CN101960052A - 涂覆有氧化物的切削刀片 - Google Patents
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Abstract
本发明涉及一种切削刀具刀片，包括硬质合金、金属陶瓷、陶瓷、基于立方氮化硼的材料或高速钢的硬合金基体，所述基体涂覆有硬质且耐磨的涂层，所述涂层包括一层或若干层，其中的至少一层为(Al，Cr)2O3层。本发明对于加工钢和不锈钢特别有用。总厚度为2μm-20μm的所述涂层包括一层或若干层，其中的至少一层为厚度为1μm-5μm的(Al，Cr)2O3层，其具有刚玉相晶体结构和成分(Al1-yCry)2O3，其中，0.5＜y＜0.7。(Al，Cr)2O3层的特征还在于具有纤维织构，所述纤维织构在涂层表面法线的方向上旋转对称，且基面相对于所述涂层表面法线的倾斜角
或者对于极点图中的最大峰值的倾斜角如由例如电子背散射衍射(EBSD)或X射线衍射(XRD)确定的为
。
Description
技术领域
本发明涉及一种用于通过去屑进行加工的刀具，包括硬质合金、金属陶瓷、陶瓷、基于立方氮化硼的材料或高速钢的硬合金基体以及硬质且耐磨的氧化物，其被设计用于在优选以高速切削速度加工钢和不锈钢中使用。所述涂层由一层或更多层组成，其中的至少一层为含有铬的织构化的物理气相沉积(PVD)的刚玉相氧化铝(Al，Cr)2O3。
背景技术
利用化学气相沉积(CVD)制造的织构化α-Al2O3层例如在EP603144、EP1528125、EP1477581、EP659153、EP1655387、EP659903、EP738336、EP1655388、EP1655392、US2007/104945以及US2004/202877中公开。
EP1479791公开了一种由硬质合金或金属陶瓷以及硬质涂层组成的切削刀具；其中，该硬质涂层包括α-Al2O3层，该α-Al2O3层通过CVD形成，其中最高峰值——α-Al2O3基面相对于表面法线的倾斜度的测量值——如由电子背散射衍射(EBSD)确定的，在0-10°的范围内。
EP744473公开了通过PVD制造的织构化γ-Al2O3层。
US5310607公开了一种硬质涂层，该硬质涂层包括(Al，Cr)2O3晶体以及含量超过5at％的铬，其中，(Al，Cr)2O3为单晶体。在低于900℃的温度下沉积该涂层。该硬质涂层通过CVD或PVD工艺沉积。
在利用涂有氧化铝的硬质合金刀具对钢进行加工时，切削刃根据不同的磨损机制(比如化学磨损、研磨磨损以及粘附磨损)并且由沿切削刃形成的裂缝引起的刀刃崩裂而磨损。任何磨损机制的支配都由具体应用确定，而且取决于加工材料的性质、采用的切削参数以及刀具材料的性质。一般而言，很难同时改进所有的刀具性质，且商用硬质合金等级关于上述一种或几种磨损类型通常已经是最优的，且因此对特定领域来说也已经是最优的。例如，可通过控制氧化铝层的织构化来实现此目标。
发明内容
本发明的目的是提供一种涂覆有耐磨且硬质的氧化物、并提高加工钢和不锈钢的性能的切削刀具。
根据本发明的切削刀具刀片包括硬质合金、金属陶瓷、陶瓷、基于立方氮化硼的材料或高速钢的硬合金基体，该基体包括金属加工性质优良的刚玉相织构化氧化物层(Al，Cr)2O3。
附图说明
图1a示出了具有标记为a轴(100)、b轴(010)以及c轴(001)的六方晶体结构的示意图。
图1b示出了纤维织构的示意图，其具有涂层表面(S)、六方结构(图1a)的c轴(001)的倾斜角
以及涂层表面的法线(n)。
图2示出了沉积室的示意性侧视图，示出有真空室(1)、阴极材料A(2a)、阴极材料B(2b)、固定装置(3)、用于偏压的电源(4)、阴极电弧电源(5a)、阴极电弧电源(5b)、用于工艺气体的入口(6)以及用于真空泵的出口(7)。
图3示出了根据本发明的涂层的断裂横截面的次级模式扫描电子显微照片。(A)基体、(B)粘结层、(C)(Al，Cr)O层、(D)(Al，Cr)N层以及(E)TiN层。
图4示出了织构化(Al，Cr)2O3层的x射线衍射图。硬质合金的峰值由实线标注，而源自(Al，Cr)2O3的峰值由虚线标注。
图5示出了根据本发明的(A)极图(001)以及(B)(Al，Cr)2O3层的极点图(001)。
具体实施方式
根据本发明，提供了一种用于通过去屑进行加工的切削刀具，该切削刀具对钢和不锈钢的金属切削特别有用，其包括硬质合金、金属陶瓷、陶瓷、基于立方氮化硼的材料或高速钢的硬合金基体，该基体上沉积有涂层，所述涂层包括：
优选根据现有技术、优选小于0.5μm的例如TiN或(Al，Cr)N的第一(最里面的)粘结层(图3(B))；
(Al1-yCry)2O3层，其中0.5≤y≤0.7，优选y＝0.6，厚度为1μm-5μm，优选为1.5μm-4.5μm，最优选为2μm-4μm，并具有织构化柱状晶粒。(Al，Cr)2O3层具有通过PVD形成的刚玉结构以及纤维织构，该纤维织构在涂层表面法线的方向上旋转对称，且基面相对于涂层表面法线(图5A)的倾斜角
(图1b)或对于极点图(图5B)中的最大峰值的倾斜角例如由电子背散射衍射(EBSD)或x射线衍射(XRD)确定的为
优选为
所述(Al，Cr)O层具有-4.5＜σ＜-0.5GPa的压缩应力水平，优选具有-3.0＜σ＜-1.0Gpa的压应力水平。
(Al1-yCry)2O3的成分y例如由EDS(能量散射光谱)或WDS(波长色散光谱)确定。
所述基体还可根据现有技术涂覆有例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N、优选为(Ti，Al)N、(Al，Cr)N的内部单层和/或多层涂层，和/或例如TiN、TiC、Ti(C，N)或(Ti，Al)N、优选为(Ti，Al)N、(Al，Cr)N的外部单层和/或多层涂层，总厚度达1μm到20μm，优选1μm到10μm，最优选2μm到7μm。
用于本发明的层的沉积方法基于下列条件下的合金阴极或复合阴极的阴极电弧蒸镀：利用Al+Cr阴极来生长(A1，Cr)2O3层，该Al+Cr阴极的成分介于(30at％的Al+70at％的Cr)与(60at％的Al+40at％的Cr)之间，优选介于(30at％的Al+70at％的Cr)与(50at％的Al+50at％的Cr)之间。蒸镀电流根据阴极大小处于50A与200A之间，优选在使用直径为63mm的阴极的情况下处于60A与90A之间。这些层在2.0Pa到5.0Pa、优选为2.0Pa到4.0Pa的总压强下在Ar+O2气氛中生长，优选在纯O2气氛中生长。偏压为-50V到-200V，优选为-75V到-125V。沉积温度在500℃与700℃之间，优选在500℃与600℃之间。
本发明还涉及根据以上所述的切削刀具刀片的用途，用于以75-600m/分钟、优选150-500m/分钟的切削速度，并且在铣削的情况下，根据切削速度和刀片型号，每齿0.08-0.5mm、优选0.1-0.4mm的平均进给，加工钢和不锈钢。
示例1
等级A：使用硬质合金刀片，成分为10wt％的Co和平衡WC。
在沉积之前，在碱性溶液和酒精的超声波槽中清洗刀片。将该系统的压强抽为小于2.0×10-3Pa，此后，用Ar离子喷射清洁刀片。首先，在3.0Pa的总压强以及大约400℃的沉积温度下，于99.995％的纯O2气氛中，通过直径为63mm的合金(40at％的Al+60at％的Cr)阴极的阴极电弧蒸镀，生长出厚度为0.2μm的TiN粘结层及随后的厚度为2.5μm的织构化(Al，Cr)2O3层，到3μm的总涂层厚度。在沉积过程中，蒸镀电流为75A，并且将偏压保持在-100V。最后，涂覆由0.3μm的(Al，Cr)N和0.2μm的TiN组成的顶部彩色涂层。
涂层的断裂横截面SEM显微照片在图3中示出具有(A)基体、(B)粘结层、(C)(Al，Cr)O层、(D)(Al，Cr)N层以及(E)TiN层。
用CuKα辐射和θ-2θ构造来获得沉积层的XRD图。图4示出了根据本发明具有织构刚玉相氧化铝(Al，Cr)2O3层的涂层的XRD图。源自(Al，Cr)2O3层的峰值用虚线标注，而硬质合金的峰值用实线标注。
在c轴(001)方向(图1a)上的沉积刚玉相(Al，Cr)2O3层的EBSD极图(图5(A))和极点图(图5(B))分别示出了在涂层表面法线(图1b)方向上(旋转对称)的纤维织构，其中基面相对于涂层表面法线的倾斜角介于20°到55°之间(图1b)。极点图中的最大峰值大约38°。利用装有HKL Nordlys II EBSD检测器、在20kV的电压下运行的LEO Ultra 55扫描电子显微镜来获得EBSD数据，并用Channel 5软件来估算数据。
利用sin2ψ法，通过XRD测量来估算(Al，Cr)2O3层的残余应力σ。利用(Al，Cr)2O3(116)反射上的CrKα辐射来执行这些测量。残余应力值用v＝0.26的泊松比和E＝420GPa的杨氏模量估算时为2.2±0.4GPa。
利用在10kV的电压下运行的具有Thermo Noran EDS检测器的LEO Ultra 55扫描电子显微镜，通过能量散射光谱(EDS)分析来估算(Al1-yCry)2O3的成分，其中y＝0.58。用Noran System 6(NSS第二版)软件来估算数据。
示例2
等级B：根据现有技术，通过在成分为10wt％的Co和平衡WC的硬质合金刀片上进行的PVD来沉积3.0μm的Ti0.34Al0.66N层。
示例3
等级C：根据现有技术，通过在成分为10wt％的Co和平衡WC的硬质合金刀片上进行的CVD来沉积3.0μm的Ti(C，N)+3.0μm的α-Al2O3组成的涂层。
示例4
等级D：用具有5wt％的Co和平衡WC成分的硬质合金刀片重复示例1。
示例5
等级E：根据现有技术，通过在成分为5wt％的Co和平衡WC的硬质合金刀片上进行PVD来沉积3.0μm的Ti0.34Al0.66N层。
示例6
等级F：根据现有技术，通过在成分为5wt％的Co和平衡WC的硬质合金刀片上进行CVD来沉积3.0μm的Ti(C，N)+3.0μm的α-Al2O3组成的涂层。
示例7
在加工钢的过程中测试等级A、等级B和等级C。
| 操作 | 端面铣削 |
| 刀具直径 | 125mm |
| 材料 | SS1672 |
| 刀片类型 | SEEX1204AFTN-M15 |
| 切削速度 | 300m/分钟 |
| 进给 | 0.2mm/齿 |
| 切削深度 | 2.5mm |
| 切削宽度 | 120mm |
| 结果 | 刀具寿命(分钟) |
| 等级A(根据本发明的等级) | 6.4 |
| 等级B | 5.6 |
| 等级C | 3.2 |
在相同的最大后刀面磨损时终止测试。利用根据本发明的等级耐磨性得到了极大的提高。
示例8
在加工不锈钢的过程中测试等级A、等级B和等级C。
| 操作 | 凸肩铣削 |
| 刀具直径 | 32mm |
| 材料 | SS1672 |
| 刀片类型 | XOEX120408-M07 |
| 切削速度 | 275m/分钟 |
| 进给 | 0.25mm/齿 |
| 切削深度 | 3mm |
| 切削宽度 | 8.8mm |
| 结果 | 刀具寿命(分钟) |
| 等级A(根据本发明的等级) | 5.8 |
| 等级B | 3.9 |
| 等级C | 1.5 |
在相同的最大后刀面磨损时终止测试。利用根据本发明的等级耐磨性得到了极大的提高。
示例9
在加工不锈钢的过程中测试等级D、等级E和等级F。
| 操作 | 间歇车削 |
| 材料 | SS2348 |
| 刀片类型 | CNMG120408-MR3 |
| 切削速度 | 80m/分钟 |
| 进给 | 0.3mm |
| 切削深度 | 2mm |
| 结果 | 刀具寿命(循环次数) |
| 等级D(根据本发明的等级) | 6 |
| 等级E | 3 |
| 等级F | 4 |
在相同的最大后刀面磨损时终止测试。利用根据本发明的等级耐磨性得到了极大的提高。
示例10
在加工钢的过程中测试等级D、等级E和等级F。
| 操作 | 间歇车削 |
| 材料 | SS1672 |
| 刀片类型 | CNMG120408-MR3 |
| 切削速度 | 350m/分钟 |
| 进给 | 0.3mm |
| 切削深度 | 2mm |
| 结果 | 刀具寿命(分钟) |
| 等级D(根据本发明的等级) | 10.7 |
| 等级E | 3.8 |
| 等级F | 9.2 |
在相同的最大后刀面磨损时终止测试。利用根据本发明的等级耐磨性得到了极大的提高。
Claims (7)
1.切削刀具刀片，包括硬质合金、金属陶瓷、陶瓷、基于立方氮化硼的材料或高速钢的硬合金基体，所述基体涂覆有硬质且耐磨的涂层，所述涂层包括一层或若干层，其中的至少一层为(Al，Cr)2O3层，其特征在于，所述层具有：刚玉相晶体结构和(Al1-yCry)2O3成分，其中0.5≤y≤0.7，优选y＝0.6，厚度为0.5μm到10μm，优选1μm-5μm；以及具有纤维织构，所述纤维织构在涂层表面法线的方向上旋转对称，且基面相对于所述涂层表面法线的倾斜角
为
或对于极点图中的最大峰值的倾斜角
为
2.根据权利要求1所述的切削刀具刀片，其特征在于，所述基面相对于所述涂层表面法线的倾斜角为
3.根据权利要求1所述的切削刀具刀片，其特征在于，所述层具有-4.5＜σ＜-0.5Gpa的残余应力，优选具有-3.0＜σ＜-1.0GPa的残余应力。
4.根据权利要求1所述的切削刀具刀片，其特征在于，所述层通过PVD沉积，优选通过阴极电弧蒸镀沉积。
5.根据前述权利要求中的任一项所述的切削刀具刀片，其特征在于，所述基体根据现有技术涂覆有例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N、优选为(Ti，Al)N、(Al，Cr)N的内部单层和/或多层涂层，和/或例如TiN、TiC、Ti(C，N)、(Al，Cr)N或(Ti，Al)N、优选为(Ti，Al)N、(Al，Cr)N的外部单层和/或多层涂层，总涂层厚度达1μm到20μm，优选为1μm到10μm。
6.制作根据权利要求1所述的切削刀具刀片的方法，其特征在于，通过以下条件来沉积(Al，Cr)2O3层：利用Al+Cr阴极的阴极电弧蒸镀，所述Al+Cr阴极具有(30at％的Al+70at％的Cr)与(60at％的Al+40at％的Cr)之间的成分，优选具有(30at％的Al+70at％的Cr)与(50at％的Al+50at％的Cr)之间的成分；在2.0Pa到5.0Pa、优选为2.0Pa到4.0Pa的总压强下，在-50V到-200V、优选在-75V到-125V的偏压下，以及在500℃与700℃之间、优选在500℃与600℃之间的沉积温度，在Ar+O2气氛、优选为纯O2气氛中，以及取决于阴极大小的50A到200A之间的蒸镀电流。
7.根据权利要求1-5的切削刀具刀片的用途，用于以75-600m/分钟、优选为150-500m/分钟的切削速度，并且在铣削的情况下，根据切削速度和刀片型号，每齿0.08-0.5mm、优选为0.1-0.4mm的平均进给，加工钢和不锈钢。
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| CN109082641B (zh) * | 2018-08-28 | 2020-05-22 | 华南理工大学 | 一种三层膜结构涂层及其制备方法 |
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| US20110044775A1 (en) | 2011-02-24 |
| KR20100126357A (ko) | 2010-12-01 |
| US8409732B2 (en) | 2013-04-02 |
| SE0800539L (sv) | 2009-09-08 |
| EP2262925A1 (en) | 2010-12-22 |
| WO2009110831A1 (en) | 2009-09-11 |
| CN101960052B (zh) | 2013-04-03 |
| EP2262925A4 (en) | 2013-08-21 |
| SE532050C2 (sv) | 2009-10-13 |
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