CN101578396A - 多层涂层切削刀具 - Google Patents

多层涂层切削刀具 Download PDF

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CN101578396A
CN101578396A CNA2007800484455A CN200780048445A CN101578396A CN 101578396 A CN101578396 A CN 101578396A CN A2007800484455 A CNA2007800484455 A CN A2007800484455A CN 200780048445 A CN200780048445 A CN 200780048445A CN 101578396 A CN101578396 A CN 101578396A
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玛丽亚·阿斯特兰德
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Abstract

本发明涉及一种涂层切削刀具,包括基体和涂层,涂层包括单个金属氮化物层X和Y交替的非周期性多层结构,其具有(Ti(1-a-b-c)AlaCrbSic)N的平均组分,其中0<a<0.5、优选为0.05<a<0.4、最优选为0.25<a<0.3,其中0<b<0.15、优选为0.02<b<0.10、最优选为0.04<b<0.08,其中0.01<c<0.17、优选为0.02<c<0.10、最优选为0.04<c<0.08,以及a+b+c<1,并且其中单个层的平均厚度是0.1nm到100nm。所述涂层切削刀具较硬并且具有较高的抗月牙洼磨损性以及较高的抗后刀面磨损性。

Description

多层涂层切削刀具
技术领域
本发明涉及一种涂层切削刀具,其中涂层具有由(Ti,Al,Cr,Si)N组成的非周期性多层结构。
背景技术
最近刀具的发展已经朝向更尖的切削刃。这要求更薄的涂层,以便保持尖的切削刃,因为厚的涂层会导致对切削性能不利的增加的刃钝化(edge rounding)。由于较高的界面剪切力,因此较厚的涂层也更易于使刃线剥落,刃越尖,则这种情况越严重。如果较薄的涂层被沉积,则要求增加的硬度,即抗磨料磨损性来维持刀具的耐磨性。
实现薄的硬涂层的一种方法是使用多层纳米复合材料涂层。用于这种多层纳米复合材料涂层的常见涂层组分是(Ti,Al)N。
提高PVD涂层的如硬度和抗氧化性的特性的另一方法是通过添加诸如Cr、Si、B的元素。
对于含Al的氮化物PVD涂层,众所周知,高的铝含量(>40at%)有利于获得高的抗后刀面磨损性和抗氧化性。但是,太高的铝含量也导致增加的月牙洼磨损,这是由于AlN从亚稳态硬立方相到更稳定的较软的六角相的相转变的缘故。
尖刃在许多切削操作,例如钻孔操作中是重要的。当钻孔时,不是仅在切削刃中发现有磨损。通常,在钻头的边缘也发现明显磨损。当打算修复钻头,即重新研磨和重新涂层时,严重的边缘磨损出现问题,因为整个磨损区都必须被去除。一般地,当重新涂层钻头时,对于每次重新涂层,总涂层厚度增加。边缘上增加的涂层厚度将增加边缘上的磨损,其中该边缘远离角落一定距离。同样,增加的涂层厚度将增加刃钝化。因此,更薄的、更耐磨的涂层是非常有利的。
切削刀具上的(Ti,Al,Cr,Si)N涂层在本领域是已知的。
EP 1 219 723 A公开了用于切削刀具的硬膜,该硬膜由Ti1-a-b-c-dAlaCrbSicBd(C1-eNe)组成,其中0.5<a<0.8、b>0.06、0≤c<0.1、0≤d<0.1、0<c+d<0.1、和0.5<e<1。该硬膜可以是多层结构的形式。
US2006/0222893公开了包括重复的层堆的多层涂层,其包括至少一个50-150nm的(Al,Cr)N层和/或至少一个75-200nm的(Ti,Si)N层以及(Al,Cr,Ti,Si)N+(Ti,Si)N+(Al,Cr,Ti,Si)N+(Al,Cr)N构成的至少一个层堆。混合的(Al,Cr,Ti,Si)N层具有多层结构,且这通过同时操作所有靶材(target)来获得。这导致涂层具有非常薄的层,在几纳米范围内。(Al,Cr,Ti,Si)N层具有20±10nm的厚度。
发明内容
本发明的目的是提供具有较高的抗月牙洼磨损性和较高的抗后刀面磨损性的涂层切削刀具。
本发明的另一目的是提供具有增加的硬度的涂层。
本发明的另一目的是提供适合于尖刃的涂层。
本发明的另一目的是提供经历较少的边缘磨损的涂层钻头。
已经令人惊讶地发现,通过用具有根据本发明的组分的非周期性多层涂敷的涂层切削刀具,可满足这些目的。
附图说明
图1示出在钻200个孔之后根据现有技术的涂有(Ti,Al,Cr,Si)N涂层的钻头上的边缘磨损。
图2示出在钻200个孔之后根据本发明的涂有(Ti,Al,Cr,Si)N涂层的钻头上的边缘磨损。
具体实施方式
根据本发明,提供了一种涂层切削刀具,包括硬质合金、金属陶瓷、陶瓷、立方氮化硼或高速钢制成的硬合金基体和涂层,该涂层包括具有交替的X和Y单个金属氮化物层、组分为(Ti,Al,Cr,Si)N的非周期性多层结构。
非周期性应理解为,多层结构中特定单个层的厚度与紧接在它下面的单个层的厚度没有关系,也与上面的特定单个层没有关系。这种多层结构在至少10个连续单个层的序列中不具有任何重复的周期。
多层结构在此意味着包括至少5个单个层的结构。但是,其可包括高达几千个单个层。
单个层的平均厚度大于0.1nm,但小于100nm,优选为大于0.5nm,但小于50nm,最优选为大于1nm,但小于30nm。多层结构中任何十个连续层的总和小于300nm。
整个涂层的总厚度是0.5μm到20μm,优选为1μm到10μm,最优选为1μm到5μm。
粘着地结合到基体或预涂覆基体的所述多层结构包括交替的层X和Y的叠层状、非周期性多层结构,其中单个层X和Y是金属氮化物,优选为多晶金属氮化物,优选为具有立方结构,其中金属元素选自钛(Ti)、铝(Al)、硅(Si)、铬(Cr)或其混合物。单个层X和Y的化学组分彼此不同。
由于小的厚度的缘故,在没有相邻层的帮助下,多层结构中每个单个层的组分不易被测量。可测量的是在整个多层结构上的平均组分。但是,每个单个层的组分可从所用的靶材组分估算出来,但不能给出确切的组分。当已经沉积了较厚的层时,厚到足以被分析,已经显示,与靶材材料的组分相比,沉积层的组分可有百分之几的不同。由于该事实,以下根据本发明的多层结构的单个层的任何组分是从沉积过程中使用的靶材组分估计出来的。
多层结构中的平均化学组分在涂层横截面范围内使用EDS(能量色散谱仪)来测量。根据本发明的整个多层结构的平均组分是(Ti(1-a-b-c)AlaCrbSic)N,其中0<a<0.5、优选为0.05<a<0.4、最优选为0.25<a<0.3,其中0<b<0.15、优选为0.02<b<0.10、最优选为0.04<b<0.08,其中0.01<c<0.17、优选为0.02<c<0.10、最优选为0.04<c<0.08,且a+b+c<1。
在本发明的一个实施例中,基体预涂覆有TiN、TiC、TiCN或(Ti,Al)N的薄的单层或多层涂层,且厚度在0.1-1μm之间,优选为0.05-0.5μm。
在本发明的一个实施例中,单个层X和Y的组分可以是(Al,Cr)N、(Ti,Si)N、(Al,Ti,Si)N、TiN、(Al,Si)N和(Al,Ti,Cr,Si)N中的任一个。
在本发明的一个实施例中,涂层包括交替的(Al,Cr)N和(Ti,Si)N的单个层的多层结构。
在本发明的一个实施例中,基体是硬质合金、金属陶瓷、陶瓷或立方氮化硼制成的切削刀具刀片。
在本发明的一个实施例中,基体是硬质合金或高速钢制成的钻头或端铣刀。
本发明还涉及一种制造涂层切削刀具的方法。该方法包括以下步骤:提供硬质合金、金属陶瓷、陶瓷或立方氮化硼或高速钢制成的硬合金基体,将涂层通过PVD技术沉积到所述基体上,该涂层包括非周期性多层结构。
可通过使用选自钛(Ti)、铝(Al)、硅(Si)、铬(Cr)或其合金的元素制成的靶材在N2或混合的N2+Ar气氛中沉积涂层。
靶材中的金属元素的组分可不同于整个多层结构中金属元素的平均组分,且仍形成本发明范围内的涂层。
在本发明的一个实施例中,靶材是(Al,Cr)、(Ti,Si)、(Al,Ti,Si)、Ti、(Al,Si)、(Al,Ti,Cr,Si)中的任一种。
在本发明的一个实施例中,靶材是(Al,Cr)和(Ti,Si)。
包括多层结构的涂层可通过不同的PVD技术并通过交替地形成单个层来沉积。单个层的厚度的非周期序列可通过从单个层靶材随机打开和闭合闸板(shutter),或者通过随机打开和闭合所述靶材来制成。另一可想到的方法是通过在所述靶材前面随机旋转或移动待涂覆基体。这优选地通过将基体放置在为获得非周期性结构而布置的3维旋转基体台上来完成。3维旋转可相对于旋转速度和旋转方向顺时针或逆时针调节。
多层结构以这样一种方式沉积,即:使得单个层的平均厚度大于0.1nm,但小于100nm,优选为大于0.5nm,但小于50nm,最优选为大于1nm,但小于30nm。多层结构中任意10个连续层的和小于300nm。
整个涂层的厚度是0.5μm到20μm,优选为1μm到10μm,最优选为1μm到5μm。
根据本发明方法制成的整个多层结构的平均组分是(Ti(1-a-b-c)AlaCrbSic)N,其中0<a<0.5、优选为0.05<a<0.4、最优选为0.25<a<0.3,其中0<b<0.15、优选为0.02<b<0.10、最优选为0.04<b<0.08,其中0.01<c<0.17、优选为0.02<c<0.10、最优选为0.04<c<0.08,且a+b+c<1。
大多数PVD技术可用于根据本发明的方法,优选使用电子束蒸发、磁控溅射或阴极电弧沉积或其组合。
在本发明的一个实施例中,本方法中使用的基体是硬质合金、金属陶瓷、陶瓷或立方氮化硼制成的切削刀具刀片。
在本发明的一个实施例中,本方法中使用的基体是硬质合金或高速钢制成的钻头或端铣刀。
示例1(本发明)
直径8mm的钻头、直径10mm的球头整体端铣刀和可转位刀片由具有10wt%的Co和余量WC的组分的硬质合金基体制成。这三种不同类型的刀具都使用阴极电弧蒸发涂覆有非周期性多层(Ti,Al,Cr,Si)N涂层。涂层厚度调节为适合于具体的刀具及其应用。多层结构从由两种不同化学组分构成的两对电弧靶材沉积,其中刀具安装在为获得非周期性结构而布置的3维旋转基体台上。在Ar+N2气氛中进行电弧蒸发。沉积之后,钻头上的涂层经受湿喷砂处理。
在表1中示出电弧靶材的组分、在涂层横截面上使用EDS测量的涂层的平均组分、以及在钻头和端铣刀的周边上和在所述刀片的后刀面上使用光学显微镜测量的每个刀具的涂层厚度。
多层结构具有非周期性,即非重复性的厚度的单个层的序列。横截面透射电子显微镜调查揭示,单个氮化物层厚度从1nm到30nm,且每个层系统中层的总数目超过100。
表1
  刀具   靶材1   靶材2   平均化学组分  厚度[μm]
  钻头   Al0.70Cr0.30   Ti0.90Si0.10   Ti0.53Al0.29Si0.06Cr0.06  3.3
  端铣刀   Al0.70Cr0.30   Ti0.90Si0.10   Ti0.53Al0.29Si0.06Cr0.06  3.3
  刀片   Al0.70Cr0.30   Ti0.90Si0.10   Ti0.53Al0.29Si0.06Cr0.06  3.0
示例2(参照)
为了对比,与示例1中的形状和组分相同的基体被涂覆有不同的商用涂层。
表2
*根据US 2006/0222893生产
示例3
将根据示例1制成的钻头与根据示例2制成的钻头进行对比。在以下切削条件中,在底部钻孔操作中测试每种钻头类型的两个钻头:
工件材料:            SS2541-03(34CrNiMo6)
操作:                钻孔
Vc[m/分钟]:          100
进给速度[mm/转]:     0.15
a,孔深度[mm]:       20
内部冷却:            是
可在下面看到结果。结果是两次试验的平均数。刀具寿命标准是后刀面磨损Vb=0.3mm,前刀面磨损/剥落kb=0.5mm,断裂或长屑(longchip)。
表3
  钻头类型No.   孔数
  本发明   1550
  商用1   525
  商用2   600
  商用3   1010
示例4
将根据示例1制成的钻头和根据示例2制成的钻头对比。在以下切削条件中,在钻通孔操作中测试每种钻头类型的3个钻头:
工件材料:            SS2244-05(42CrMo4)
操作:                钻孔
Vc[m/分钟]:          70
进给速度[mm/转]:     0.15
a,孔深度[mm]:       18
内部冷却:            是
可在下面看到结果。结果是三次试验的平均数。刀具寿命标准是后刀面磨损Vb=0.3mm,前刀面磨损或剥落kb=0.5mm,断裂或长屑。
表4
  钻头类型No.   孔数
  本发明   1300
  商用1   200
  商用2   700
  商用3   573
示例5
球头整体端铣刀,直径10mm,用于机加工根据示例1制成的硬化钢,并且与根据示例2制成的球头整体端铣刀进行对比。在以下切削条件中,在铣削操作下测试每种类型的两个端铣刀:
工件材料:        1.237952HRC,硬化钢
操作:            仿形铣削
ae[mm]:          0.2
ap[mm]:          0.2
Vc[m/分钟]:      196
fz,[mm/齿]:     0.127
冷却剂:          压缩空气
可在下面看到结果。刀具寿命标准是平均后刀面磨损Vb为0.15mm,或最大后刀面磨损Vb,max为0.20mm。
表5
  端铣刀   铣削距离(m)
  本发明   720
  商用1   450
示例6
将根据示例1制成的可转位刀片和根据示例2制成的可转位刀片进行对比。在以下切削条件中,在铣削操作下测试每种类型的两个可转位刀片:
工件材料:    Dievar 47HRC,硬化钢
操作:        铣削
Vc[m/分钟]:  120
ae,[mm]:    2.0
ap,[mm]:    4.0
fz,[mm/齿]: 0.12
可在下面看到结果。结果是两次测试的平均数。刀具寿命标准是Vb为0.2mm,或者破裂或缺口磨损为0.30mm。
表6
  刀片No.   铣削距离(m)
  本发明   40.25
  商用4   13.1

Claims (8)

1.一种涂层切削刀具,包括基体和涂层,所述涂层包括单个金属氮化物层X和Y交替的非周期性多层结构,其特征在于,所述涂层的平均组分是(Ti(1-a-b-c)AlaCrbSic)N,其中0<a<0.5、0<b<0.15、0.01<c<0.17、并且a+b+c<1。
2.根据权利要求1所述的涂层切削刀具,其特征在于,单个层的平均厚度为0.1nm到100nm。
3.根据前述权利要求中任一项所述的涂层切削刀具,其特征在于,0.05<a<0.4、0.02<b<0.10并且0.02<c<0.10。
4.根据前述权利要求中任一项所述的涂层切削刀具,其特征在于,所述多层结构包括交替的(Ti,Si)N和(Al,Cr)N的单个层。
5.一种制作涂层切削刀具的方法,包括提供基体,通过PVD技术在所述基体上沉积涂层,所述涂层包括单个金属氮化物层X和Y交替的非周期性多层结构,其特征在于,所述多层结构的平均组分是(Ti(1-a-b-c)AlaCrbSic)N,其中0<a<0.5、0<b<0.15、0.01<c<0.17并且a+b+c<1。
6.根据权利要求5所述的方法,其特征在于,单个层的平均厚度为0.1nm到100nm。
7.根据权利要求5和6中任一项所述的方法,其特征在于,0.05<a<0.4、0.02<b<0.10并且0.02<c<0.10。
8.根据权利要求5、6和7中任一项所述的方法,其特征在于,所述多层结构通过使用(Ti,Si)和(Al,Cr)靶材来沉积。
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US20080166588A1 (en) 2008-07-10
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US8119262B2 (en) 2012-02-21
EP1939328B1 (en) 2018-02-21
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US20080166583A1 (en) 2008-07-10
CN101578396B (zh) 2012-05-09
EP1939327A1 (en) 2008-07-02
KR20080061323A (ko) 2008-07-02
JP2008162009A (ja) 2008-07-17
KR20090094108A (ko) 2009-09-03
SE0602814L (sv) 2008-06-28
JP4874947B2 (ja) 2012-02-15
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WO2008079088A2 (en) 2008-07-03
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