置内を排気して10-2Pa以下の真空に保持しながら、ヒーターで装置内を500℃に加熱した後、前記回転テーブル上で自転しながら回転する工具基体に-1000Vの直流バイアス電圧を印加し、かつAl-Ti合金からなるカソード電極とアノード電極との間に200Aの電流を流してアーク放電を発生させ、装置内にAlおよびTiイオンを発生させ、もって工具基体表面をボンバード洗浄し、
(c)次に、装置内に反応ガスとして窒素ガスを導入して4Paの反応雰囲気とすると共に、前記回転テーブル上で自転しながら回転する工具基体に-50Vの直流バイアス電圧を印加し、かつ、前記Al-Ti合金からなるカソード電極(蒸発源)とアノード電極との間に120Aの電流を流してアーク放電を発生させ、前記工具基体の表面に、表8に示される目標組成、目標層厚の(Ti,Al)N層を蒸着形成し、参考被覆工具14、15を製造した。
その結果を表7および表8に示す。
図3に、本発明被覆工具2について測定した結晶粒内平均方位差(すなわちGOS値)のヒストグラムの一例を示し、また、図4には、比較被覆工具2について測定した結晶粒内平均方位差のヒストグラムの一例を示す。
さらに電子線後方散乱回折装置を用いて縦断面方向から0.1μm間隔で解析し、幅10μm、縦は膜厚の測定範囲内での縦断面方向からの測定を5視野で実施し、該複合窒化物または複合炭窒化物層を構成する立方晶結晶粒に属する全ピクセル数を求め、前記5視野での該硬質被覆層に対する測定において全測定ピクセル数との比によって、該複合窒化物または複合炭窒化物層を構成する立方晶結晶粒の面積割合を求めた。
切削試験:乾式高速正面フライス、センターカット切削加工、
被削材:JIS・SCM440幅100mm、長さ400mmのブロック材、
回転速度:955 min-1、
切削速度:375 m/min、
切り込み:1.2 mm、
一刃送り量:0.15 mm/刃、
切削時間:8分。
なお、本発明被覆工具34~38については、表3に示される形成条件で、表17に示すような下部層および/または表18に示すような上部層を形成した。
なお、本発明被覆工具19~28については、表3に示される形成条件で、表12に示される下部層および/または表13に示される上部層を形成した。
なお、本発明被覆工具19~28と同様に、比較被覆工具19~28については、表3に示される形成条件で、表12に示される下部層および/または表14に示される上部層を形成した。
なお、アークイオンプレーティングの条件は、実施例1に示される条件と同様の条件を用いた。
切削条件1:
被削材:JIS・S45Cの長さ方向等間隔4本縦溝入り丸棒、
切削速度:370m/min、
切り込み:1.5mm、
送り:0.1mm/rev、
切削時間:5分、
(通常の切削速度は、220m/min)、
切削条件2:
被削材:JIS・FCD700の長さ方向等間隔4本縦溝入り丸棒、
切削速度:320m/min、
切り込み:1.2mm、
送り:0.2mm/rev、
切削時間:5分、
(通常の切削速度は、200m/min)。
表15に、前記切削試験の結果を示す。
なお、本発明被覆工具34~38については、表3に示される形成条件で、表17に示すような下部層および/または表18に示すような上部層を形成した。
なお、本発明被覆工具34~38と同様に、比較被覆工具34~38については、表3に示される形成条件で、表17に示すような下部層および/または表19に示すような上部層を形成した。
なお、アークイオンプレーティングの条件は、実施例1に示される条件と同様の条件を用い、前記工具基体の表面に、表19に示される目標組成、目標層厚の(Al,Ti)N層を蒸着形成し、参考被覆工具39,40を製造した。
さらに、実施例1に示される方法と同様の方法を用いて、界面側の領域と表面側の領域における{100}面の法線がなす傾斜角の傾斜角度数分布を求め、0~12度の範囲に存在する度数の合計が度数全体に対して占める割合を求めた。その結果を、表18および表19に示す。
工具基体:立方晶窒化ホウ素基超高圧焼結体、
切削試験:浸炭焼入れ合金鋼の乾式高速断続切削加工、
被削材:JIS・SCr420(硬さ:HRC60)の長さ方向等間隔4本縦溝入り丸棒、
切削速度:240 m/min、
切り込み:0.12mm、
送り:0.12mm/rev、
切削時間:4分。
表20に、前記切削試験の結果を示す。
B 粒界
1 工具基体
2 硬質被覆層
3 複合窒化物または複合炭窒化物層
Claims (6)
- 炭化タングステン基超硬合金、炭窒化チタン基サーメットまたは立方晶窒化ホウ素基超高圧焼結体のいずれかで構成された工具基体の表面に、硬質被覆層を設けた表面被覆切削工具において、
(a)前記硬質被覆層は、化学蒸着法により成膜された平均層厚2~20μmのTiとAlの複合窒化物または複合炭窒化物層を少なくとも含み、組成式:(Ti1-xAlx)(CyN1-y)で表した場合、複合窒化物または複合炭窒化物層のAlのTiとAlの合量に占める原子比としての平均含有割合xavgおよび複合窒化物または複合炭窒化物層のCのCとNの合量に占める原子比としての平均含有割合yavgが、それぞれ、0.60≦xavg≦0.95、0≦yavg≦0.005を満足し、
(b)前記複合窒化物または複合炭窒化物層は、NaCl型の面心立方構造を有するTiとAlの複合窒化物または複合炭窒化物の相を少なくとも含み、
(c)また、前記複合窒化物または複合炭窒化物層を構成する結晶粒中のNaCl型の面心立方構造を有する結晶粒の結晶方位を、電子線後方散乱回折装置を用いて縦断面方向から解析し、結晶粒個々の結晶粒内平均方位差を求めた場合該結晶粒内平均方位差が2度以上を示す結晶粒が複合窒化物または複合炭窒化物層の面積割合で20%以上存在し、
(d)さらに、前記結晶粒の工具基体表面の法線方向に対する結晶面である{100}面の法線がなす傾斜角を前記複合窒化物または複合炭窒化物層を層厚方向に二分した界面側の領域と表面側の領域に分けて測定し、測定された前記傾斜角のうち法線方向に対して0~45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分して各区分内に存在する度数を集計した場合、
界面側の領域において、0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をMdegとすると、Mdegが10~40%であり、
表面側の領域において、0~12度の範囲内の傾斜角区分に最高ピークが存在すると共に、前記0~12度の範囲内に存在する度数の合計が、傾斜角度数分布における度数全体に対しての割合をNdegとすると、NdegがMdeg+10~Mdeg+30%であることを特徴とする表面被覆切削工具。 - 前記NaCl型の面心立方構造を有するTiとAlの複合窒化物または複合炭窒化物が前記(Ti1-xAlx)(CyN1-y)で表されるTiとAlの複合窒化物または複合炭窒化物層に占める面積割合は70%以上であることを特徴とする請求項1に記載の表面被覆切削工具。
- 前記複合窒化物または複合炭窒化物層は、前記複合窒化物または複合炭窒化物層について、前記縦断面方向から観察した場合に、複合窒化物または複合炭窒化物層内の立方晶構造を有する個々の結晶粒の平均粒子幅Wが0.1~2μm、平均アスペクト比Aが2~10である柱状組織を有することを特徴とする請求項1または2に記載の表面被覆切削工具。
- 前記工具基体と前記TiとAlの複合窒化物または複合炭窒化物層の間にTiの炭化物層、窒化物層、炭窒化物層、炭酸化物層および炭窒酸化物層のうちの1層または2層以上のTi化合物層からなり、0.1~20μmの合計平均層厚を有する下部層が存在することを特徴とする請求項1乃至請求項3のいずれかに記載の表面被覆切削工具。
- 前記複合窒化物または複合炭窒化物層の上部に、少なくとも酸化アルミニウム層を含む上部層が1~25μmの合計平均層厚で形成されていることを特徴とする請求項1乃至請求項4のいずれかに記載の表面被覆切削工具。
- 前記複合窒化物または複合炭窒化物層は、少なくとも、トリメチルアルミニウムを反応ガス成分として含有する化学蒸着法により成膜されたものであることを特徴とする請求項1乃至請求項5のいずれかに記載の表面被覆切削工具。
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2015
- 2015-05-21 JP JP2015104042A patent/JP6548073B2/ja active Active
- 2015-05-28 WO PCT/JP2015/065424 patent/WO2015182711A1/ja active Application Filing
- 2015-05-28 EP EP15800683.3A patent/EP3150310B1/en active Active
- 2015-05-28 US US15/314,050 patent/US10329671B2/en active Active
- 2015-05-28 CN CN201580040260.4A patent/CN106573311B/zh active Active
- 2015-05-28 KR KR1020167035765A patent/KR20170012355A/ko unknown
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JP2011516722A (ja) * | 2008-03-12 | 2011-05-26 | ケンナメタル インコーポレイテッド | 硬質材料で被覆された物体 |
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US20160332236A1 (en) * | 2015-05-13 | 2016-11-17 | Kennametal Inc. | Cutting Tool Made by Additive Manufacturing |
US9975182B2 (en) * | 2015-05-13 | 2018-05-22 | Kennametal Inc. | Cutting tool made by additive manufacturing |
US11123801B2 (en) | 2015-05-13 | 2021-09-21 | Kennametal Inc. | Cutting tool made by additive manufacturing |
JP2017047526A (ja) * | 2015-08-31 | 2017-03-09 | 三菱マテリアル株式会社 | 硬質被覆層がすぐれた耐チッピング性を発揮する表面被覆切削工具 |
WO2017038840A1 (ja) * | 2015-08-31 | 2017-03-09 | 三菱マテリアル株式会社 | 硬質被覆層がすぐれた耐チッピング性を発揮する表面被覆切削工具 |
US20180257147A1 (en) * | 2015-08-31 | 2018-09-13 | Mitsubishi Materials Corporation | Surface-coated cutting tool in which hard coating layer exhibits excellent chipping resistance |
US10710168B2 (en) | 2015-08-31 | 2020-07-14 | Mitsubishi Materials Corporation | Surface-coated cutting tool in which hard coating layer exhibits excellent chipping resistance |
Also Published As
Publication number | Publication date |
---|---|
CN106573311B (zh) | 2018-12-21 |
KR20170012355A (ko) | 2017-02-02 |
EP3150310A1 (en) | 2017-04-05 |
US10329671B2 (en) | 2019-06-25 |
EP3150310B1 (en) | 2020-12-16 |
EP3150310A4 (en) | 2018-01-17 |
US20170198400A1 (en) | 2017-07-13 |
CN106573311A (zh) | 2017-04-19 |
JP6548073B2 (ja) | 2019-07-24 |
JP2016005863A (ja) | 2016-01-14 |
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