CN101166597A - 具有冷却剂通道的复合制品和工具制造方法 - Google Patents

具有冷却剂通道的复合制品和工具制造方法 Download PDF

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CN101166597A
CN101166597A CNA2006800145502A CN200680014550A CN101166597A CN 101166597 A CN101166597 A CN 101166597A CN A2006800145502 A CNA2006800145502 A CN A2006800145502A CN 200680014550 A CN200680014550 A CN 200680014550A CN 101166597 A CN101166597 A CN 101166597A
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composite
metal
composite article
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mould
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普拉卡什·K·默钱达尼
迈克尔·E·沃勒
杰弗里·L·韦戈尔德
比利·D·斯韦伦金
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TDY Industries LLC
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    • 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
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    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/22—Making metal-coated products; Making products from two or more metals
    • 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
    • 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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  • 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)

Abstract

本发明的实施例包括复合制品和制造这种制品的方法，该复合制品包括至少一第一区域和一第二区域。第一区域可包括第一复合材料，其中第一区域包括小于5wt.％重量的立方相碳化物，第二区域可包括第二复合材料，其中第二复合材料在至少一种特性方面与第一复合材料不同。复合制品还可包括至少一个冷却剂通道。在某些实施例中，第一和第二复合材料可以各包括粘结剂中的硬颗粒，其中这些硬颗粒独立地包括碳化物、氮化物、硼化物、硅化物、氧化物及其固溶体中至少之一，并且粘结剂包括从钴、镍、铁及其合金中选出的至少一种金属。在具体实施例中，第一复合材料和第二复合材料可以各包括粘结剂中的金属碳化物，例如硬质合金。

Description

具有冷却剂通道的复合制品和工具制造方法
技术领域
本发明总体上涉及形成具有复合构造的制品(例如，工具坯)的方法，所述复合构造包括不同的成分和/或微观结构的区域。本发明还涉及旋转工具和旋转工具的工具坯，旋转工具具有复合构造和至少一个冷却剂通道。本发明的方法基本上应用于旋转工具的生产，并且可以例如应用于硬质合金旋转工具的生产，该硬质合金旋转工具用于材料去除操作，例如钻孔、铰孔、钻埋头孔、镗孔和端铣削。
背景技术
硬质合金旋转工具(即，受到驱动进行旋转的工具)通常用于机加工操作，例如钻孔、铰孔、钻埋头孔、镗孔、端铣削和攻丝。这类工具一般具有实心的整体构造。这类工具的制造过程可以包括固结冶金粉末(包括微粒陶瓷和粘结金属)，以形成压块。然后烧结该压块以形成具有实心整体构造的圆柱形工具坯。正如这里所使用的，整体构造是指工具由例如硬质合金材料构成，该材料在工具内的任何工作容积处都具有大致相同的特性。在烧结之后，对工具坯进行适当的机加工，以形成旋转工具的具有特定几何形状的切削刃和其它部件。旋转工具包括例如钻、端铣刀、铰刀和丝锥。
由硬质合金构成的旋转工具适合于许多工业应用，包括由例如金属、木材和塑料制成的材料的切割和成形。硬质合金工具因这些材料的特性中结合了拉伸强度、耐磨性和韧性而在工业上很重要。硬质合金材料包括至少两相：至少一种硬陶瓷组分和由金属粘结剂构成的柔软基体。硬陶瓷组分可以是例如在元素周期表中位于IVB至VIB族内的元素的碳化物。通常的示例是碳化钨。粘结剂可以是金属或金属合金，一般是钴、镍、铁或这些金属的合金。粘结剂将陶瓷组分“接合”在三维空间中互连的基体内。硬质合金可以通过固结由至少一种粉末陶瓷组分和至少一种粉末粘结剂构成的冶金粉末混合物来制造。
硬质合金材料的物理和化学性质部分地取决于用于生产该材料的冶金粉末的单个组分。硬质合金材料的性质由例如陶瓷组分的化学组成、陶瓷组分的颗粒尺寸、粘结剂的化学组成以及粘结剂与陶瓷组分的比例确定。通过改变冶金粉末的组分，可以将诸如钻和端铣刀的旋转工具生产成具有与特定应用场合相匹配的独特性质。
整体旋转工具还可以包括延伸通过其主体和柄部的冷却剂通道，以允许诸如油或水的冷却剂流到旋转工具的切削表面。冷却剂可以在柄端部处进入通道并在钻尖处离开。冷却剂冷却旋转工具和工件，并有助于将碎屑和灰尘从孔中喷出。在机加工操作期间使用冷却剂除了延长工具寿命以外，还允许利用旋转工具的更高的切削速度和更快的进给速率。具有冷却剂通道的旋转工具特别适合于在硬材料中钻深孔。
然而，旋转工具的整体构造在本质上限制了其性能和应用范围。例如，图1示出螺旋钻10的侧视图和端视图，该螺旋钻10具有用于在诸如木材、金属和塑料的构造材料中形成并抛光孔的典型设计。螺旋钻10包括最初切入工件中的横刃11。钻10的切削尖14跟随横刃11并且在钻孔的同时去除大部分材料。切削尖14的外周16对孔进行抛光。在切削过程中，切削速度从钻的中心到钻的外周显著不同。该现象在图2中示出，该图示意性地比较了典型螺旋钻的切削尖的内径D1、外径D3和中径D2的切削速度。在图2(b)中，外径D3为1.00英寸，直径D1和D2分别为0.25和0.50英寸。图2(a)示出螺旋钻以每分钟200转的速度工作时三个不同直径处的切削速度。如图2(a)和(b)所示，在旋转工具的切削刃上的不同点处测量的切削速度将随着距工具旋转轴线的距离的增加而增加。
由于切削速度的变化，具有整体构造的钻和旋转工具将不能经受均匀的磨损和/或切削和工具切削刃在从工具切削表面的中心到外侧边缘的不同点处的开裂。此外，在钻经过表面硬化的材料时，横刃一般用于穿透外层，而钻体的剩余部分去除表面硬化材料的较软芯部的材料。因此，在上述应用场合使用的整体构造的常规钻的横刃的磨损速度将比切削刃的剩余部分的磨损速度快得多，从而致使这种钻的使用寿命相对较短。在这两种情况下，由于常规硬质合金钻的整体构造，必须频繁地重新研磨切削刃，从而大大地限制了刀刃的使用寿命。频繁的重新研磨和工具改变也会导致所使用的机床有过多的停机时间。
因此，已经使用了诸如复合旋转工具的复合制品，例如在美国专利No.6,511,265中所描述的那些工具，该专利的全部内容在此引作参考。如果适当设计，复合旋转工具与具有整体性更强的构造的旋转工具相比可以具有增加的工具使用寿命。然而，需要这样的钻和其它旋转工具，它们在工具的不同区域具有不同的特性并包括冷却剂通道。作为示例，需要这样的硬质合金钻和其它旋转工具，无论相对于工具旋转轴在工具表面上的位置如何，都将受到大致均匀的磨损，并且允许在切削表面处进行冷却。需要一种具有冷却剂通道的复合旋转工具，使得复合旋转工具可以具有与整体式旋转工具相同的益处。还需要一种制造复合旋转工具和包括冷却剂通道的复合旋转工具的通用方法。
发明内容
本发明的实施例包括复合制品，该复合制品包括至少一第一区域和一第二区域。第一区域可包括第一复合材料，其中第一区域包括小于5wt.％重量的立方相碳化物(cubic carbides)，第二区域可包括第二复合材料，其中第二复合材料在至少一种特性方面与第一复合材料不同。复合制品还可包括至少一个冷却剂通道。在一些实施例中，第一和第二复合材料可以各包括粘结剂中的硬颗粒，其中这些硬颗粒独立地包括碳化物、氮化物、硼化物、硅化物、氧化物及其固溶体中至少之一，并且粘结剂包括从钴、镍、铁及其合金中选出的至少一种金属。在具体实施例中，第一复合材料和第二复合材料可以各包括粘结剂中的金属碳化物。
所述特性可以是从由弹性模量、硬度、耐磨性、断裂韧度、拉伸强度、耐蚀性、热膨胀系数和导热系数构成的组中选出的至少一种特性。复合制品例如可以是旋转工具、旋转工具坯、钻、端铣刀、丝锥、杆和棒中之一。在一些实施例中，复合制品还可包括两个或更多的冷却剂通道，并且这些冷却剂通道可以是大致直线或大致螺旋线的形状。
本发明的实施例还包括一种形成制品的方法，该方法包括共挤出包括金属碳化物的至少两种复合材料以形成生坯。所述复合材料可以是上述的那些。可以通过模具进行所述至少两种复合材料的共挤出，并且在某些实施例中，模具可包括用于在生坯中制出内部通道的装置。模具可包括至少一根丝线以形成生坯内的内部通道，其中丝线可以是刚性的或柔韧的。
实施例还包括一种制造具有复合结构的旋转工具的方法，该方法包括：将挤出的第一粉末金属置于模具空隙的第一区域中；将第二冶金粉末金属置于空隙的第二区域中，所述挤出的第一粉末金属不同于第二冶金粉末；压缩模具以使挤出的第一粉末金属和第二粉末金属固结以形成生坯。可以烧结生坯以形成制品。在烧结之前或之后可以从生坯中去除材料以提供至少一个切削刃。
读者通过考虑下面对本发明实施例的详细描述，将理解本发明上述的细节和优点以及其它。读者在利用本发明时也可以理解本发明的其它细节和优点。
附图说明
本发明的特点和优点可以通过参照附图更好地理解，附图中：
图1(a)和1(b)分别是具有冷却剂通道的常规螺旋钻的平面图和端视图；
图2(a)是示出图2(b)所示的常规螺旋钻的三个直径D1、D2和D3处的切削速度的图示；
图3(a)和(b)包括根据本发明方法的实施例生产的杆的横截面(图3(a))和纵截面(图3(b))，该杆包括中心碳化物等级B的芯和硬质合金等级A的壳；
图4(a)-(d)示出复合硬质合金的实施例的截面图；
图5(a)-(d)是坯的实施例，示出不同构造的冷却剂通道的示例，例如直的单一冷却剂通道(图5(a))；两个直的通道(图5(b))；两个螺旋形或螺线形通道(图5(c))；以及三个螺旋形或螺线形通道(图5(d))；
图6(a)示出共挤出挤压设备，用于将等级A的管和等级B的杆共挤压通过具有内部螺旋锯齿的模具，以生产具有螺旋形或螺线形通道的坯；
图6(b)示出通道模具；
图6(c)是离开具有螺旋锯齿的模具的具有内部通道的共挤压复合硬质合金杆的照片；
图7示出用在本发明的方法的实施例中的干套模均衡压制设备，其中本发明的方法包括固结具有挤出杆的硬质合金等级B和由硬质合金等级A制成的内部通道；
图8(a)是具有本发明内部冷却剂通道的复合杆的纵截面的照片，照片中的尼龙丝线已经插入到通道中，从而更清晰地示出其位置和冷却剂通道的路径；和
图8(b)是由具有内部冷却剂通道的复合硬质合金制成的钻的纵截面的照片。
具体实施方式
本发明提供了旋转切削工具、切削工具坯、杆和其它具有复合构造的制品以及制造这些制品的方法。如果期望，这些制品还可包括内通道，例如冷却剂通道。正如这里所使用的，旋转工具是具有至少一个受到驱动以进行旋转的切削刃的工具。正如这里所使用的，“复合”构造是指具有在化学组成和/或显微结构方面不同的区域的制品。这些不同导致这些区域在至少一种特性方面具有不同的性质。所述特性可以是例如硬度、拉伸强度、耐磨性、断裂韧性、弹性模量、耐蚀性、热膨胀系数和导热系数中的至少一个。可以根据本发明构造的复合旋转工具包括钻和端铣刀以及其它可以用于例如钻孔、铰孔、钻埋头孔、镗孔、端铣削和对材料进行攻螺纹的工具。
本发明更具体地提供了一种复合旋转工具，其具有至少一个切削刃、至少两个硬质合金材料的区域和至少一个冷却剂通道，其中所述至少两个硬质合金材料的区域在至少一种特性方面不同。可以通过在两个硬质合金材料的区域中间改变化学组成和显微结构中至少之一来提供不同的特性。区域的化学组成是例如陶瓷组分和/或区域粘结剂的化学组成和区域的硬质合金与粘结剂之比的函数。例如，旋转工具的两个硬质合金材料区域之一与两个区域中另一区域相比，可以显示出更大的耐磨性、增强的硬度和/或更大的弹性模量。
本发明的各方面可以参照工具坯400来描述，工具坯400在图4(a)中以横切轴线的横截面示出。工具坯400是具有两个共轴设置的硬质合金区域410、420和冷却剂通道430的大体圆柱形的烧结体。然而对本领域的技术人员显然的是，本发明的下面的讨论也可以适于制造几何形状更为复杂和/或具有多于两个区域的复合旋转工具和工具坯。因此，下面的讨论不是限制本发明，而是仅示出本发明的实施例。
在图4(a)的实施例中，圆柱形的旋转工具坯400包括两个不同的硬质合金区域，即芯区域400和外部区域410。芯区域420和外部区域410均由包括连续粘结剂基体的陶瓷颗粒的硬质合金材料制成。优选地，芯区域420和外部区域410中的硬质合金材料包括由属于周期表的IVB至VIB族的一种或多种元素的包括小于5％的立方相碳化物或在一些应用场合小于3wt.％的立方相碳化物的碳化物构成的陶瓷组分。本发明的实施例可以包括小于5wt.％的立方相碳化物，因为立方相碳化物可以降低制品的横向断裂韧度，增加制造成本并降低断裂韧度。这对于用于机械加工硬工件的工具来讲尤其重要，其中机加工导致剪切作用并且钻的强度应当是最大的。
每个区域中陶瓷组分优选地占硬质合金材料总重量约60至约80的重量百分比。硬质合金颗粒嵌入在粘结剂材料基体内，每个区域中所述粘结剂材料优选地占全部材料的约2至约40的重量百分比。粘结剂优选地是Co、Ni、Fe和这些元素的合金中的一种或多种。粘结剂例如还可含有含量达到在粘结剂中的溶解度极限的元素，诸如W、Cr、Ti、Ta、V、Mo、Nb、Zr、Hf和C。此外，粘结剂可以含有达重量百分比为5的元素，诸如Cu、Mn、Ag、Al和Ru。本领域的技术人员将理解，硬质合金材料的任一或全部构成组分可以以元素的形式、作为化合物、和/或作为中间合金引入。
工具坯400的芯区域420在界面415处自生地结合到外部区域410。图4(a)中所示的界面440是圆柱形的，但要理解，本发明复合旋转工具的硬质合金材料区域的界面的形状不限于圆柱形的构造。区域之间在界面415处的自生结合可以例如通过粘合剂基体而形成，其中粘合剂基体从芯区域420三维地延伸到外部区域410，或者从外部区域410三维地延伸到芯区域420。两个区域中粘结剂与陶瓷组分之比可以相同或不同，并且可以在区域之间改变以影响区域的相对特性。仅作为示例地，复合工具坯30相邻区域中粘结剂与陶瓷组分之比可以变化1至10重量百分比。本发明复合旋转工具的不同区域中的硬质合金材料的特性可以适应于具体的应用场合。
本领域的技术人员在考虑本发明的描述之后将理解，本发明的改进的旋转工具可以构造成具有数个不同的硬质合金材料层，以产生从工具的芯区域到周边的一个或多个特性的量值的递变。从而，例如可以提供这样一种螺旋钻，该螺旋钻具有多个共轴设置的硬质合金材料区域，并且其中每个这样的区域与相邻的更接近中心设置的区域相比依次具有更大的硬度和/或耐磨性。冷却剂通道可以设置在任一区域中，或与两个或更多区域相交。本发明的方法提供了压出制品的设计中较大的设计灵活性。或者，本发明的旋转工具可以具有其它的复合构造，其中在工具的不同区域处存在不同的特定特性。
本发明的复合硬质合金旋转工具的主要优点在于，为工具设计者提供了使工具各区域的性质适合于不同的应用场合的灵活性。例如，本发明的具体复合坯的各个硬质合金材料区域的尺寸、定位、厚度、几何形状和/或物理性质可以选择成适合于由该坯所制造的旋转工具的特定应用场合。此外，冷却剂通道可以定位于期望的位置，并且可以是螺旋形、螺线形、直线形或这些形状的组合。因此，例如，在使用中经受显著弯曲的旋转工具的一个或多个硬质合金区域的刚度可以是具有增强弹性模量的硬质合金材料的刚度；可以使具有切削表面且切削速度大于其它区域的一个或多个硬质合金区域的硬度和/或耐磨性增大；和/或可以增强在使用中受到化学接触的硬质合金材料的区域的耐蚀性。
图4(b)和4(c)示出本发明的另外的实施例。这些实施例还可以包括通道，例如冷却剂通道。图4(b)的实施例包括具有不同硬质合金等级的内部区域的管。在该示例中，杆440包括由第一硬质合金制成的外部区域441、由第二硬质合金制成的第一内部区域442、和可以包括相同或不同硬质合金的附加内部区域443。杆440可以通过例如共挤出包括填充有杆452和453的管451的组件450而生产。杆452可以由例如至少一种特性与杆453不同的硬质合金制成。
仅作为示例地，图4和5示出本发明旋转工具的另外的实施例。图4示出根据本发明构造的阶梯钻110。该阶梯钻110包括具有多个螺旋形取向的切削刃114的切削部分112。钻110还包括由卡盘接收的用于将钻安装到机床(未示出)的安装部分116。示出了钻110的局部横截面，以显示在至少一种特性方面彼此不同的三个硬质合金材料区域。第一区域118设置在钻110的切削尖处。构成区域118的硬质合金材料相对于形成钻110的芯的芯区域120显示出增强的耐磨性和硬度。芯区域由相对于剩下的两个区域显示出增强的弹性模量的硬质合金材料制成。增强的弹性模量减小了迫使钻110接触工件时钻110弯曲的趋势。钻还包括确定多个螺旋形取向的切削刃114的外部区域122。外部区域围绕芯区域120并相对于芯区域120共轴设置。外部区域122由硬质合金材料组成，并且相对于芯区域120和尖区域118显示出增强的硬度和耐磨性。由外部区域122确定的切削表面114与接近钻中心轴的切削区域相比经受更快的切削速度。因此，外部区域122的增强的耐磨性和硬度可以选择成使得切削表面的均匀磨损可以实现。
本发明的实施例还包括制造复合硬质合金制品的另外的方法。实施例包括通过共挤出包括硬质合金的至少两种复合材料以形成生坯来形成复合制品的方法。共挤出可以通过直接或间接挤出过程来进行。挤压机的供料腔填充有两个等级的材料，例如两个等级的硬质合金粉末，和混合有塑料粘结剂的粘结剂粉末。塑料粘结剂材料的含量可以为约33wt.％至67wt.％，并且可以降低粉末金属混合物的粘度以允许进行挤压操作。
硬质合金的挤压过程是本领域熟知的。在典型的挤压过程中，金属粉末与塑料粘结剂混合。可以使用任何典型的塑料粘结剂，例如基于苯甲醇、纤维素、聚合物或石油产品的塑料粘结剂。一般地，使用高光泽混合过程以确保金属粉末与塑料粘结剂之间的紧密接触。
金属/粘结剂混合器可以由螺旋进料机抽吸通过挤压机以生产挤出产品。本发明方法的实施例包括至少两个硬质合金等级的共挤出。这里使用的术语共挤出是指同时挤出两种材料以形成结合有该两种材料的单一制品。在本发明的方法中可以采用任何共挤出过程，例如抽吸两个等级的硬质合金，以分离浇口杯或模具的区段，其中两个等级彼此紧密接触地离开模具。
共挤出过程的实施例在图6(a)中示出。供料腔600填充有由第一等级的硬质合金粉末制成的杆610和由第二等级的硬质合金粉末制成的管620。杆610和管620各由本领域熟知的单独的挤出过程形成。在一些实施例中，管620可以直接挤出到供料腔600中。在单独挤出过程中形成的杆610而后可以插入到已经处于供料腔600中的管620中。
在该挤出过程的实施例中，活塞(未示出)推动杆610和管620通过供料腔并进入浇口杯630。浇口杯630的横截面积从供料腔到模具640减小。浇口杯630使硬质合金粉末致密并固结，从而使杆610与管620之间紧密接触并形成生坯(“挤出材料”)。
在一些实施例中，挤出过程还可以包括结合在浇口杯630和模具640之间的通道模具650。该通道模具包括两根丝线660或者该通道模具可以包括用于制成生坯中的内部通道的其它装置。丝线660连接到保持丝线660的臂670上，使得它们可以接触到挤出材料。丝线660使得在挤出材料中形成通道。丝线660可以由任何能够在挤出材料中形成通道的材料制成，例如，但不限于，尼龙、涂有聚合物的金属丝、聚乙烯、高密度聚乙烯、聚酯、聚氯乙烯、聚丙烯、芳族聚酰胺、凯夫拉尔(Kevlar)、聚醚醚酮、天然材料、棉花、大麻和黄麻。优选地在一些应用中，例如为了形成螺旋形取向的通道，丝线是柔韧的丝线。然而，对于直线取向的通道和在一些螺旋的应用中，可以使用刚性丝线。这些通道可以用作旋转工具中的冷却剂通道。丝线660可以用于形成螺旋形取向的通道、线性取向的通道或其组合。丝线的横截面或构成组件的其它通道可以具有任何形状，例如圆形、椭圆形、三角形、正方形或六角形。
在挤出材料相对于通道模具650旋转的实施例中，螺旋形取向的通道可以形成在挤出材料中。通过在模具640中并入螺旋锯齿，可以使挤出材料旋转。在图6(c)中，挤出材料680离开模具645，在模具645的内表面上具有螺旋锯齿。随着挤出材料通过锯齿，使挤出材料相对于通道模具(未示出)旋转。或者，可以使模具旋转来使挤出材料相对于通道模具旋转。可以使用其它的通道模具，这种模具包括固定螺旋线圈，其中使挤出材料以与螺旋线圈相同的旋转方向相对于通道模具旋转，或者可以使用任何其它的通道形成装置。
通道模具可以是单独的组件或者可以整合到挤出系统中的浇口杯、模具或其它组件。通道模具能够在挤出材料中制造出至少一个通道。通道的数量和尺寸可以由挤出材料的尺寸、通道的尺寸和挤出材料的最终应用场合来限定。在包括具有丝线的通道模具的实施例中，丝线的数量将对应于形成在挤出材料中的通道的数量。对于旋转工具的应用，可以优选地具有与例如出屑槽相等数量的通道。
本发明的实施例还可包括在供料腔中装载至少两个硬质合金等级。装载于供料腔中的至少一个硬质合金等级可以挤出为如下形式：杆、管、棒、条、矩形、齿形、星形或任何其它可以在挤出过程中形成的形状。在旋转工具或辊的应用中，可以优选地，两个硬质合金等级中的至少一个是杆形状的形式，并且至少一个硬质合金是管的形状。在其它应用中，供料腔可以填充有不同硬质合金等级的多个管和/或多个杆。如果使用多个杆，则挤出材料可以在特定区域中形成有特定等级的硬质合金，或者挤出材料可以在其横截面上随机分布。
本发明的进一步的实施例可以包括挤出硬质合金等级以形成挤出的生坯并用第二硬质合金等级压制该挤出的生坯以形成压制的生坯。该挤出的生坯例如可以有选择地包括如上所述形成的内部通道。
应用上述方法提供根据本发明的复合旋转工具的实际示例如下。
虽然已经结合一些实施例描述了本发明，但是本领域的技术人员将在考虑上述描述的基础上意识到可以采用本发明的许多变形和改变。所有这些本发明的改变和变形将由前面的描述和所附的权利要求覆盖。

Claims (68)

1.一种复合制品，包括：
至少一第一区域和一第二区域，其中，第一区域包括第一复合材料和小于5wt.％重量的立方相碳化物，第二区域包括第二复合材料，其中第一复合材料在至少一种特性方面与第二复合材料不同；以及
至少一个冷却剂通道。
2.如权利要求1的复合制品，其中，第一和第二复合材料各包括粘结剂中的硬颗粒，这些硬颗粒独立地包括碳化物、氮化物、硼化物、硅化物、氧化物及其固溶体中至少之一，并且粘结剂包括从钴、镍、铁及其合金中选出的至少一种金属。
3.如权利要求1的复合制品，其中，所述特性是从由弹性模量、硬度、耐磨性、断裂韧度、拉伸强度、耐蚀性、热膨胀系数和导热系数构成的组中选出的至少一种特性。
4.如权利要求1的复合制品，其中，第一复合材料和第二复合材料各包括粘结剂中的金属碳化物。
5.如权利要求4的复合制品，其中，第一复合材料的金属碳化物的金属和第二复合材料的金属碳化物的金属各从由IVB族、VB族和VIB族元素构成的组中选出。
6.如权利要求4的复合制品，其中，第一区域通过粘结剂基体自生地结合到第二区域。
7.如权利要求4的复合制品，其中，第一复合材料的粘结剂和第二复合材料的粘结剂各包括从由钴、钴合金、镍、镍合金、铁和铁合金构成的组中选出的金属。
8.如权利要求4的复合制品，其中，第一复合材料的粘结剂和第二复合材料的粘结剂在化学组成方面不同。
9.如权利要求4的复合制品，其中，第一复合材料的粘结剂的重量百分比不同于第二复合材料的粘结剂的重量百分比。
10.如权利要求4的复合制品，其中，第一复合材料的金属碳化物在化学组成和平均粒度中至少一个方面不同于第二复合材料的金属碳化物。
11.如权利要求4的复合制品，其中，第一复合材料和第二复合材料各包括2至40重量百分比的粘结剂和60至98重量百分比的金属碳化物。
12.如权利要求11的复合制品，其中，第一复合材料和第二碳化物材料中之一包括比第一复合材料和第二复合材料中另一个多1至10重量百分比的粘结剂。
13.如权利要求1的复合制品，其中，复合制品是旋转工具、旋转工具坯、钻、端铣刀、丝锥、杆和棒中之一。
14.如权利要求1的复合制品，其中，第一区域内的第一复合材料的弹性模量不同于第二区域内的第二复合材料的弹性模量。
15.如权利要求1的复合制品，其中，第一区域内的第一复合材料的硬度和耐磨性中至少之一不同于第二区域内的第二复合材料。
16.如权利要求1的复合制品，还包括两个冷却剂通道。
17.如权利要求1的复合制品，其中，所述至少一个冷却剂通道基本上是直的。
18.如权利要求1的复合制品，其中，所述至少一个冷却剂通道为大致螺旋形。
19.如权利要求18的复合制品，包括两个冷却剂通道。
20.如权利要求1的复合制品，其中，复合材料是硬质合金。
21.一种形成制品的方法，包括：
共挤出包括金属碳化物的至少两种复合材料，以形成生坯。
22.如权利要求21的形成制品的方法，其中，通过模具进行所述至少两种复合材料的共挤出。
23.如权利要求22的方法，其中，模具包括用于在生坯中制出内部通道的装置。
24.如权利要求22的方法，其中，模具包括至少一根丝线。
25.如权利要求24的方法，其中，所述至少一根丝线形成生坯内的内部通道。
26.如权利要求24的方法，其中，模具包括至少两根丝线。
27.如权利要求26的方法，其中，模具包括三根丝线。
28.如权利要求24的方法，其中，至少一根丝线是柔韧的丝线。
29.如权利要求28的方法，其中，所述柔韧的丝线包括尼龙、涂有聚合物的金属丝线、聚乙烯、高密度聚乙烯、聚酯、聚氯乙烯、聚丙烯、芳族聚酰胺、凯夫拉尔、聚醚醚酮、棉花、动物肠线、大麻和黄麻中至少之一。
30.如权利要求24的方法，其中，丝线是刚性的。
31.如权利要求30的方法，其中，丝线包括金属。
32.如权利要求21的方法，还包括：
用至少两个硬质合金等级装载供料腔。
33.如权利要求32的方法，其中，至少一个硬质合金等级是挤出的形式。
34.如权利要求33的方法，其中，所述挤出的形式是杆、棒和管中至少之一。
35.如权利要求32的方法，其中，装载供料腔包括装载杆形的至少一个硬质合金等级和管形的至少一个硬质合金。
36.如权利要求33的方法，其中，多个硬质合金等级以管的形状装载到供料腔中。
37.如权利要求32的方法，还包括：
挤出管形式的第一硬质合金等级。
38.如权利要求37的方法，还包括：
挤出杆形式的第二硬质合金等级。
39.如权利要求38的方法，其中，杆形式的硬质合金被直接挤出到共挤出机的供料腔中。
40.如权利要求21的方法，其中，复合材料是硬质合金。
41.如权利要求21的方法，其中，生坯包括两个硬质合金等级并且所述硬质合金等级共轴设置。
42.如权利要求21的方法，其中，模具包括通道模具。
43.如权利要求42的方法，其中，将所述至少两个硬质合金等级共挤出通过包括内部螺旋锯齿的模具。
44.如权利要求42的方法，其中，将所述至少两个硬质合金共挤出通过旋转的模具。
45.如权利要求22的方法，其中，生坯包括至少一个通道。
46.如权利要求22的方法，其中，生坯包括两个螺旋形通道。
47.如权利要求1的复合制品，其中，所述第一硬质合金材料和所述第二硬质合金材料中至少之一包括平均粒度为0.3至10μm的碳化钨颗粒。
48.如权利要求1的复合制品，其中，所述第一硬质合金材料和所述第二硬质合金材料中至少之一包括平均粒度为0.5至10μm的碳化钨颗粒，且所述第一硬质合金材料和所述第二硬质合金材料中另一个包括平均粒度为0.3至1.5μm的碳化钨颗粒。
49.如权利要求1的复合制品，其中，复合制品是钻、端铣刀和丝锥中之一。
50.如权利要求5的复合制品，其中，所述第一硬质合金材料和所述第二硬质合金材料中之一包括比所述第一硬质合金材料和所述第二硬质合金材料中另一个多1至10重量百分比的所述粘结剂。
51.如权利要求1的复合制品，其中，所述第一区域内的所述第一硬质合金材料的弹性模量不同于所述第二区域内的所述第二硬质合金材料的弹性模量。
52.如权利要求1的复合制品，其中，所述第一区域内的所述第一硬质合金材料的弹性模量为90×106至95×106psi，所述第二区域内的所述第二硬质合金材料的弹性模量为69×106至92×106psi。
53.如权利要求1的复合制品，其中，所述第一区域内的所述第一硬质合金材料的硬度和耐磨性中至少之一不同于所述第二区域内的所述第二硬质合金材料。
54.如权利要求1的复合制品，其中，所述第一硬质合金材料包括6至15重量百分比的钴合金，所述第二硬质合金材料包括10至15重量百分比的钴合金。
55.一种制造具有复合结构的旋转工具的方法，该方法包括：
将挤出的第一粉末金属置于模具空隙的第一区域中；
将第二冶金粉末金属置于空隙的第二区域中，所述挤出的第一粉末金属不同于第二冶金粉末；
压缩模具以使所述挤出的第一粉末金属和第二粉末金属固结以形成生坯；和
过压烧结所述生坯。
56.如权利要求55的方法，还包括：
从所述生坯中去除材料以提供至少一个切削刃。
57.如权利要求56的方法，其中，模具是干套模橡皮模具，并且其中，压缩模具包括均衡地压缩干套模橡皮模具以形成生坯。
58.如权利要求56的方法，其中，从生坯去除材料包括对生坯进行机加工，以形成至少一个确定至少一个螺旋形取向的切削刃的螺旋形取向的出屑槽。
59.如权利要求55的方法，其中，所述挤出的第一复合粉末包括至少一个通道。
60.如权利要求59的方法，其中，所述挤出的第一粉末金属包括至少两个通道。
61.如权利要求55的方法，其中，第一粉末金属和第二粉末金属都包括粉末粘结剂和由IVB族、VB族和VIB族元素构成的组中选出的至少一种元素的碳化物的颗粒。
62.如权利要求61的方法，其中，第一粉末金属和第二粉末金属的粘结剂各包括从由钴、钴合金、镍、镍合金、铁和铁合金构成的组中选出的至少一种金属。
63.如权利要求55的方法，其中，第一粉末金属和第二粉末金属各包括2至40重量百分比的粉末粘结剂和60至98重量百分比的碳化物颗粒。
64.如权利要求55的方法，其中，第一粉末金属和第二粉末金属中至少之一包括平均粒度为0.3至10μm的碳化钨颗粒。
65.如权利要求55的方法，其中，过压烧结生坯包括在300-2000psi的压力下、在1350℃至1500℃的温度下对生坯进行加热。
66.如权利要求55的方法，其中，压缩模具包括在5000至50000psi的压力下均衡地压缩模具。
67.如权利要求55的方法，其中，通过压缩模具形成的生坯包括：
通过使第一冶金粉末固结而提供的包括第一硬质合金材料的第一区域；和
通过使第二冶金粉末固结而提供的包括第二硬质合金材料的第二区域，第一区域和第二区域在至少一种特性方面不同。
68.如权利要求67的方法，其中，所述特性是从由弹性模量、硬度、耐磨性、断裂韧度、拉伸强度、耐蚀性、热膨胀系数和导热系数构成的组中选出的至少一种特性。
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WO2007001870A3 (en) 2007-05-10
US20060288820A1 (en) 2006-12-28
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US8318063B2 (en) 2012-11-27
US8808591B2 (en) 2014-08-19
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CA2596309A1 (en) 2007-01-04
US20130043615A1 (en) 2013-02-21
UA95912C2 (ru) 2011-09-26
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