CN102665976A - 立方氮化硼烧结体工具 - Google Patents

立方氮化硼烧结体工具 Download PDF

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Publication number
CN102665976A
CN102665976A CN2011800046156A CN201180004615A CN102665976A CN 102665976 A CN102665976 A CN 102665976A CN 2011800046156 A CN2011800046156 A CN 2011800046156A CN 201180004615 A CN201180004615 A CN 201180004615A CN 102665976 A CN102665976 A CN 102665976A
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sintered body
equal
boron nitride
cubic boron
compound
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CN102665976B (zh
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冈村克己
阿部真知子
久木野晓
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Sumitomo Electric Hardmetal Corp
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Sumitomo Electric Hardmetal Corp
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Abstract

本发明提供了一种立方氮化硼烧结体工具,其至少在切削刃处具有由立方氮化硼颗粒和粘结相构成的立方氮化硼烧结体。cBN的含量为大于或等于20体积%且小于或等于60体积%。所述粘结相至少包含Al2O3和Zr化合物。在所述烧结体中的任意的直线上,Al2O3所占的连续距离的平均值为大于或等于0.1μm且小于或等于1.0μm,并且Al2O3所占的所述连续距离的标准偏差为小于或等于0.8。在所述直线上,在X表示Al2O3与所述Zr化合物之间的接触点的数目,并且Y表示Al2O3与cBN之间的接触点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分之间的接触点的数目的总和的情况下,X/Y大于或等于0.1且小于或等于1。所述Zr化合物的平均粒径为大于或等于0.01μm且小于或等于0.1μm。

Description

立方氮化硼烧结体工具
技术领域
本发明涉及包含立方氮化硼(下文中也称为cBN)作为主要成分的cBN烧结体。
背景技术
至今为止,使用立方氮化硼的高硬度烧结体是已知的。cBN颗粒的硬度、强度和韧性均比陶瓷粘合剂的高,充当烧结体的骨架,并且起到保持这种材料的强度以使其能够承受对高硬度淬硬钢的切削的作用。相反,陶瓷粘合剂的作用是,使得cBN颗粒(难烧结材料)能够在工业水平的压力和温度下被烧结,同时由于陶瓷粘合剂与铁的反应性比cBN的低,因此提供了抑制化学/热磨损的效果。
cBN烧结体大致分为两类:一类具有高的cBN含量,其中cBN颗粒彼此结合,并且余物由含有Co和/或Al作为主要成分的粘合剂组成(下文简称为高cBN含量烧结体);另一类具有相对较低的cBN含量,其中cBN颗粒彼此接触的比率低,并且以颗粒之间插入有对钢的亲和性低且由Ti的氮化物(TiN)或Ti的碳化物(TiC)组成的陶瓷的形式而结合在一起(以下简称为低cBN含量烧结体)。
在切屑破碎并且难以产生剪切热的应用中,前者(高cBN含量烧结体)由于cBN具有优异的机械特性(高硬度、高强度、高韧性)和高的热传导性,因此实现了出色的稳定性和长的寿命,并且适合对由于与硬颗粒摩擦而经常发生机械磨损和损伤的铁系烧结部分,以及由于高速连续切削中的热冲击而经常发生损伤的灰铸铁进行高效切削。然而,在连续的切屑产生大量的剪切热从而使切削刃暴露在高温下的淬硬钢等的加工中,高cBN含量烧结体的寿命较短,这是因为,与常规的硬质合金工具和陶瓷工具相比,被铁热磨损的cBN成分导致了磨损更加迅速的发展。
相反,后者(低cBN含量烧结体)由于粘合剂在高温下与钢的亲和性比cBN的低且由TiN陶瓷或TiC陶瓷组成,因而表现出优异的耐磨性,特别是在不能使用常规的硬质合金工具和陶瓷工具进行实用加工的淬硬钢加工中,作为能够实现比常规工具的寿命长十倍至几十倍寿命的切削工具,低cBN含量烧结体打开了淬硬钢切削的市场。
已经开发了多种这样的cBN烧结体。
例如,日本专利特开No.2000-044347(专利文献1)和日本专利特开No.2000-044350(专利文献2)描述了一种cBN烧结体,该cBN烧结体由45体积%至70体积%的cBN颗粒和包含选自由以下物质组成的组中的至少一种物质的粘结相组成,所述物质为:第4a族、5a族和6a族元素的碳化物、氮化物、碳氮化物和硼化物;Al的氮化物、硼化物、氧化物、碳氮化物和硼化物;以及它们的相互固溶体。其中,限定了粘结相的厚度的平均值和标准偏差。
此外,日本专利特开No.2002-302732(专利文献3)描述了一种cBN烧结体,该cBN烧结体由粒径大于或等于0.01μm且小于或等于0.70μm的超细cBN颗粒和由以下至少一种物质组成的粘结相组成,这些物质为:第4a族、5a族和6a族元素;Al;它们的碳化物、氮化物和硼化物;以及它们的相互固溶体和混合物,其中,限定了粘结相的厚度的平均值。
如上文所述,在铸铁的高效切削中,实际使用了高cBN含量烧结体。近年来,汽车发动机性能的提高伴随着在气缸体中采用铝来减轻重量的进展。关于衬套(汽缸体的活塞滑动的部分),采用了具有优异的强度和耐磨性的铸铁,并且近年来正逐渐采用大规模生产性优于砂型铸铁的离心铸造铸铁。离心铸造是这样一种技术,其中,在铸造衬套时使铸模旋转,从而利用离心力来制造中空的铸件,而不需要使用芯体。
在上述离心铸造中,理论上而言,铸模的接触部分和最内径部分被急速冷却,由此导致在这些区域中产生可加工性非常差的枝状晶体组织或玫瑰状组织,因此上述离心铸造具有这样的问题:当在通过切削实现所需内径,并且待切削部分的铸铁组织为上述枝状晶体组织或玫瑰状组织时,工具的寿命显著劣化。还具有工具寿命不稳定的问题,这是因为铸铁组织根据衬套的生产批量而发生很大的变化。如此一来,目前的事实是,常规的高cBN含量烧结体的耐磨性不足,并且不能够提供令人满意的工具寿命。
鉴于这样的情况,WO 2008/087940(专利文献4)采用Al2O3作为粘结相的主要成分,并且添加了合适量的ZrO2和TiC,从而在离心铸造铸铁加工时使工具寿命稳定。然而,还没有获得令人满意的工具寿命。
引用列表
专利文献
专利文献1:日本专利特开No.2000-044347
专利文献2:日本专利特开No.2000-044350
专利文献3:日本专利特开No.2002-302732
专利文献4:WO 2008/087940
发明内容
技术问题
鉴于上述问题,本发明的目的是提供一种cBN烧结体工具,该工具在切削通过离心铸造而制备的、并且具有上述可加工性差的枝状晶体组织和玫瑰状组织的混合物的铸铁时,具有高的切削性能和优异的工具寿命。
解决问题的手段
仔细观察对具有枝状晶体组织或玫瑰状组织的铸铁进行切削时的cBN烧结体工具的磨损形态,结果发现,在由Ti化合物或Al化合物构成的粘结剂相中,在具有优异耐热性的Al2O3颗粒的界面或晶界处出现裂纹,并且裂纹的传播导致磨损的发展,这在某些情况下导致断裂。
在常规技术中,由Al2O3、cBN、ZrO2和TiC构成的cBN烧结体的Al2O3的平均厚度厚,使得其具有差的耐断裂性。此外,虽然将粘结相的厚度和标准偏差限定为合适值的技术已被人们所公知,但Al2O3的含量少,因此在加工离心铸造铸铁时,耐磨性不足。
因此,为了确定作为裂纹起始点的Al2O3颗粒的界面或晶界的最佳设置,并且确定提供强化Al2O3效果的Zr化合物的最佳设置,发明人制备了粒径、含量和各成分的混合方法不同的cBN烧结体,并且考察了与切削性能的相关性。结果,成功地实现了将Zr化合物和cBN颗粒最佳地设置在Al2O3中,从而使耐热性优异但韧性差的Al2O3间断,并且将Al2O3的平均厚度和标准偏差设定在最佳的范围内,由此获得了耐热性和韧性之间的高度平衡。
具体而言,本发明具有以下构成。
(1)一种立方氮化硼烧结体工具,其至少在切削刃处包含立方氮化硼烧结体,所述立方氮化硼烧结体由立方氮化硼颗粒和粘结相构成,所述立方氮化硼烧结体工具的特征在于
cBN含量为大于或等于20体积%且小于或等于60体积%,
所述粘结相至少包含Al2O3和Zr化合物,
在所述烧结体中的任意的直线上,Al2O3所占的连续距离的平均值为大于或等于0.1μm且小于或等于1.0μm,并且Al2O3所占的所述连续距离的标准偏差为小于或等于0.8,
在所述直线上,在X表示Al2O3与所述Zr化合物之间的接触点的数目,并且Y表示Al2O3与cBN之间的接触点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分之间的接触点的数目的总和的情况下,X/Y为大于或等于0.1且小于或等于1,并且
所述Zr化合物的平均粒径为大于或等于0.01μm且小于或等于0.1μm。
(2)根据上述项(1)所述的立方氮化硼烧结体工具,其特征在于
作为包含在上述烧结体中的所述Zr化合物,包含总计大于或等于0.5体积%且小于或等于5体积%的ZrC和ZrO2
(3)根据上述项(1)或(2)所述的立方氮化硼烧结体工具,其特征在于
在上述烧结体中的任意的直线上,X/Y为大于或等于0.5且小于或等于0.9。
本发明的有益效果
本发明能够提供具有高的切削性能和优异的工具寿命的cBN烧结体工具。即,成功地实现了将Zr化合物和cBN颗粒最佳地设置在Al2O3中,从而使耐热性优异但韧性差的Al2O3间断,并且将Al2O3的平均厚度和标准偏差设定在最佳的范围内,由此获得了耐热性和韧性之间的高度平衡。
此外,由于Al2O3与cBN颗粒之间的结合力弱,因此通过利用插入它们之间的结合力强的除Al2O3以外的高反应性化合物(例如,TiAl、Ti、Al、TiZr、Zr等)来使cBN颗粒与Al2O3颗粒结合,并且使Zr化合物分散在Al2O3中,能够获得更高的耐磨性和耐断裂性。特别是,优选预先利用Zr或TiZr被覆cBN颗粒。
具体实施方式
本发明的cBN烧结体工具是这样的cBN烧结体工具,其至少在切削刃处包含由cBN颗粒和粘结相构成的cBN烧结体,所述cBN烧结体工具的特征在于,cBN含量为大于或等于20体积%且小于或等于60体积%,所述粘结相包含Al2O3和Zr化合物,在所述烧结体中的任意的直线上,Al2O3所占距离的平均值和标准偏差分别为大于或等于0.1μm且小于或等于1.0μm、以及小于或等于0.8,在所述直线上,在X表示Al2O3与Zr化合物之间的接触点的数目,并且Y表示Al2O3与cBN之间的接触点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分之间的接触点的数目的总和的情况下,X/Y为大于或等于0.1且小于或等于1,并且所述Zr化合物的平均粒径为大于或等于0.01μm且小于或等于0.1μm。
上述cBN烧结体工具可以是这样的cBN烧结体工具,其至少在由硬质合金制成的基材的充当切削刃的部分处具有cBN烧结体,或者可以是仅由cBN烧结体构成的cBN烧结体工具。此外,充当切削刃的cBN烧结体可以在其表面上具有硬质陶瓷涂层。
下面对cBN烧结体部分进行详细说明。
上述cBN烧结体的特征在于,cBN的含量为大于或等于20体积%且小于或等于60体积%。cBN含量小于20体积%将导致烧结体的耐断裂性降低,而cBN含量大于60体积%将导致耐磨性降低。更优选的是,cBN含量为大于或等于40体积%且小于或等于50体积%。上述cBN烧结体的特征还在于,粘结相至少包含Al2O3和Zr化合物。这能够提高耐磨性和耐断裂性。
上述cBN烧结体的特征在于,在烧结体中的任意的直线上,Al2O3所占的连续距离的平均值为大于或等于0.1μm且小于或等于1.0μm。平均值小于0.1μm将导致耐热性降低,而平均值大于1.0μm将导致耐断裂性降低。更优选的是,平均值为大于或等于0.3μm且小于或等于0.6μm。上述cBN烧结体的特征还在于,在任意直线上,Al2O3所占的连续距离的标准偏差不大于0.8。标准偏差大于0.8将导致耐断裂性变化很大。更优选的是,标准偏差大于或等于0.2且小于或等于0.6。
上述cBN烧结体的进一步的特征在于,在上述直线中,在X表示Al2O3与所述Zr化合物之间的接触点的数目,并且Y表示Al2O3与cBN之间的接触点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分之间的接触点的数目的总和的情况下,X/Y为大于或等于0.1且小于或等于1。当X/Y小于0.1时,不能提供Zr化合物对Al2O3韧性的增强效果,而X/Y大于1将导致Al2O3对耐热性的增强效果降低。
上述cBN烧结体的特征在于,其中的Zr化合物的平均粒径为大于或等于0.01μm且小于或等于0.1μm。当Zr化合物的平均粒径小于0.01μm时,不能提供Zr化合物对Al2O3韧性的增强效果,而平均粒径超过0.1μm将导致Zr化合物本身易于破碎,并且导致烧结体的耐断裂性降低。更优选的是,Zr化合物的平均粒径为大于或等于0.03μm且小于或等于0.06μm。
由于具有上述构成,本发明使得在cBN烧结体中能够将Zr化合物和cBN颗粒最佳地设置在Al2O3中,从而使耐热性优异但韧性差的Al2O3间断,并且能够进一步将Al2O3的平均厚度和标准偏差设定在最佳的范围内,由此使烧结体的耐热性和韧性之间达到高度平衡。
此外,作为包含在上述烧结体中的Zr化合物,通过包含总计大于或等于0.5体积%且小于或等于5体积%的ZrC和ZrO2,能够进一步提高耐断裂性和耐磨性。即,作为包含在上述烧结体中的Zr化合物,本发明的cBN烧结体工具优选包含总计大于或等于0.5体积%且小于或等于5体积%的ZrC和ZrO2,并且更优选包含总计大于或等于1.5体积%且小于或等于4.5体积%的ZrC和ZrO2
ZrC和ZrO2在提高Al2O3韧性方面是特别高效的。当这两种化合物的总和小于烧结体的0.5体积%时,不能够提供提高韧性的效果,而当这些化合物的总和超过5体积%时,将导致Al2O3的含量相对降低、以及耐热性的降低。
此外,在上述烧结体中的任意直线上,X/Y为大于或等于0.5且小于或等于0.9将使得抵抗断裂的可靠性增加。即,优选的是,对于本发明的cBN烧结体工具而言,在上述烧结体中的任意直线上,X/Y为大于或等于0.5且小于或等于0.9。
实施例
[cBN烧结体工具的制备]
(cBN烧结体的制备)
利用由ZrO2制成的、直径为0.2mm的球介质,预先将平均粒径为小于或等于50nm(除了某些实施例和对比例之外)的表1中所示出的Zr化合物、平均粒径为小于或等于300nm的Ti化合物、以及平均粒径为小于或等于200nm的Al2O3在流速为0.2L/min至0.5L/min的乙醇溶剂中混合并粉碎30至120分钟,之后去除所述介质,从而制备特定粘结剂,其中超细Zr化合物均匀地分散在Al2O3中。可以通过以实验方式在上述范围内改变粉碎和混合的条件,或者改变Zr化合物的含量,从而实现对X/Y值的控制。
关于实施例1至11,通过球磨机混合法,利用由ZrO2制成的、直径为3mm的球介质均匀地混合cBN颗粒和上述粘结剂,从而提供混合粉末,将该混合粉末沉积在由硬质合金制成的支持板上,并且填充到由Mo制成的胶囊中,并且随后在超高压装置中,在7.0GPa的压力、1600度的温度下烧结30分钟。
关于实施例12和13,利用RF溅射PVD装置预先分别用TiZr和Zr被覆cBN颗粒,使得平均膜厚为30nm,并且按照与上文所述的相同方式进行填充和烧结。
各实施例和对比例中的cBN烧结体的组成在表1中示出。
(工具的制备)
将所获得的烧结体切割成预定的形状,利用市售可得的钎接材料将其接合到由硬质合金制成的工具基材上,并且磨削加工成预定的工具形状。
[评价]
(cBN烧结体特性的测定)
关于在各实施例和对比例中所获得的如上所述的cBN烧结体,采用接下来所描述的方法测量在烧结体中的任意直线上,Al2O3连续所占的距离的平均值和标准偏差。
首先,对cBN烧结体进行镜面抛光,并且利用电子显微镜,以10000倍的放大率对任意区域中的cBN烧结体组织的反射电子图像进行拍照。观察与组成相对应的明暗之间的对比,并且利用作为辅助设备的EDX(能量色散型X射线光谱)从多种元素的重叠状态中估测化合物。结果证明,黑色区域为cBN颗粒,而灰色区域和白色区域为粘结相。此外,据鉴别,暗的灰色区域为Al2O3,亮的白色阴影区域为Zr化合物(氧化物、碳化物、氮化物、硼化物、氮硼化物)。
接下来,在照片上画出任意直线,并且获得直线上的X/Y值,其中X表示Al2O3与Zr化合物彼此接触的点的数目,并且Y表示Al2O3与cBN彼此接触的点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分彼此接触的点的数目的总和。
在本文中,考虑到组织的均一性,确定直线的数目使得直线上的接触点的总数目不小于50个。此外,在这些直线数目的直线上,测定被上述Al2O3连续所占的距离(长度),并且获得了其平均值和标准偏差。关于cBN的含量,基于上述烧结体组织的照片,通过图像处理对cBN颗粒区域和粘结相区域进行二值化,并且将cBN颗粒所占的区域作为体积含量。根据XRD(X射线衍射)来确定粘结相的组成。
关于Zr化合物和Ti化合物的含量,基于在上述烧结体组织照片中的明暗之间的对比,通过图像处理来计算它们各自的占据面积,并且将该面积作为体积含量。关于Zr化合物的平均粒径,示出了所装入的原料粉末的平均粒径,并且根据上述烧结体组织的照片,可以确定原料粉末的粒径基本保持不变。结果在表1中示出。
(切削测试)
在以下条件下,对上文所制备的各工具进行切削测试。
工件材料:FC250(离心铸造铸铁套的内部加工,硬度:HB230)
工具形状:CNGA120408
切削条件:切削速度Vc=700m/分钟
进给速度f=0.3mm/rev.
切削深度ap=0.05mm
利用切削液
工具寿命:将后刀面磨损量或崩裂的量达到0.2mm时的时间点定为工具寿命的终止。
结果在表2中示出。
表1
Figure BDA00001668303700091
Figure BDA00001668303700101
表2
Figure BDA00001668303700102
由表2显而易见的是,与对比例的工具相比,实施例的工具表现出更好的切削性能。
虽然上文对本发明的实施方案和实施例进行了描述,但应当理解,本文所公开的实施方案和实施例在各方面都是示例性的,而非限定性的。本发明的范围不仅由上文的说明来限定,而且还由权利要求来限定,并且本发明旨在涵盖与权利要求等同的范围和含义内的任何更改。

Claims (3)

1.一种立方氮化硼烧结体工具,其至少在切削刃处包含立方氮化硼烧结体,所述立方氮化硼烧结体含有立方氮化硼颗粒和粘结相,
所述立方氮化硼烧结体的立方氮化硼含量大于或等于20体积%且小于或等于60体积%,
所述粘结相至少包含Al2O3和Zr化合物,
在所述立方氮化硼烧结体中的任意的直线上,Al2O3所占的连续距离的平均值大于或等于0.1μm且小于或等于1.0μm,并且Al2O3所占的所述连续距离的标准偏差小于或等于0.8,
在所述直线上,在X表示Al2O3与所述Zr化合物之间的接触点的数目,并且Y表示Al2O3与所述立方氮化硼之间的接触点的数目以及Al2O3与除Al2O3和Zr化合物以外的粘结相成分之间的接触点的数目的总和的情况下,X/Y大于或等于0.1且小于或等于1,并且
所述Zr化合物的平均粒径大于或等于0.01μm且小于或等于0.1μm。
2.根据权利要求1所述的立方氮化硼烧结体工具,其中
作为包含在所述立方氮化硼烧结体中的所述Zr化合物,包含总计大于或等于0.5体积%且小于或等于5体积%的ZrC和ZrO2
3.根据权利要求1所述的立方氮化硼烧结体工具,其中
在所述立方氮化硼烧结体中的任意的直线上,X/Y大于或等于0.5且小于或等于0.9。
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