CN101088757A - 具有涂层的铣削刀片 - Google Patents

具有涂层的铣削刀片 Download PDF

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CN101088757A
CN101088757A CNA2007101101090A CN200710110109A CN101088757A CN 101088757 A CN101088757 A CN 101088757A CN A2007101101090 A CNA2007101101090 A CN A2007101101090A CN 200710110109 A CN200710110109 A CN 200710110109A CN 101088757 A CN101088757 A CN 101088757A
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layer
milling
thickness
cutting
iron
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比约恩·永贝里
莱夫·阿克松
伊布拉尼姆·萨迪克
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Sandvik Intellectual Property AB
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Abstract

本发明公开了一种具有涂层的硬质合金铣削刀片,特别适用于在干燥环境中的灰口铸铁、高合金化灰口铸铁、具有或不具有铸造表皮的蠕墨铸铁(CGI)的粗加工的或半精加工的铣削。所述的刀片具有低立方碳化物含量的WC-Co硬质合金、W合金化粘结相以及涂层,该涂层包括具有柱状晶粒的TiCxNy内层,接着是前刀面上的湿法喷砂的α-Al2O3层,以及刀后角边上的涂色顶层。本发明还涉及一种制造上述切削工具的方法。

Description

具有涂层的铣削刀片
技术领域
本发明涉及一种具有涂层的硬质合金铣削刀片,特别适用于在干燥环境中的灰口铸铁、高合金化灰口铸铁、具有或不具有铸造表皮的蠕墨铸铁(CGI)的粗加工或半精加工铣削。
背景技术
当硬质合金切削刀片用于铸铁的加工时,切削刀刃会由于不同的磨损原理,如化学磨损以及磨损量而被磨损。另外,铣削切削刀刃通常会产生梳状裂缝。形成的梳状裂缝垂直于刀刃,且这是周期负荷和热负荷作用的结果。当梳状裂缝延伸至硬质合金体一定的深度后,刀刃就开始产生碎裂和断裂。
铸铁构件的显著特点就是:其硬表面区的结构相当大偏离其整体结构。其表面区通常包含硬夹杂物和模具上来的沙粒。这使得对铸铁的切削有很高的要求。同时,切削刀片应当能够应付大范围的切削条件,如不同的切削速度、切削深度和切削给进速度以及可控的外部条件,如工件的振动。
所有的这些因素要求切削刀片的多种性能。用于铣削铸铁的商用硬质合金刀片一般优选地相对于一种或两种所述的磨损类型进行优化。
美国专利No.5912051披露了一种特别适用于干铣削灰口铸铁的、具有涂层的切削刀片。
美国专利No.6062776披露了一种具有涂层的硬质合金切削刀片,其特别适用于在需要具有高硬度的硬质合金刀刃的切削加工中,湿铣削或干铣削具有或不具有磨蚀表面区的低合金钢和中合金钢,或不锈钢工件。所述的外部切削条件为:工件的复杂形状、振动、碎屑锻压、碎屑的再次切削等等。
美国专利No.6177178披露了一种特别适用于湿铣削和干铣削低合金钢和中合金钢的、具有涂层的硬质合金切削刀片。
WO 01/16388披露了一种具有涂层的刀片,其特别适用于在高的切削速度下,干铣削或湿铣削具有或不具有磨蚀表面区的低合金钢或中合金钢,以及在高的切削速度下,铣削淬硬钢。
美国专利No.6638609披露了一种具有涂层的铣削刀片,其特别适用于在低的或中等的切削速度下,干铣削具有或不具有铸皮(castskin)的灰口铸铁,以及在中等切削速度下,湿铣削具有或不具有铸皮的球墨铸铁和蠕墨铸铁。
美国专利申请2006/0115683披露了一种具有涂层的铣削刀片,其特别适用于在高的切削速度下,干铣削具有或不具有铸皮的灰口铸铁,以及在高的切削速度下,干铣削具有或不具有铸皮的球墨铸铁或蠕墨铸铁。所述的刀片为具有低含量立方碳化物的WC-Co硬质合金,以及高W-合金化粘结相,以及包含柱状晶粒的TiCxNy内层,其上为α-Al2O3湿喷砂层。
发明内容
本发明的目的在于提供一种较现有的刀具具有显著的优良的切削性能的、具有涂层的硬质合金切削刀,其特别适用于优选在较高的切削速度下,粗铣削灰口铸铁、高合金化灰口铸铁,以及蠕墨铸铁。
令人惊讶的发现,如果所述的刀片包括:具有W-合金化粘结相、良好平衡的化学组分以及一定晶粒尺寸的WC的硬质合金体,柱状TiCxNy-层和后处理的α-Al2O3顶层,则考虑到上述切削工艺中常见的不同的磨损类型,能够制得具有良好性能的铣削切削工具刀片。
根据本发明,具有涂层的切削刀片包含硬质合金体,其成分为7.3-7.9wt%的Co,优选7.5-7.7wt%的Co;1.0-2.0wt%、优选1.3-1.7wt%的Ta、Nb和Ti的金属立方碳化物,以及余量为WC,优选90.6-91.2wt%WC。Ti含量优选在工业杂质的水平上或为0。矫顽磁性,Hc的值应在13.8-15.7kA/m的范围内,优选为14.2-15.2kA/m内。
钴粘结相同W合金化。粘结相中W的含量如下式所示:
CW-比值=磁性-%Co/wt-%Co
其中磁性-%Co为磁性Co的重量百分比,以及wt-%Co为硬质合金中Co的重量百分比。
CW-值为Co粘结相中W含量的函数。0.75-0.8的CW-值相当于粘结相中很高的W-含量,而CW-比值为1大体上相当于没有W-合金化。
本发明中所述的良好的切削性能在下述情况下得到:
A)硬质合金体具有与W合金化的钴粘结相,相当于CW-比值为0.85-0.94,优选为0.88-0.92,以及
B)涂覆之前的刀片具有25-50μm的刀刃倒角。
C)涂层具有:
-TiCxNyOz第一最内层,其中x+y+z=1,y>x以及z<0.2,优选y>0.8,z=0,且总厚度为0.1-1.5μm,优选总厚度>0.4μm。
-TiCxNy第二层,其中x+y=1,x>0.3,y>0.3,且厚度为4.5-9.5μm,优选为5-7.5μm,具有柱状晶。
-TiCxNyOz第三层,其中x+y+z=1,x>0.3,z>0.3,0≤y<0.2,且厚度为0.3-1.5μm。
-平滑的α-Al2O3第四层,厚度为9-15μm,优选为10-12μm,且在10μm长度范围内的切削区域的表面粗糙度为Ra<0.4μm。
-Al2O3第四层的层厚同TiCxNy第二层的层厚比值优选为1.3-2.4。
-刀后角边上厚度为0.1-2μm的涂色顶层,优选为TiN或ZrN。
本发明还涉及到一种制造涂层切削工具刀片的方法,所述的刀片具有硬质合金体,其成分为7.3-7.9wt%的Co,优选为7.5-7.7wt%的Co;1.0-2.0wt%,优选1.3-1.7wt%的Ta、Nb和Ti的金属立方碳化物;余量为WC,优选为90.6-91.2wt%的WC。Ti含量优选处于工业杂质水平或更少,下至0。选择制造条件,以得到烧结结构,其矫顽磁性,Hc值为13.8-15.7kA/m,优选为14.2-15.2kA/m;以及合金有W的钴粘结相,其相当于CW-比值为0.85-0.94,优选为如上述限定的0.88-0.92。在将刀片湿喷砂至形成25-50μm切削刀刃倒角后,沉积出包含如下层的涂层:
-TiCxNyOz第一最内层,其中x+y+z=1,y>x以及z<0.2,优选y>0.8,z=0,且总厚度为0.1-1.5μm,优选>0.4μm,利用已知的CVD法。
-TiCxNy第二层,其中x+y=1,x>0.3,y>0.3,优选x>0.5,且厚度为4.5-9.5μm,优选5-7.5μm,具有柱状晶粒,且利用MTCVD法,将氰化甲烷作为在温度范围为700-900℃下形成层的源和氮源。然而,确切的条件在一定程度上依赖于所使用设备的类型。
-TiCxNyOz第三层,其中x+y+z=1,x>0.3,z>0.3,0≤y<0.2,且厚度为0.3-1.5μm,利用反应混合物TiCl4、CO、H2或TiCi4、CO、H2、N2通过CVD法制得。
-光滑α-Al2O3第四层,其厚度为9-15μm,优选为10-12μm,利用已知的CVD法。
Al2O3第四层同TiCxNy第二层的层厚比值优选为1.3-2.4。
-厚度为0.1-2μm的涂色顶层,优选为TiN或ZrN,利用CVD或PVD法。
最后,对前刀面上和沿着切削刀刃线的Al2O3层进行湿喷砂,以得到光滑表面精度,优选地,利用包含Al2O3沙砾和水的浆料,在长度10μm范围内的切削区域的表面粗糙度为Ra<0.4μm。或者,在将涂色顶层沉积在刀后角面之前,可以进行这个湿喷砂步骤。
本发明还涉及利用上述切削工具刀片,以150-375m/min的切削速度,以及由切削速度和刀片的几何尺寸确定的0.1-0.35mm/齿的给进量,对铸铁,如灰口铸铁、高合金化灰口铸铁或蠕墨铸铁进行干铣削。
具体实施方式
实施例1(本发明)
在型号为R245-12T3M-KM、R290-12T308M-KM以及SPKN1204EDR的机器中,将粉末压制成硬质合金铣削坯体,所述粉末的成分为:7.6wt%的Co、1.25wt%的TaC、0.30wt%的NbC以及余量的WC,随后在1410℃下,利用常用工艺对该铣削坯体进行烧结,烧结刀片的Hc的值为14.7kA/m,以及磁性Co的含量为6.85wt%,相当于0.90的CW比值。利用湿喷砂法使刀片形成半径为35μm的切削刀刃倒角,然后涂覆上厚度为0.5μm的第一TiCxNy层,其具有相当于y值大约为0.95的高含氮量,然后涂覆上厚度为6μm的第二TiCxNy层,利用MTCVD法(温度为850-885℃,并将CH3CN用作碳/氮源),x的值大约为0.55,且具有柱状晶结构。在同样涂覆循环的过程的随后步骤里,沉积厚度为1μm的第三Ti(C,O)层,然后沉积厚度为11μm的第四α-Al2O3层以及厚度为1μm的TiN顶层。
为了除去TiN顶层以及在10μm的长度上形成表面光洁度为Ra=0.2μm的暴露Al2O3层,利用铝土沙砾,在前刀面上对刀片进行湿喷砂处理。
实施例2(现有技术)
同实施例1所述的刀片具有同一类型,如表1所述的硬质合金铣削刀由现有的技术制得。
表1
变量 基质成分,wt%    Hc,CW Ka/m比值   涂层厚度,μm以及类型
Co  TaC  NbC  WC
试样A 6.0 -    -    余量    16.1  0.94   5.5 TiCN,4.0 α-Al2O3
试样B 7.6 1.25 0.27 余量    14.8  0.91   7.1 TiCN,7.0 α-Al2O3
实施例3
通过对高合金化灰口铸铁的汽缸体盖的端面进行铣削,对本发明实施例1所述的刀片进行测试。
工具:R245-12T3M-KM
切削机中刀片的数量:24pcs
标准:表面光洁度以及工件屑
参照物:R245-12T3M-KM,实施例2中现有技术的试样A
切削数据
切削速度:Vc=350m/min
给进率:  Fz=0.15mm每齿
切削深度:Ap=0.5mm
干铣削
测得:试样A的工具的使用寿命为174个汽缸体盖,本发明所述的刀片为215个。
结果:本发明所述刀片的使用寿命提高了23%,并且具有良好的表面光泽。
实施例4
通过对高合金化灰口铸铁的中心汽缸体的端面铣削,对本发明实施例1所述的刀片进行测试。
工具:R245-12T3M-KM
切削机中刀片的数量:10pcs
标准:表面光洁度以及工件屑
参照物:R245-12T3M-KM,实施例2中现有技术的试样A
切削数据
切削速度:Vc=251m/min
给进率:  Fz=0.24mm每齿
切削深度:Ap=2-3mm
干铣削
两次试验中,试样A的平均使用寿命为50分钟,本发明所述的刀片的使用寿命为80分钟。
实施例5
通过对灰口铸铁制成的发电机枢轴回转体的端面铣削,对本发明实施例1所述的刀片进行测试。
工具:SPKN1204 EDR
切削机中刀片的数量:8pcs
标准:表面光洁度以及工件屑
参照物:SPKN1204 EDR,实施例2中现有技术的试样B
切削数据
切削速度:Vc=350m/min
给进率:  Fz=0.19mm每齿
切削深度:Ap=3-4mm
干铣削
试样B以及本发明所述的刀的使用寿命分别为3 8分钟和56分钟。
实施例6
通过对蠕墨铸铁(CGI)的汽缸体盖进行端面铣削,对本发明实施例1所述的刀片进行测试。
工具:R290-12T308M-KM
切削机中刀片的数量:6pcs
标准:表面光洁度以及工件屑
参照物:R290-12T308M-KM,实施例2中现有技术的试样A
切削数据
切削速度:Vc=300m/min
给进率:  Fz=0.15mm每齿
切削深度:Ap=3.0mm
干铣削
试样A以及本发明所述的刀的使用寿命分别为60个汽缸体盖和85个汽缸体盖。
从实施例1-6可清楚地看出,同现有技术的刀片相比,本发明所述的刀片具有良好的切削性能。其主要的优点就是:刀侧面磨损和凹坑磨损增长缓慢,这是因为硬质合金体中成分含量均衡,以及总涂层厚度非常大。

Claims (7)

1.一种用于在铣削干燥条件下对具有或不具有铸皮的灰口铸铁、高合金化灰口铸铁以及蠕墨铸铁(CGI)进行铣削的切削工具刀片,其包括具有涂层的硬质合金体,其特征在于;所述硬质合金体具有25-50μm的边缘半径,其包含WC,7.3-7.9wt%的Co以及1.0-2.0wt%的Ti、Ta和Nb的金属立方碳化物,0.85-0.94的CW-比值,13.8-15.7kA/m的矫顽磁性Hc,并且所述涂层包括:
-TiCxNyOz第一最内层,其中x+y+z=1,y>x且z<0.2,总厚度为0.1-1.5μm,
-具有柱状晶粒的TiCxNy第二层,其中x+y=1,x>0.3,y>0.3,且厚度为4.5-9.5μm,
-TiCxNyOz第三层,其中x+y+z=1,x>0.3,z>0.3,0≤y<0.2,且厚度为0.3-1.5μm,
-平滑α-Al2O3第四层,且厚度为9-15μm,优选地,在长度10μm范围内的切削区域内的表面粗糙度为Ra<0.4μm,
-刀后角边上厚度为0.1-2μm的涂色顶层,优选为TiN或ZrN。
2.根据权利要求1所述的用于铣削的切削工具刀,其特征在于:Ti含量处于工业杂质水平或更少。
3.根据权利要求1或2所述的用于铣削的切削工具刀,其特征在于:所述的硬质合金体包含1.3-1.7wt%的Ta和Nb的碳化物。
4.一种制造具有硬质合金体和涂层的铣削切削工具刀的方法,其特征在于以下步骤:
-提供一种硬质合金体,其包含WC,7.3-7.9wt%的Co以及1.0-2.0wt%的Ti、Ta和Nb的金属立方碳化物,以及W-合金化粘结相,其具有0.85-0.94的CW-比值和13.8-15.7kA/m的矫顽磁性Hc,
-将刀片湿喷砂至形成25-50μm刀刃倒角,
-利用CVD法沉积TiCxNyOz第一最内层,其中x+y+z=1,y>x且z<0.2,总厚度为0.1-1.5μm,
-利用MTCVD法沉积具有柱状晶粒的TiCxNy第二层,其中x+y=1,x>0.3,y>0.3,且厚度为4.5-9.5μm,其中MTCVD法利用氰化甲烷作为在温度范围为700-900℃下形成层的碳源和氮源,
-利用CVD法沉积TiCxNyOz第三层,其中x+y+z=1,x>0.3,z>0.3,0≤y<0.2,且厚度为0.3-1.5μm,
-利用已知的CVD法沉积α-Al2O3第四层,厚度为9-15μm,以及
-利用CVD法或PVD法,在刀后角边上沉积厚度为0.1-2μm的涂色顶层,优选为TiN或ZrN,
-对前刀面上和沿着切削刀刃线的Al2O3层进行湿喷砂,得到光滑的表面光洁度,且优选地,利用水中包含Al2O3沙砾的浆料,在长度10μm范围内的切削区域的表面粗糙度为Ra<0.4μm。
5.根据权利要求4所述的方法,其特征在于:Ti含量处于工业杂质水平或=0。
6.根据权利要求4或5所述的方法,其特征在于:所述硬质合金体包含1.3-1.7wt%的Ta和Nb的碳化物。
7.利用权利要求1-3所述的切削工具刀,在150-375m/min的切削速度下,对铸铁,如灰口铸铁、高合金化灰口铸铁、蠕墨铸铁进行干铣削,且根据切削速度和刀片的几何形状,给进量在0.1-0.35mm/齿。
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