CN101186135A - 用于磨削蠕墨铸铁的涂层刀片 - Google Patents

用于磨削蠕墨铸铁的涂层刀片 Download PDF

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CN101186135A
CN101186135A CNA200710193215XA CN200710193215A CN101186135A CN 101186135 A CN101186135 A CN 101186135A CN A200710193215X A CNA200710193215X A CN A200710193215XA CN 200710193215 A CN200710193215 A CN 200710193215A CN 101186135 A CN101186135 A CN 101186135A
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埃曼努埃尔·戴维
英厄马尔·赫斯曼
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    • 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
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    • B23B—TURNING; BORING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23B2224/00—Materials of tools or workpieces composed of a compound including a metal
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Abstract

本发明公开了一种涂层磨削刀片，其尤其有用于在湿性条件下、以中等切削速度磨削蠕墨铸铁，这种涂层磨削刀片包括硬质合金主体和涂层。硬质合金主体包括WC，7.3－7.9wt％的Co、1.0－1.8wt％的Ta和Nb的立方碳化物、和高W合金的粘结相。未涂层的切削刃的半径为25－45μm。所述层包括：第一层，邻近于硬质合金的TiCxNyOz层，具有这样一种成分，即x+y＝1，x＞＝0，第二层，TiCxNyOz层，厚度为1－2μm，具有这样一种成分，即x＞0.4，y＞0.4，0＝＜z＜0.1，第三层，TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y+z＞＝1，z＞0，α－Al2O3层，厚度为2.1－3.3μm，和另一层，较厚的TiN层，厚度为0.1－2.5μm，沿刀刃线没有该TiN层。

Description

用于磨削蠕墨铸铁的涂层刀片
技术领域
本发明涉及尤其有用于在干湿条件下、以中等切削速度至高切削速度磨削蠕墨铸铁(CGI)的涂层硬质合金切削工具刀片。
背景技术
由于环境原因，蠕墨铸铁(CGI)(有时也称为蠕虫状石墨铸铁)在发动机制造业中变成为越来越有利的材料。在CGI具有比合金灰口铸铁高75％的拉伸强度以及大大约45％的硬度的情况下，CGI尤其适合于承受机械和/或热载荷的复杂部件，诸如在柴油机机体和气缸盖中，在这些地方，更清洁的排放需要更高的内部操作压力。CGI允许开发更轻、更强的气缸体和气缸盖。
在发动机设计中，CGI发动机发展的近来趋势是增加能量密度。制造者所需的正是可以对材料进行迅速且有效地加工，且加工工艺的总成本和周期时间与灰口铸铁和铝制部件的相似操作相当。
CGI具有独特的形态，也称为珊瑚构造，其在蠕墨和铁基质之间产生强有力的粘附性能。这抑制了裂缝在材料中产生和蔓延，并且提供了相对于合金灰口铸铁的增强的机械性能以及相对于球墨铸铁的提高的导热性。所有这些改善了机械性能，且这种材料的强度为灰口铸铁的两倍。
CGI可以制造为具有不同的珠光体含量，以适合所需的应用，这与加工工艺存在关联。更具体地，通常，用于气缸体和气缸盖的CGI的珠光体含量为大约90vol％，而球化率为大约20vol％。
由于CGI的加工倾向于需要更高的切削力，即温度，故CGI的独特的粒状结构尤其需要工具寿命。难以在与合金灰口铸铁相同的条件下对CGI进行加工。珠光体的含量为影响工具寿命的主要因素。而且，碳化物量也影响工具寿命，但是其程度较低。
加工CGI时的主要问题为形成有毛刺，这缩短了工具寿命。
如果仅考虑每个部件的加工和成本，(工具寿命)，则对于CGI的磨削的一般建议是在干性条件下进行。
然而，如果考虑机床的可靠性，则将要理解的是，如果在干性条件下使用机床，那么由于干性加工将产生高温、切屑、灰尘等，故机床制造者将无法确保机床的功能。高温、热切屑和灰尘将影响机床和部件。
由于上述原因，故即使每个部件的成本增加，但大多数的CGI的磨削也在利用冷却剂进行湿性磨削时完成。
发明内容
本发明的目的是提供一种尤其有用于CGI的中等速度磨削至高速磨削的磨削刀片，这种磨削刀片能够在干湿条件下执行这些操作，并且周期时间和成本与合金灰口铸铁的相似工艺相当。
现在意外地发现，通过平衡基底和涂层特性，以满足磨削应用中的载荷，获得了一种切削工具刀片，该切削工具刀片在以中等切削速度至高切削速度、利用流体冷却剂湿磨蠕墨铸铁或者在干性条件下干磨蠕墨铸铁时具有优良的切削性能。
根据本发明的切削工具刀片改善了工具寿命。CGI的磨削的标准通常为部件的表面精加工、毛刺等等，这取决于热裂缝和刀侧面磨损的存在。意外地是，发现热裂缝的数量减少，并且工具寿命增长。
根据本发明的切削工具刀片具有硬质合金主体，该硬质合金主体具有相当高W合金的粘结相，WC、TiCxNy层、α-Al2O3层的良好平衡的化学成分和晶粒尺寸，和TiN层，刀片具有通过擦刷刀刃所获得的平滑切削刃。
根据本发明，涂层切削工具刀片设置为由硬质合金主体组成，该硬质合金主体的成分为7.3-7.9wt％的Co，优选为7.6wt％的Co，1.0-1.8wt％的金属Ta和Nb的立方碳化物，优选为1.4-1.7wt％的金属Ta和Nb的立方碳化物，和余量的WC。WC的平均晶粒直径为1.5-2.5μm，优选为大约1.8μm。
钴粘结相与W高度合金。粘结相中的W含量可表示为：
CW-比＝磁性-％Co/wt-％Co
其中，磁性-％Co是磁性Co的重量百分比，wt-％Co是硬质合金中的Co的重量百分比。CW值为粘结相中的W含量的函数。大约为1的CW值相当于粘结相中的低W含量，大约0.75-0.8的CW值相当于粘结相中的高W含量。
根据本发明，如果硬质合金主体的CW比为0.86-0.94，则获得改善的切削性能。
未涂层的切削刃的半径为25-45μm。
硬质合金刀片至少部分涂覆有4.7-6.8μm厚的涂层，该涂层包括至少三层TiCxNyOz层。TiCxNyOz层的总厚度为2.1-3.3μm，并且这三层包括：
第一层，邻近于所述硬质合金的TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y＝1，x＞＝0，优选x＜0.2，且z＝0，
第二层，TiCxNyOz层，厚度为1-2μm，具有这样一种成分，即x＞0.4，y＞0.4，0＝＜z＜0.1，优选z＝0，
第三层，邻近于α-Al2O3层的TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y+z＞＝1，优选x+y+z＝1，z＞0，优选z＞0.2，并且优选y＜0.2，α-Al2O3层，厚度为2.1-3.3μm，和
另外的较厚TiN层，厚度为0.1-2.5μm，优选1.2μm，优选地沿切削刃没有该TiN层。也可沿切削刃部分地没有下面的氧化铝层。
本发明还涉及一种制造涂层切削工具刀片的方法，涂层切削工具刀片包括硬质合金主体，该硬质合金主体的成分为7.3-7.9wt％的Co，优选为7.6wt％的Co，1.0-1.8wt％的Ta和Nb的立方碳化物，优选为1.4-1.7wt％的Ta和Nb的立方碳化物，和余量的WC。WC的平均晶粒尺寸为1.5-2.5μm，优选为大约1.8μm。
在将刀片喷砂为具有25-45μm的刀刃半径之后，沉积如下的涂层：
利用已知的CVD方法，沉积第一层，即邻近于所述硬质合金的TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y＝1，x＞＝0，优选x＜0.2，且z＝0，
优选地利用MTCVD技术，沉积第二层，即TiCxNyOz层，厚度为1-2μm，具有这样一种成分，即x＞0.4，y＞0.4，0＝＜z＜0.1，优选z＝0，其中MTCVD技术利用乙腈作为碳源和氮源，用以在700-900℃的温度下形成该层。然而，确切条件在一定程度上取决于所使用的设备的设计，第三层，即邻近于α-Al2O3层的TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y+z＞＝1，优选x+y+z＝1，z＞0，优选z＞0.2，且优选y＜0.2，利用已知的CVD技术，沉积α-Al2O3层，厚度为2.1-3.3μm，和另外的较厚TiN层，厚度为0.1-2.5μm，优选1.2μm。
利用基于例如SiC的刷子擦刷刀刃线，例如公开在US 5,861,210中的SiC。优选地沿切削刃去除TiN-层，并且可沿切削刃部分地去除氧化铝层。
本发明还涉及利用根据上述发明的切削工具刀片用于磨削蠕墨铸铁，磨削或者为干磨，或者为利用流体冷却剂的湿磨，根据接合长度，切削速度为80-280m/分钟，并且根据切削速度和刀片几何形状，进给为0.1-0.35mm/齿。
具体实施方式
示例1
A.根据本发明的型号为TNEF 1204AN-KX的硬质合金磨削刀片，成分为7.6wt％的Co，1.25wt％的TaC，0.30wt％的NbC，余量为WC，平均晶粒尺寸为1.8μm，在喷砂至35μm的刀刃半径后，与W合金化的粘结相(CW-比为0.9)以如下方式涂覆：
第一层，0.5μm的TiC0.05N0.95，以已知的CVD方法，利用由TiCl4，H2和N2组成的反应混合物，
第二层，1.7μm的柱形TiC0.55N0.45，利用已知的MTCVD技术，温度为885-850℃，并且CH3CN作为碳/氮源，
第三层，0.5μm的TiC0.5O0.5粘结层，其具有针状晶粒，
第四层，其包括利用已知的CVD技术形成的2.7μm的α-Al2O3层和最后的大约1.3μm的TiN顶层。XRD测量结果证实，Al2O3层为100％的α相。
在涂覆周期之后，利用SiC刷子对刀片的刀刃线进行擦刷操作。
B.Sandvik GC4020商业等级
C.型号TNEF1204AN-KM的硬质合金磨削刀片，成分为6％的Co和余量的WC，并且将50μm的刀刃半径涂覆与A相同的涂层。
示例2
对刀片A，B和C进行如下的性能试验：
操作：表面磨削-粗磨
工件：柴油机机体顶面
材料：CGI 85％珠光体和23％球化率
工具：Sandvik Coromant R260.31-315
标准：表面精加工(毛刺形成)
切削数据
切削速度：Vc＝200m/分钟
进给速率/齿：Fz＝0.20mm/转
切削深度：Ap＝4mm
干性条件
结果：工具寿命             发动机机体的数量
等级A：(本发明)            874
等级B：Sandvik GC 4020     695
等级C：参照                456
示例3
对刀片A，B和C进行如下的性能试验：
操作：表面磨削-粗磨
工件：气缸盖
材料：CGI90％珠光体和17％球化率
工具：Sandvik Coromant R260.31-250
标准：表面精加工(毛刺形成)
切削数据
切削速度：Vc＝178m/分钟
进给率/齿：Fz＝0.18mm/转
切削深度：Ap＝3.5mm
湿性条件
刀片类型：TNEF 1204AN-KX
结果：工具寿命             气缸盖的数量
等级A：(本发明)           748
等级B：Sandvik GC 4020    576
等级C：参照               487

Claims (7)

1.一种切削工具刀片，其用于在干性或湿性条件下、以中等切削速度至高切削速度磨削蠕墨铸铁，这种切削工具刀片包括硬质合金主体和涂层，其特征在于：所述硬质合金主体包括WC，7.3-7.9wt％的Co、1.0-1.8wt％的Ta和Nb的立方碳化物、和CW比为0.86-0.94的高W合金的粘结相，未涂层切削刃的半径为25-45μm，
并且所述涂层包括：
第一层，邻近于所述硬质合金的TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y＝1，x＞＝0，优选x＜0.2，且z＝0，
第二层，TiCxNyOz层，厚度为1-2μm，具有这样一种成分，即x＞0.4，y＞0.4，0＝＜z＜0.1，优选z＝0，
第三层，TiCxNyOz层，厚度＜1μm，具有这样一种成分，即x+y+z＞＝1，优选x+y+z＝1，且z＞0，优选z＞0.2，并且优选y＜0.2，
α-Al2O3层，厚度为2.1-3.3μm，和
另外的较厚TiN层，厚度为0.1-2.5μm，优选1.2μm。
2.如权利要求1所述的磨削刀片，其特征在于：所述硬质合金包括1.4-1.7wt％的Ta和Nb的碳化物。
3.如前述权利要求中的任一项所述的磨削刀片，其特征在于：所述最外层的TiN层沿切削刃不存在。
4.一种制造磨削刀片的方法，磨削刀片用于在干性或湿性条件下、以中等切削速度至高切削速度磨削蠕墨铸铁，所述磨削刀片包括硬质合金主体和涂层，其特征在于：WC-Co基硬质合金主体包括WC，7.3-7.9wt％的Co、1.0-1.8wt％的Ta和Nb的立方碳化物，和CW比为0.86-0.94的高W合金的粘结相，所述方法包括如下步骤：
将所述刀片处理成具有25-45μm的刀刃半径；
利用CVD方法，沉积邻近于所述硬质合金的第一层TiCxNyOz层，其厚度＜1μm，具有这样一种成分，即x+y＝1，x＞＝0，优选x＜0.2，且z＝0，
利用MTCVD技术，沉积第二层TiCxNyOz层，其厚度为1-2μm，具有这样一种成分，即x＞0.4，y＞0.4，0＝＜z＜0.1，优选z＝0，其中MTCVD技术利用乙腈作为碳源和氮源，用以在700-900℃的温度范围下形成层
沉积第三层TiCxNyOz层，其厚度＜1μm，具有这样一种成分，即x+y+z＞＝1，优选x+y+z＝1，且z＞0，优选z＞0.2，并且优选y＜0.2，
利用已知的CVD技术，沉积α-Al2O3层，其厚度为2.1-3.3μm，和
利用已知的CVD技术，沉积另外的较厚TiN层，其厚度为0.1-2.5μm，优选1.2μm。
5.如前述权利要求所述的方法，其特征在于：所述硬质合金主体包括1.4-1.7wt％的Ta和Nb的碳化物。
6.如权利要求4和5中的任一项所述的方法，其特征在于：通过利用SiC刷子沿所述切削刃进行擦刷，去除所述最外层的TiN层。
7.利用根据权利要求1-3的切削工具刀片用于对蠕墨铸铁进行干磨，或者利用流体冷却剂对其进行湿磨，根据接合的长度，切削速度为80-280m/分钟，并且根据切削速度和刀片几何形状，进给为0.1-0.35mm/齿。
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