CN101524905A - 氧化物涂覆的切削刀片 - Google Patents

氧化物涂覆的切削刀片 Download PDF

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CN101524905A
CN101524905A CN200910134697A CN200910134697A CN101524905A CN 101524905 A CN101524905 A CN 101524905A CN 200910134697 A CN200910134697 A CN 200910134697A CN 200910134697 A CN200910134697 A CN 200910134697A CN 101524905 A CN101524905 A CN 101524905A
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汤米·拉尔森
马茨·约翰松
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Abstract

本发明涉及氧化物涂覆的切削刀片，其包括硬质合金、金属陶瓷、陶瓷、立方氮化硼基材料或高速钢的主体，该主体涂覆了硬质耐磨涂层，所述涂层包括一层或几层，其中至少一层是(Al，Cr)2O3层。本发明对于钢和不锈钢的机械加工特别有用。总厚度为1－20μm的所述涂层包括一层或几层，其中至少一层是厚度为0.5－10μm的(Al，Cr)2O3层，该(Al，Cr)2O3层具有刚玉相晶体结构及0.5≤y≤0.7的组成(Al1－yCry)2O3。所述(Al，Cr)2O3层进一步的特征是具有纤维织构，所述纤维织构沿着所涂覆表面法线方向以基面相对于所涂覆表面法线的倾角φ或极坐标中最高峰对应的倾角φ呈旋转对称，其中0°＜φ＜ 20°，如通过例如电子背散射衍射(EBSD)或者X射线衍射(XRD)所测定。

Description

氧化物涂覆的切削刀片
技术领域
本发明涉及用于通过排屑来进行机械加工的工具，其包括硬质合金(hard alloy of cemented carbide)、金属陶瓷、陶瓷、立方氮化硼基材料或高速钢主体，及被设计用来优选在高切削速度下对钢和不锈钢进行机械加工的硬质耐磨氧化物。所述涂层是由一层或多层构成，其中至少一层是织构的物理气相淀积(PVD)的刚玉相含铬氧化铝(A1，Cr)2O3。
背景技术
在例如EP603144、EP1528125、EP1477581、EP659153、EP1655387、EP659903、EP738336、EP1655388、EP1655392、US2007/104945、US2004/202877中公开了用化学气相淀积(CVD)制备的织构的α-Al2O3层。
EP1479791公开了由硬质合金或金属陶瓷和硬质涂层构成的切削工具；其中硬质涂层含有由CVD形成的α-Al2O3层，该α-Al2O3层具有测量如通过电子背散射衍射(EBSD)确定的在0-10度范围内的α-Al2O3基面相对于表面法线的倾角的最高峰。
EP744473公开了由PVD制备的织构的γ-Al2O3层。
US5310607公开了含有(Al，Cr)2O3晶体以及铬含量高于5原子％的硬质涂层，其中(Al，Cr)2O3是单晶。该涂层是在低于900℃的温度淀积的。该硬质涂层是用CVD或PVD工艺来淀积的。
当使用涂覆有氧化铝的硬质合金工具来对钢进行机械加工时，切削刀刃依照不同的磨损机理如化学磨损、磨料磨损、粘附磨损并且通过由沿着切削刀刃形成的裂纹而引发的崩刃(edge chipping)所磨损。任何一种磨损机理的支配作用是由应用所决定的，并取决于被机械加工的材料的性能、所采用的切削参数和工具材料的性能。通常，同时改进所有的工具性能是非常困难的，商售的硬质合金等级已通常针对一种或几种上述的磨损类型进行了优化，因此而优选用于特定的应用领域。例如，这可以通过控制氧化铝层的织构来实现。
发明内容
本发明的一个目的是提供一种用于钢和不锈钢的机械加工的、性能提高了的、涂覆有耐磨硬质氧化物的切削工具。
根据本发明的切削工具刀片(insert)包含硬质合金、金属陶瓷、陶瓷、立方氮化硼基材料或高速钢的主体，并包括具有优异金属机械加工性能的刚玉相(Al，Cr)2O3的织构氧化物层。
附图说明
图1a展示了标记有a-轴(100)、b-轴(010)和c-轴(001)的六方晶体结构的示意图。
图1b展示了标记有(S)涂层表面、六方晶体结构(图1a)的c-轴(001)的倾角(
Figure A20091013469700051
)和涂层表面法线(n)的纤维织构的示意图。
图2展示了淀积室的示意性侧视图，该侧视图显示了：(1)真空室、(2a)阴极材料A、(2b)阴极材料B、(3)工件夹具、(4)用于加偏压的电源、(5a)阴极弧电源、(5b)阴极弧电源、(6)工艺气体的入口和(7)用于真空泵的出口。
图3展示了根据本发明涂层的断裂横截面的二次模式(secondarymode)扫描电子显微图。(A)主体、(B)粘合层、(C)(Al，Cr)O层、(D)(Al，Cr)N层和(E)TiN层。
图4展示了织构的(Al，Cr)2O3层的X射线衍射图案。硬质合金的峰用实线标记，而源自(Al，Cr)2O3的峰用虚线标记。
图5展示了根据本发明的(Al，Cr)2O3层的(A)(001)极图和(B)(001)极坐标(pole plot)曲线。
具体实施方式
根据本发明，提供了用于通过排屑来进行机械加工的切削工具，其在钢和不锈钢的金属切削方面特别有用，其包括硬质合金、金属陶瓷、陶瓷、立方氮化硼基材料或高速钢的主体，在该主体上淀积有涂层，所述涂层包括：
根据现有技术优选小于0.5μm的优选例如TiN或(Al，Cr)N的第一(最内部的)粘合层(图3(B))。
厚度为0.5-10μm、优选1-5μm、最优选2-4μm的0.5≤y≤0.7、优选y＝0.6的(Al1-yCry)2O3层，其具有织构的柱状晶粒。该(Al，Cr)2O3层具有通过PVD形成的刚玉结构和纤维织构，所述纤维织构沿着所涂覆表面法线方向以基面相对于所涂覆表面法线(图5A)的倾角(图1b)或极坐标中最高峰对应的倾角
Figure A20091013469700062
(图5B)呈旋转对称，其中
Figure A20091013469700063
优选
Figure A20091013469700064
如通过例如电子背散射衍射(EBSD)或者X射线衍射(XRD)所测定。
所述(Al，Cr)O层具有-4.5＜σ＜-0.5GPa、优选-3.0＜σ＜-1.0GPa的压缩应力水平。
(Al1-yCry)2O3的组成y是通过例如EDS或WDS所测定的。
所述主体可以根据现有技术进一步涂覆有总厚度达到1至20μm、优选1至10μm以及最优选2至7μm的例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N、优选(Ti，Al)N、(Al，Cr)N的单层和/或多层内涂层，和/或例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N、优选(Ti，Al)N、(Al，Cr)N的单层和/或多层外涂层。
用于本发明的层的淀积方法是基于合金或复合阴极在下列条件下的阴极弧蒸发：(Al，Cr)2O3层是使用具有(20原子％Al+80原子％Cr)和(60原子％Al+40原子％Cr)之间、优选(30原子％Al+70原子％Cr)和(50原子％Al+50原子％Cr)之间组成的Al+Cr阴极来生长的。蒸发电流取决于阴极尺寸是在50A和200A之间，并优选使用63mm直径的阴极时在60A和90A之间。所述层是在总压力为2.0Pa至7.0Pa、优选4.0Pa至7.0Pa的Ar+O2气氛、优选纯O2气氛中生长的。偏压是-50V至-200V、优选-50V至-100V。淀积温度是在500℃和700℃之间、优选600℃和700℃之间。
本发明也涉及根据上述的切削工具刀片以75-600m/分钟、优选150-500m/分钟的切削速度用于钢和不锈钢的机械加工的用途，根据切削速度和刀片几何形状，在铣削的情况下，每齿的平均走刀量为0.08-0.5mm、优选0.1-0.4mm。
实施例1
级别A：使用组成为10.3wt％Co和余量WC的硬质合金刀片。
在淀积前，将该刀片在碱溶液和乙醇的超声浴中清洗。该体系被抽真空至低于2.0×10-3Pa的压力，之后将该刀片用Ar离子溅射清洗。首先，通过63mm直径的合金化(40原子％Al+60原子％Cr)阴极(图2a中的位置(2a)和(2b))在总压力为5.5Pa的99.995％纯O2气氛中和约650℃的淀积温度下的阴极弧蒸发，生长0.2μm厚的TiN粘合层，继之生长2.5μm厚的织构的(Al，Cr)2O3层，总涂层厚度达到3μm。在淀积过程中，蒸发电流为75A，偏压保持在-75V。最后，涂覆由0.3μm(Al，Cr)N和0.2μm TiN构成的顶部涂层。
该涂层断裂的横截面SEM显微图显示在图3中，其中(A)主体、(B)粘合层、(C)(Al，Cr)O层、(D)(Al，Cr)N层和(E)TiN层。
所淀积的层的XRD图案是使用CuKα-射线和θ-2θ配置(configuration)来获得的。图4显示了具有织构的刚玉相氧化铝(Al，Cr)2O3层的根据本发明涂层的XRD图案。源自(Al，Cr)2O3的峰用虚线标记，而硬质合金的峰用实线标记。
所淀积的刚玉相(Al，Cr)2O3层在c-轴(001)方向(图1a)的EBSD极图(图5(A))和极坐标曲线(图5(B))，分别显示了基面相对于所涂覆表面法线的倾角
Figure A20091013469700081
(图1b)为0°和20°之间的、沿着所涂覆表面法线方向(图1b)(旋转对称)的纤维织构。极坐标中最高峰接近0°。EBSD数据是使用装配有HKL NordlysII EBSD探测仪、在20kV下工作的LEO Ultra 55扫描电子显微镜获得的，并用Channel 5软件评价。
(Al，Cr)2O3涂层的残余应力σ是通过使用sin2ψ法的XRD测量评价的。该测量是使用CrKα射线在(Al，Cr)2O3的(116)反射面上进行的。残余应力值为2.1+0.2GPa，其是使用v＝0.26的泊松比和E＝420GPa的杨氏模量所评价的。
(Al1-yCry)2O3的组成y＝0.49，是使用在10kV工作的带有ThermoNoran EDS探测仪的LEO Ultra 55扫描电子显微镜，通过能量散射谱(EDS)分析来评测的。数据是使用Noran System Six(NSS ver 2)软件评价的。
实施例2
级别B：根据现有技术，在组成为10.3wt％Co和余量WC的硬质合金刀片上，通过PVD淀积了3.0μm的Ti0.34Al0.66N层。
实施例3
级别C：根据现有技术，在组成为10.3wt％Co和余量WC的硬质合金刀片上，通过CVD淀积了由3.0μm Ti(C，N)+3μm α-Al2O3所构成的涂层。
实施例4
级别D：使用组成为5.3wt％Co和余量WC的硬质合金刀片重复实施例1。
实施例5
级别E：根据现有技术，在组成为5.3wt％Co和余量WC的硬质合金刀片上，通过PVD淀积了3.0μm的Ti0.34Al0.66N层。
实施例6
级别F：根据现有技术，在组成为5.3wt％Co和余量WC的硬质合金刀片上，通过CVD淀积了由3.0μm Ti(C，N)+3μm α-Al2O3所构成的涂层。
实施例7
在钢的机械加工中，对级别A、B和C进行试验。
  操作   面铣削(face milling)
  刀具直径   125mm
  材料   SS1672
  刀片类型   SEEX1204AFTN-M15
  切削速度   300m/分钟
  走刀量   0.2mm/齿
  切削深度   2.5mm
  切削宽度   120mm
  结果   工具寿命(分钟)
  级别A(根据本发明的级别)   7.4
  级别B   6.2
  级别C   3.3
试验是在相同的最大侧面(flank)磨损时停止的。使用根据本发明的级别，耐磨损性得到很大改进。
实施例8
在不锈钢的机械加工中，对级别A、B和C进行试验。
  操作   肩铣削(shoulder milling)
  刀具直径   32mm
  材料   SS1672
  刀片类型   XOEX120408-M07
  切削速度   275m/分钟
  走刀量   0.25mm/齿
  切削深度   3mm
  切削宽度   8.8mm
  结果   工具寿命(分钟)
  级别A(根据本发明的级别)   6.2
  级别B   4.1
  级别C   失败
试验是在相同的最大侧面磨损时停止的。使用根据本发明的级别，耐磨损性得到很大改进。
实施例9
在不锈钢的机械加工中，对级别D、E和F进行试验。
  操作   断续车削
  材料   SS2348
  刀片类型   CNMG120408-MR3
  切削速度   80m/分钟
  走刀量   0.3mm
  切削深度   2mm
  结果   工具寿命(循环数)
  级别D(根据本发明的级别)   7
  级别E   2
  级别F   5
试验是在相同的最大侧面磨损时停止的。使用根据本发明的级别，耐磨损性得到很大改进。
实施例10
在不锈钢的机械加工中，对级别D、E和F进行试验。
  操作   断续车削
  材料   SS1672
  刀片类型   CNMG120408-MR3
  切削速度   350m/分钟
  走刀量   0.3mm
  切削深度   2mm
  结果   工具寿命(分钟)
  级别D(根据本发明的级别)   11.1
  级别E   4.5
  级别F   9.2
试验是在相同的最大侧面磨损时停止的。使用根据本发明的级别，耐磨损性得到很大改进。

Claims (7)

1.切削工具刀片，其包括硬质合金、金属陶瓷、陶瓷、立方氮化硼基材料或高速钢的主体，该主体涂覆了硬质耐磨涂层，所述涂层包括一层或几层，其中至少一层是(Al，Cr)2O3层，其特征在于所述层具有刚玉相晶体结构及(Al1-yCry)2O3的组成其中0.5≤y≤0.7、优选y＝0.6，厚度为0.5-10μm、优选为1-5μm，并且具有纤维织构，所述纤维织构沿着所涂覆表面法线方向旋转对称，其中基面相对于所涂覆表面法线的倾角
Figure A2009101346970002C1
是
Figure A2009101346970002C2
或者极坐标中最高峰对应的倾角是
Figure A2009101346970002C4
2.根据权利要求1的切削工具刀片，其特征在于，所述基面相对于所涂覆表面法线的倾角
Figure A2009101346970002C5
是
3.根据权利要求1的切削工具刀片，其特征在于，所述层具有-4.5＜σ＜-0.5GPa、优选-3.0＜σ＜-1.0GPa的残余应力。
4.根据权利要求1的切削工具刀片，其特征在于，所述层是用PVD、优选用阴极弧蒸发来淀积的。
5.根据前述权利要求中任一项的切削工具刀片，其特征在于，所述主体根据现有技术涂覆有例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N，优选(Ti，Al)N、(Al，Cr)N的单层和/或多层内涂层，和/或例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N，优选(Ti，Al)N、(Al，Cr)N的单层和/或多层外涂层，总涂层厚度达到1至20μm、优选1至10μm。
6.制造根据权利要求1的切削工具刀片的方法，其特征在于，使用Al+Cr阴极，通过阴极弧蒸发来淀积(Al，Cr)2O3层，所述Al+Cr阴极具有(20原子％Al+80原子％Cr)和(60原子％Al+40原子％Cr)之间、优选(30原子％Al+70原子％Cr)和(50原子％Al+50原子％Cr)之间的组成，蒸发电流是在50A和200A之间，在总压力为2.0Pa至7.0Pa、优选4.0Pa至7.0Pa的Ar+O2气氛、优选纯O2气氛中，偏压是-50V至-200V、优选-50V至-100V，且淀积温度是在500℃和700℃之间、优选在600℃和700℃之间。
7.根据权利要求1至5的切削工具刀片以75-600m/分钟、优选150-500m/分钟的切削速度对钢和不锈钢进行机械加工的用途，其中根据切削速度和刀片几何形状，在铣削的情况下，每齿的平均走刀量是0.08-0.5mm、优选0.1-0.4mm。
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