CN101568399B - 切削工具 - Google Patents

切削工具 Download PDF

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CN101568399B
CN101568399B CN2006800568155A CN200680056815A CN101568399B CN 101568399 B CN101568399 B CN 101568399B CN 2006800568155 A CN2006800568155 A CN 2006800568155A CN 200680056815 A CN200680056815 A CN 200680056815A CN 101568399 B CN101568399 B CN 101568399B
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cutting
ground
coating
cutting tip
cutting element
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CN101568399A (zh
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朴权熙
千成洙
罗相雄
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Taegutec Ltd
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Abstract

在本文中公开了一种包括细微的和均匀的氧化铝基底材的切削工具。在示范性实施方案中，氧化铝基底材包括0.1-25体积％的一种或多种金属氧化物，或者5-80体积％的金属碳氮化物和0.01-10体积％的一种或多种金属氧化物。构成所述的金属氧化物和所述的金属碳氮化物的金属选自元素周期表的III-VI族(包括La族和Ac族)的元素、Mg和Co。所述的加入到氧化铝中的金属氧化物存在于氧化铝颗粒的边界上，由此阻止氧化铝颗粒在烧结过程中过分生长。

Description

切削工具
技术领域
本发明通常涉及一种氧化铝基陶瓷切削工具，更具体的，涉及一种具有在其表面上形成的涂层的氧化铝基陶瓷切削工具。
背景技术
氧化铝由于其优异的机械性能和耐热性而被广泛的用作切削工具底材原料。在氧化铝切削工具的表面上形成TiN涂层来改善表面粗糙度、降低切削阻力和防止工件在切削工具上的粘附。但是，TiN涂层硬度低，并因此容易因为在切削操作过程中存在的摩擦而可能发生磨损。当切削硬材料例如铸铁时，TiN涂层更容易发生磨损。此外，TiN涂层在曝露于大气和高于1000℃时容易氧化。因此，当切削工具进行高速切削时，经受高温的TiN涂层容易发生氧化和从底材上剥离。
TiN涂层的脱除导致切削刃被快速磨损。此外，这导致了切削阻力的升高，由此加速了该切削工具的磨损。这缩短了切削工具的寿命。
发明内容
技术问题
本发明的一个目标是提供一种涂覆的氧化铝基陶瓷切削工具，其具有提高的耐磨损性。
本发明另外一个目标是提供一种涂覆的氧化铝基陶瓷切削工具，其具有在高速切削下提高的机械性能。
本发明仍然的另外一个目标是提供一种涂覆的氧化铝基陶瓷切削工具，其具有提高的工具寿命。
技术方案
为了达到上述目标和其他目标，本发明的切削工具包含氧化铝基底材。优选所述的底材包括0.1-25体积％的一种或多种金属氧化物，或者5-80体积％的金属碳氮化物(metal carbonitride)和0.01-10体积％的一种或多种金属氧化物。构成所述的金属氧化物和所述的金属碳氮化物的金属选自元素周期表的III-VI族(包括La族和Ac族)的元素、Mg和Co。所述的加入到氧化铝中的金属氧化物存在于氧化铝颗粒(grains)的边界上，由此阻止氧化铝颗粒在烧结过程中过分生长。结果，可以获得细微的和均匀的氧化铝基底材。
此外，当将5-80体积％的金属碳氮化物加入到氧化铝中时，通过同样的原理，能够获得细微的氧化铝颗粒和均匀的微观结构。此外，金属碳氮化物提供了比金属氧化物更大的韧性(toughness)增加，由此扩大了氧化铝基陶瓷切削工具的应用，包括高硬度钢的高速切削。
同样，在切削工具的底材上形成一个或多个Al-Ti-Cr基氮化物涂层。该一个或多个Al-Ti-Cr基氮化物涂层是在切削工具的底材上以0.3-5.0μm，优选0.5-2.0μm的厚度形成的。所述的Al-Ti-Cr基氮化物涂层的组成可以是AlWTiXCrYSiZCVN1-V(W+X+Y+Z＝1，V＝0～1)。
此外，所述的涂层可以通过物理气相沉积(PVD)方法来形成。
附图说明
图1是表示不同的类型的其中可应用了本发明的切削刀片(cuttinginserts)的照片。
图2是电子显微镜照片，表示根据本发明第一实施方案的切削工具的横截面。
图3是电子显微镜照片，表示常规的切削工具的横截面。
图4是在进行了比较涂层与底材的附着强度的维氏硬度测试之后，图2的切削工具的光学显微镜照片。
图5是在进行了比较涂层与底材的附着强度的维氏硬度测试之后，图3的切削工具的光学显微镜照片。
图6是电子显微镜照片，表示根据本发明第二实施方案的切削工具的横截面。
图7和8是表示常规切削工具的横截面的电子显微镜照片。
图9是在进行了比较涂层与底材的附着强度的维氏硬度测试之后，图6的切削工具的光学显微镜照片。
图10是在进行了比较涂层与底材的附着强度的维氏硬度测试之后，图7的切削工具的光学显微镜照片。
图11是在进行了比较涂层与底材的附着强度的维氏硬度测试之后，图8的切削工具的光学显微镜照片。
图12是本发明第一实施方案的切削工具与常规切削工具的工具寿命比较图。
图13是根据本发明第一实施方案的切削工具的光学显微镜照片，其表示了在使用后的切削刃(cutting edge)的磨损程度。
图14-16是常规切削工具的光学显微镜照片，其表示了在使用后它们各自的切削刃的磨损程度。
图17是本发明第二实施方案的切削工具与常规切削工具的工具寿命比较图。
图18是根据本发明第二实施方案的切削工具的光学显微镜照片，其表示了在使用后切削刃的磨损程度。
图19-21是常规切削工具的光学显微镜照片，其表示了在使用后它们各自的切削刃的磨损程度。
具体实施方式
根据本发明的第一实施方案，氧化铝基陶瓷切削刀片包含了氧化铝和0.1-25体积％的一种或多种金属氧化物。构成所述的金属氧化物的金属选自元素周期表III-VI族(包括La族和Ac族)的元素、Mg和Co。该切削刀片具有在所述表面上形成的一个或多个Al-Ti-Cr基氮化物涂层。优选该一个或多个Al-Ti-Cr基氮化物涂层的厚度是0.3-5.0μm，优选0.5-2.0μm。当该涂层的厚度小于0.3μm时，该涂层在切削加工过程中容易发生磨损和剥离。因此，没有提供该涂层的增加工具寿命的作用。此外，当所述涂层比0.5μm厚时，底材和涂覆材料之间的附着强度变差，涂层容易剥离或者损坏。这缩短了工具寿命。
图1是表示不同类型的切削刀片的照片，本发明能够用于这些切削刀片。虽然参考切削工具的实施方案来描述本发明，但是应当理解本发明也可以用于由陶瓷制成的不同的机械结构或者功能零件。
图2和3是所述的切削刀片和常规切削刀片各自的横截面照片，该照片是用电子显微镜放大7000倍来拍摄的，用于比较涂层与底材的附着强度。图2表示了根据本发明的切削刀片的横截面，其中组成为(TiAlCrN+TiN)的涂层是通过PVD，以大约1.2μm的厚度涂覆到氧化铝基底材上的，该底材的组成为(Al2O3+8.0％ZrO2+0.3％MgO)。图3表示了常规切削刀片的横截面，其中组成为TiN的涂层是通过PVD，以大约1.0μm的厚度涂覆到氧化铝基底材上的，该底材的组成为(Al2O3+3.0％ZrO2+0.3％MgO)。
通过比较图2和3可以看出，图2的切削刀片具有无任何间隙的紧密附着到底材上的涂层，而图3的切削刀片表现出在涂层和底材之间存在着许多不规则的间隙(如箭头所示)。
图4是用于比较涂层与底材的附着强度的照片，该照片是通过光学显微镜放大200倍来拍摄的。图4表示了在其经历了维氏硬度测试之后，根据本发明第一实施方案的切削刀片的表面。图5是通过光学显微镜放大200倍所拍摄的照片，其表示了在其经历了同样的维氏硬度测试之后，常规切削刀片的表面。在两个面之间具有136°角的金刚石棱锥(压头(indenter))被用于该维氏硬度测试中。
通过比较图4和5，证实图4的切削工具的涂层没有从底材上剥离，并且在它的表面上形成了类似于所述压头形状的棱锥形的凹痕。图5的切削工具的涂层由于压头的压力而发生了与底材严重的剥离。这样的涂层脱离是由于该涂层与底材之间差的附着强度造成的。
根据本发明的第二实施方案，氧化铝基陶瓷切削刀片包含氧化铝、5-80体积％的金属碳氮化物、和0.1-10体积％的一种或多种金属氧化物。构成所述的金属碳氮化物和所述的金属氧化物的金属选自元素周期表III-VI族(包括La族和Ac族)的元素、Mg和Co。该切削刀片具有形成于表面上的一个或多个Al-Ti-Cr基氮化物涂层。优选该一个或多个Al-Ti-Cr基氮化物涂层的厚度是0.3-5.0μm，优选0.5-2.0μm。
图6-8是通过电子显微镜放大7000倍所拍摄的照片，用于比较涂层与底材的附着强度，其表示了所述的切削刀片和常规切削刀片各自的横截面。图6表示了根据本发明第二实施方案所构造的切削刀片的横截面，其中组成为TiAlCrN的涂层是通过PVD，以大约1.2μm的厚度涂覆到氧化铝基底材上的，该底材的组成为(Al2O3+35％TiCN+0.5％MgO+1.0％Y2O3)。图7表示了一种常规切削刀片的横截面，其中组成为TiN的涂层是通过PVD，以大约0.2μm的厚度涂覆到氧化铝基底材上的，该底材的组成为(Al2O3+26％TiCN+0.5％MgO)。图8表示了另外一种常规切削刀片的横截面，其中组成为TiN的涂层是通过PVD，以0.2μm的厚度涂覆到氧化铝基底材上的，该底材的组成为(Al2O3+30％TiCN+0.3％MgO)。
通过比较图6-8可以看出，图6的切削刀片具有无任何间隙的紧密附着到底材上的涂层，而图7和8的切削工具的涂层在表面的几个地方发生了剥离(如箭头所示)。
图9是用于比较涂层与底材的附着强度的照片，该照片是通过光学显微镜放大200倍拍摄的。图9表示了在其经历了维氏硬度测试之后，根据本发明第二实施方案的切削刀片的表面。图10和11是通过光学显微镜放大200倍的照片，其表示了在它们经历了维氏硬度测试之后，图7和8各自所示的切削刀片的表面。
通过比较图9-11证实了图9的切削工具的涂层没有从底材上剥离，并且在它的表面上形成了类似于所述压头形状的棱锥形凹痕。图10和11的切削工具的涂层在压头周围与切削工具的底材发生了严重剥离。
下面描述根据本发明所构造的切削刀片的测试实施例。
[测试实施例1]
如下所述来进行根据本发明所构造的切削刀片的切削性能测试。
测量每个切削刀片的工具寿命，其中该工具寿命是将切削工具的切削面(flank face)的磨损量达到0.25mm所耗费的时间。
在所述的切削性能测试中，使用下面的刀片：切削刀片A包含组成为(Al2O3+8.0％ZrO2+0.3％MgO)的底材，并且在其上没有形成任何的涂层；切削刀片B包含在底材上的第一TiAlCrN涂层和第二TiN涂层，该底材具有与切削刀片A的底材相同的组成；切削刀片C包含在底材上的TiN涂层，该底材的组成为(Al2O3+3.0％ZrO2+0.3％MgO)；切削刀片D包含组成为(Al2O3+10.0％ZrO2+0.5％MgO)的底材，并且在其上没有形成任何的涂层。所述的切削刀片是符合ISO标准的SNGN120412旋转刀片。切削刀片B是根据本发明的，而切削刀片C和D是常规的。
切削条件如下：切削速度(v)＝600rpm；供料速度(f)＝0.3mm/rev；切削深度(d)＝2mm。此外，每个切削刀片被用来测试切削直径为150mm、长度为700mm的灰铸铁棒。测试结果在下面的[表1]和图12中给出。
[表1]
Figure G2006800568155D00061
可由表1可见，本发明的涂覆切削刀片B的工具寿命大约是具有相同底材的未涂覆切削刀片A的两倍。此外，可以看到本发明的切削刀片B的工具寿命明显比常规切削刀片C和D的寿命提高了。另一方面，可以看到切削刀片C的TiN涂层几乎对工具寿命的提高没有贡献。
此外，本发明人将切削刀片A-D在与上面的[测试实施例1]相同的条件下进行切削15分钟，并且测量切削后的切削刀片的切削面和凹口磨损量(flank and notch wear amounts)。凹口磨损量表示最深磨损部分的磨损量。切削面磨损量表示磨损部分的平均磨损量，而非凹口磨损量。
[表2]
Figure G2006800568155D00071
根据该切削结果，本发明的切削刀片B具有最小的切削面磨损量和凹口磨损量。
图13-16是通过光学显微镜放大200倍所拍摄的照片，其表示了切削刀片A-D各自的磨损特征[表2]。观察到切削刀片B的磨损量比其他切削刀片A、C和B的磨损量明显要小得多。这是因为切削刀片B的涂层与底材的优异的附着强度，其阻止了涂层与底材轻易的剥离。所述的涂层降低了切削刀片与工件(甚至在铸铁切削的情况中)之间的摩擦系数，由此抑制了切削工具的磨损。
[测试实施例2]
测量每个切削刀片的工具寿命，其中切削刀片是：切削刀片E包含组成为(Al2O3+1.0％Y2O3+35.0％TiCN+0.5％MgO)的底材，并且在其上没有形成任何的涂层；切削刀片F包含在底材上形成的TiAlCrN涂层，该底材具有与切削刀片E相同的组成；切削刀片G包含在底材上形成的TiN涂层，该底材的组成为(Al2O3+26.0％TiCN+0.5％MgO)；切削刀片H包含在底材上的TiN涂层，该底材的组成为(Al2O3+30.0％TiCN+0.3％MgO)。所述的切削刀片是符合ISO标准的CNGA120408旋转刀片。切削刀片F是根据本发明的，而切削刀片G和H是常规的。
切削条件是：切削速度(v)＝270rpm；供料速度(f)＝0.1mm/rev；切削深度(d)＝2mm。此外，每个切削刀片用来测试切削直径为150mm、长度为700mm的硬化合金钢棒。该测试的结果表示在下面的[表3]和图17中。
[表3]
Figure G2006800568155D00081
从上[表3]可以看出，本发明的涂覆的切削刀片F的工具寿命大约是具有同样底材的未涂敷的切削刀片E的两倍。此外，可以看出本发明的切削刀片F的工具寿命显著高于常规的切削刀片G和H。
此外，在与上面的[测试实施例2]相同的条件下用切削刀片E-H进行切削15分钟，并观察切削刀片的每个特征。每个切削刀片的磨损量如下所示。
[表4]
Figure G2006800568155D00082
作为切削结果，切削刀片F表现出最小的磨损量。
图18-21是通过光学显微镜放大200倍所拍摄的照片，其表示了切削刀片E-H[表4]各自的磨损特征。具有未涂敷底材的切削刀片E是黑色的，而具有由TiAlCrN或者TiN所制成的涂层的其他切削刀片是黄色的。在切削硬化合金钢的情况中，在切削部分中发生了均匀的磨损，没有观察到凹口磨损，这与切削铸铁的情况是不同的。这是由于切削刀片F的涂层与底材优异的附着强度所导致的，其阻止了涂层轻易从底材上剥离。所述的涂层降低了切削刀片和工件(甚至在铸铁切削的情况中)之间的摩擦系数，由此抑制了切削工具的磨损。
虽然已经参考其示例性的实施方案对本发明进行了具体的展示和描述，但是本领域技术人员将理解可以进行不同的改变或者改进，而不脱离本发明的范围。
工业适用性
根据本发明的氧化铝基陶瓷切削工具，涂覆材料借助于在底材上牢固的附着来保持，并且在高硬度材料例如铸铁或者硬化钢的高速切削过程中不从底材上剥离。因此，提供了一种具有出色的耐磨损性和明显提高的工具寿命的切削工具。

Claims (6)

1.一种切削工具，其包含氧化铝基底材和形成在该底材表面上的一个或多个Al-Ti-Cr基氮化物涂层，其中该一个或多个Al-Ti-Cr基氮化物涂层是AlWTiXCrYSiZCVN1-V，其中W+X+Y+Z＝1并且V＝0～1。
2.权利要求1的切削工具，其中该氧化铝基底材包含氧化铝和0.1-25体积％的一种或多种金属氧化物，其中构成所述金属氧化物的金属选自元素周期表的III-VI族包括La族和Ac族的元素、Mg和Co。
3.一种切削工具，其包含氧化铝基底材和形成在该底材表面上的一个或多个Al-Ti-Cr基氮化物涂层，其中该氧化铝基底材包含氧化铝、5-80体积％的金属碳氮化物和0.01-10体积％的一种或多种金属氧化物，其中构成所述金属碳氮化物和所述的金属氧化物的金属选自元素周期表的III-VI族包括La族和Ac族的元素、Mg和Co。
4.权利要求1-3任何一个的切削工具，其中该一个或多个Al-Ti-Cr基氮化物涂层的厚度是0.3-5.0μm。
5.权利要求1-3任何一个的切削工具，其中该一个或多个Al-Ti-Cr基氮化物涂层的厚度是0.5-2.0μm。
6.权利要求1-3任何一个的切削工具，其中该一个或多个Al-Ti-Cr基氮化物涂层是通过PVD方法形成的。
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CN101568399A (zh) 2009-10-28
EP2114595A1 (en) 2009-11-11
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BRPI0622222A2 (pt) 2012-01-03
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