CN102741447A - 切削工具 - Google Patents
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Abstract
本发明的切削工具包括基底材料和在其上形成的多层涂层。所述多层涂层包含从基底材料朝向所述多层涂层的外表面以A-层、C-层和B-层的顺序重复沉积的A-层、B-层和C-层。A-层由a1层和a2层组成,其中每100nm非周期性沉积8~20层的所述a1层和a2层。A-层、B-层和C-层的各单元层的厚度分别为0.5~2.0μm、0.1μm~0.5μm和55~95nm。
Description
技术领域
本发明主要涉及切削工具,并且更具体地,涉及具有在切削工具的表面上形成的多层涂层的切削工具。
背景技术
各种类型的涂层常规地用于改进切削性能和延长切削工具的寿命。为了改进涂层的性能,使用以多个层堆叠的多层涂层,其中每层的厚度为几纳米。在这样的多层涂层中,相邻层的组成不同地设置,由此导致在相邻层之间不同的晶格参数和相互作用。因此,多层涂层的硬度和耐磨性得到改进。然而,当具有仅几纳米厚度的多个层堆叠时,由于来自堆叠结构的累积的扭应力引起抗冲击性降低,存在因此提高脆性断裂的发生的问题。
在另一个现有技术的技术中,通过向其中沉积多层、各多层的厚度为几纳米的结构内,采用夹层的厚层(其厚度为几百纳米至几微米),来增强多层涂层的韧性和抗冲击性。厚层降低由沉积的层(其中各层具有几纳米厚度)引起的高扭应力,以改进多层涂层的韧性和抗冲击性。然而,为了实现上述效果,夹层的层必须厚,其因此降低由具有几纳米厚度的层之间的相互作用所预期的硬度增强效果。这引起多层涂层的硬度和耐磨性劣化的问题。
因此,常规的多层涂层仅能改进机械性质中的一种,即,硬度或韧性。因此,具有现有技术的多层涂层的切削工具仅局限于实现一个目的,即,高耐磨性或高抗冲击性。此外,由于与另一种性质相比,机械性质中的一种(即,耐磨性或抗冲击性)相对较差,现有技术的多层涂层在延长切削工具的寿命方面存在局限。
发明内容
技术问题
本发明的一个目的是增强切削工具的技术性质——耐磨性和抗冲击性两者,由此使得切削工具能够用于需要高耐磨性或高抗冲击性中任一种的广泛的过程。本发明的另一个目的是提供具有多层涂层的切削工具,其显著提高切削工具的寿命,即使提高切削速度也如此。
解决问题的方案
为了实现上述目的,本发明的切削工具包括基底材料和在基底材料的表面上形成的多层涂层。多层涂层包含A-层、B-层和C-层。这些层从基底材料朝向所述多层涂层的外表面以A-层、C-层和B-层的顺序重复沉积。A-层由a1层和a2层组成,这些a1层包含Ti46~49Al51~54N并且厚度为4nm~30nm,而这些a2层包含Ti34~38Al62~66N并且厚度为2nm~25nm。a1层和a2层非周期性地沉积。a1层和a2层的沉积的层的总数为每100nm 8~20。A-层的一个单元层包括由a1层和a2层组成的沉积的层,并且厚度为0.5~2.0μm。B-层包含Ti34~38Al62~66N,并且由B-层组成的一个单元层的厚度为0.1μm~0.5μm。C-层包含Ti46~49Al51~54N并且厚度为55~95nm。
在本发明的多层涂层中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)小于0.3。
此外,在A-层中a1层与a2层的总厚度比率(总a1层厚度/总a2层厚度)为1.1~2.1。
在本发明的多层涂层中A-层具有调节至27~32 GPa的硬度。此外,B-层具有调节至22~24 GPa的硬度,并且C-层具有调节至26~30 GPa的硬度。
本发明的有益效果
根据本发明,由于通过多层涂层改进切削工具的机械性质——耐磨性和抗冲击性两者,切削工具可广泛用于需要高耐磨性或高抗冲击性中任一种的过程。另外,由于改进耐磨性和抗冲击性两者,在切削工作期间切削刀刃高度稳定。因此,切削工具的寿命可显著增强,即使提高切削速度也如此。
附图简述
图1为包含本发明的多层涂层的切削工具的示意图。
图2为溅射装置的一个实施方案的略图,其用于形成具有本发明的多层涂层的切削工具。
图3为其中当A-层由各种组成在基底材料1 (Micro WC - 9~11重量% Co)上形成时,比较切削工具寿命的图。
图4为其中当A-层由各种组成在基底材料2 (General WC - 10~13重量% Co - 1~2重量%较少金属碳化物)上形成时,比较切削工具寿命的图。
图5(a)为显示非周期性沉积的a1层和a2层的厚度的图。
图5(b)为其中a1层和a2层非周期性沉积的A-层的一部分的显微照片。
图6(a)为显示几乎周期性沉积的a1层和a2层的厚度的图。
图6(b)为其中a1层和a2层几乎周期性沉积的A-层的一部分的显微照片。
图7(a)显示测量非周期性沉积的a1层和a2层和几乎周期性沉积的a1层和a2层的韧性的方法。
图7(b)为其中在非周期性沉积的a1层和a2层和几乎周期性沉积的a1层和a2层之间比较韧性的图。
图8(a)为其中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)为1的多层涂层的示意图。
图8(b)为其中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)为0.2的多层涂层的示意图。
图9为其中当B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)为1和0.2时,比较耐磨性和抗冲击性的图。
图10(a)为在切削测试后切削刀刃的照片,其中SCM4工件由包含具有C-层的多层涂层的切削工具切削。
图10(b)为在切削测试后切削刀刃的照片,其中SCM4工件由包含没有C-层的多层涂层的切削工具切削。
图11(a)为在切削测试后切削刀刃的照片,其中SUS304工件由包含具有C-层的多层涂层的切削工具切削。
图11(b)为在切削测试后切削刀刃的照片,其中SUS304工件由包含没有C-层的多层涂层的切削工具切削。
图12(a)为显示在使用SUS304工件的切削过程中比较切削工具的寿命的图,其中在对比实施例与具有基底材料(Micro WC — 5.5~6.5重量% Co)的实验实施例之间进行比较,实验实施例中在本发明的多层涂层中B-层包含Ti46~49Al51~54N,并且C-层包含Ti34~38Al62~66N,而对比实施例中的多层涂层仅包含A-层,而没有B-层和C-层。
图12(b)为显示在使用Inconel718工件的切削过程中比较切削工具的寿命的图,其中在对比实施例与具有基底材料(Micro WC — 5.5~6.5重量% Co)的实验实施例之间进行比较,其中在本发明的多层涂层中B-层包含Ti46~49Al51~54N,并且C-层包含Ti34~38Al62~66N,而对比实施例中的多层涂层仅包含A-层,而没有B-层和C-层。
发明实施方案
将参考附图来说明本发明的详细实施方案。
图1为包含本发明的一个实施方案的多层涂层的切削工具的示意图。本发明的切削工具包括基底材料和在基底材料的表面上形成的多层涂层。基底材料可由材料例如碳化钨制成。在基底材料的表面上形成的多层涂层包含A-层、B-层和C-层。这些层从基底材料朝向多层涂层的外表面以A-层、C-层和B-层的顺序重复沉积。
A-层包含a1层和a2层,二者均具有可显著增强多层涂层的硬度的组成,并且形成沉积的结构以改进多层涂层的韧性。此外,本发明的多层涂层的韧性可通过具有预定厚度的B-层增强。B-层减轻由A-层中的a1层和a2层的沉积而产生的扭应力。此外,本发明的多层涂层结构化,使得具有预定的组成和预定的厚度的C-层首先在A-层上沉积,其中B-层随后在C-层的顶部沉积。通过这样做,可均匀形成B-层,并且B-层的韧性增强效果可最大化。如此,通过非周期性沉积a1层和a2层,本发明的多层涂层的韧性可增强。通过C-层使B-层的韧性增强效果最大化。因此,足够的韧性所需的B-层可薄薄地形成。由于B-层变薄,A-层的厚度比率提高,这提高整个多层涂层的硬度。并且,与当形成薄的B-层时整个多层涂层的韧性会降低的预期相反,当B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)控制在小于0.3时,多层涂层的韧性增强。下文中,将详细说明本发明的多层涂层的各层的功能和性质。
A-层通过交替沉积a1层和a2层形成,其中a1层和a2层具有彼此不同的组成。a1层包含Ti46~49Al51~54N,而a2层包含Ti34~38Al62~66N。如此,由层之间的相互作用引起的硬度增强效果最大化。这导致显著增强多层涂层的耐磨性,以及显著改进切削工具的寿命。如下所述,关于a1层和a2层的组成,本发明的发明人进行若干切削性能测试。
[实验1]
在该实验中,在基底材料1 (Micro WC - 9~l l重量% Co)和基底材料2 (General WC - 10~13重量% Co -1~2重量%较少金属碳化物)的表面上形成涂层。通过两种类型的电弧靶在这两种基底材料的表面上形成涂层,如图2所示。五种不同类型的涂层随后在每种基底材料上沉积。在每个实验实施例中,具有如下表1所示组成的靶用作Q-位置靶和R-位置靶。在实验实施例1~4中,通过在Q-位置和R-位置排列具有不同组成的靶,形成多层涂层。此外,在实验实施例5中,通过在Q-位置和R-位置排列具有Τi50Al50组成的相同类型的靶,形成单层涂层。
[表1]
实验实施例 | Q靶 | R靶 |
1 | Τi | Τi50Al50 |
2 | Τi75Al25 | Τi50Al50 |
3 | Τi75Al25 | Τi33Al67 |
4 | Τi50Al50 | Τi33Al67 |
5 | Τi50Al50 | Τi50Al50 |
通过在SKT4工件和SKD11工件的切削过程期间测量切削工具的寿命,进行切削性能测试。如下进行切削性能测试:在150m/分钟切削速度、0.1 mm/齿进料速率和2.0mm切削深度的条件下,经由干式-切削来切削SKT4工件。在150m/分钟的切削速度、0.12mm/齿的进料速率和2.0mm的切削深度的条件下,经由干式-切削来切削SKD11工件。两个切削过程均使用八角形铣刀片(milling insert)。比较切削工具的寿命,并通过测量直至侧表面的磨耗量达到0.45mm的切削距离来评价。图3显示包含在基底材料1的表面上形成的涂层(使用每个实验实施例的靶)的切削工具的寿命。图4显示包含在基底材料2的表面上形成的涂层(使用每个实验实施例的靶)的切削工具的寿命。图3和4证实,与其它实验实施例相比,包含如下多层涂层的切削工具具有显著提高的寿命:该多层涂层通过使用具有Ti50Al50组成的Q-靶和具有Ti33Al67组成的R-靶而形成。通过实验实施例4的靶形成的多层涂层的两种类型的层经鉴定具有Ti46~49Al51~54N和Ti34~38Al62~66N的组成。由此,可理解的是,如果具有Ti46~49Al51~54N和Ti34~38Al62~66N的组成的层交替沉积,则由于晶格常数的差异,由层之间的相互作用所预期的硬度增强可最大化,并且多层涂层的耐磨性变得显著增强。这最终延长切削工具的寿命。
此外,在A-层中,a1层与a2层的总厚度比率(总a1层厚度/总a2层厚度)调节至1.1~2.1。如果在A-层中a1层与a2层的总厚度比率(总a1层厚度/总a2层厚度)低于1.1,则耐磨性增强,但是抗冲击性劣化。然而,如果总厚度比率超过2.1,则抗冲击性增强,但是耐磨性下降。因此,为了保持耐磨性和抗冲击性二者均良好,a1层与a2层的总厚度比率(总a1层厚度/总a2层厚度)限制在1.1-2.1之间。
此外,组成A-层的a1层和a2层的厚度落入4nm~30nm和2nm~25nm范围内。并且,它们非周期性地沉积。也就是说,a1层和a2层各自具有如上所述范围的厚度。每100nm沉积总计8~20层的a1层和a2层。其中a1层和a2层如上所述沉积的A-层的一个单元层的厚度为0.5~2.0μm。通过这种非周期性沉积,A-层的韧性显著增强。因此,使用具有如上所述组成的a1层和a2层,本发明的多层涂层可提供通过层之间的相互作用使硬度增强最大化的功能效果。此外,通过沉积a1层和a2层使得它们具有非周期性厚度,本发明的多层涂层还可改进A-层的韧性。如下,关于a1层和a2层的厚度,本发明的发明人进行了切削性能测试。
[实验2]
在实验实施例1中,非周期性沉积厚度为6nm~21nm的a1层(Ti47Al53N)和厚度为3nm~15nm的a2层(Ti37Al63N),如图5(a)所示。图5(b)为通过显微镜观察时的实验实施例1的多层涂层的照片。在实验实施例2中,周期性沉积厚度为3~7nm的a1层(Ti47Al53N)和厚度为3~6nm的a2层(Ti37Al63N),如图6(a)所示。图6(b)为通过显微镜观察时的实验实施例2的多层涂层结构的照片。
在该实验中,测试包含所述两种涂层的切削工具的切削性能。图7(b)显示切削性能测试的两个实验实施例以及来自两个对比实施例的测试结果。使用铣削方法进行切削性能测试,如图7(a)所示。使用SKT4工件的测试,以V=50 m/分钟、d=2mm、干式和0.15 mm/齿初始进料速率的条件开始,并且使用SPKN 1203类型的铣刀片。将切削工件200mm而不破坏刀片称为一次走刀(pass)。通过以0.07mm/齿的间隔提高进料速率直至刀片破坏(例如,0.15-0.22-0.29-0.36-0.43...)来进行测试,并且根据刀片已进行多少“走刀”而不破坏,相对评价每个刀片的韧性。
如该实验的结果所示,具有a1层和a2层的非周期性沉积物的实验实施例证明韧性为具有几乎周期性沉积的对比实施例的两倍大。
在本发明的多层涂层中,B-层的组成为Ti34~38Al62~66N,并且B-层的一个单元层的厚度为0.1μm~0.5μm。由于厚度超过0.1μm,B-层减轻在A-层中累积的扭应力。此外,由于B-层的厚度小于0.5μm,其防止在多层涂层中的耐磨性劣化。
在本发明的多层涂层中,B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)控制在小于0.3。因此,提供显著增强多层涂层的耐磨性的功能效果。如下,关于B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度),本发明的发明人进行了切削性能测试。
[实验3]
如图8(a)所示,该测试的实验实施例1显示了一个切削性能实验,其中形成多层涂层,使得B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)为1。如图8(b)所示,实验实施例2显示关于切削工具的耐磨性和抗冲击性的切削性能测试,其中形成多层涂层,使得B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)为0.3。在两种条件下对耐磨性进行测试,一种使用SCM4工件在V=250、fz=0.1、ap=3.0的条件下进行,另一种使用SUS304工件在V=150、fz=0.1、ap=2.0的条件下进行。使用SCM440工件,在N=100、(开始)fz=0.28、ap=2.0的条件下进行抗冲击性测试。图9呈现显示实验实施例1和2的切削性能测试结果之间的比较的图。图9中的平均百分比是指相对于包含没有B-层的涂层的切削工具的平均寿命比率。
如在图9中提供的测试结果所示,当与没有B-层的涂层相比时,使用SUS304工件的实验实施例1,其中B-层与A-层的总厚度比率(B-层的总厚度/A-层的总厚度)为1,显示耐磨性相当劣化。另一方面,实验实施例2,其中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)控制为0.3,显示不仅耐磨性增强而且抗冲击性增强。这些实验实施例指出,尽管B-层的厚度比率(其主要控制韧性)降低,但抗冲击性可增强。这是因为当B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)变得小于0.3时,在A-层和B-层之间形成更多的界面。此外,由于裂纹蔓延通过界面处的裂纹分离和裂纹偏转而受到抑制,因此韧性增强。
为本发明的多层涂层的一部分的C-层包含Ti46~49Al51~54N并且厚度为55~95nm。C-层总是在A-层顶上形成,并且起到A-层与B-层之间的转移层的作用。由于C-层的组成和厚度保持在上述范围内,C-层有助于B-层均匀形成,并且有助于使B-层的韧性增强效果最大化。当C-层的厚度变得小于50nm时,由于C-层不能均匀覆盖整个刀片,难以在C-层顶上均匀形成B-层。当C-层的厚度超过95nm时,抗冲击性可能劣化。在以下条件下,关于C-层的功能效果,本发明的发明人进行了切削过程。在切削后,切削刀刃如图10和11所示。
[实验4]
该测试的对比实施例1~4采用与在实验3的实验实施例2中所用相同的那些涂层。这类涂层不含C-层。该实验的实验实施例1~4采用与在实验3的实验实施例2中所用相同的涂层,但是此时具有C-层。实验实施例1和2以及对比实施例1和2使用SCM4工件,在V=250m/分钟、f=0.1 mm/齿、d-c=3.0mm、干式和0.8M切削长度的条件下进行测试,并且之后观察切削刀刃。实验实施例3和4以及对比实施例3和4使用SUS304工件,在V=150m/分钟、f=0.1 mm/齿、d-c=2.0mm、干式和0.8M切削长度的条件下进行测试,并且之后观察切削刀刃。
显示实验实施例1和2的图10(a)以及显示对比实施例1和2的图10(b)指出,与对比实施例1和2相比,实验实施例1和2在细屑和侧表面磨耗性质方面提供更大的优异性。此外,显示实验实施例3和4的图11(a)以及显示对比实施例3和4的图11(b)显示,与对比实施例3和4相比,实验实施例3和4在细屑和侧表面磨耗性质方面提供更大的优异性。此外,它们显示,与对比实施例3和4相比,实验实施例3和4的偏差更小。
由这些结果可以清楚,加入C-层使B-层的韧性增强效果最大化,并且导致整个涂层的耐磨性和抗冲击性进一步增强。
此外,本发明的发明人进行了以下测试,以证实当B-层和C-层的组成彼此交换时的涂层性能。
[实验5]
本实验在车削操作测试中将B-层的组成与C-层的组成转换,随后比较结果。图12(a)和12(b)分别显示在使用SUS304工件和Inconel718工件的实验中多层涂层的性能测试结果,二者均使用平行四边形形状的刀片(基底材料:Micro WC -5.5%~6.5重量%Co)。在该实验中,实验实施例的多层涂层包含A-层、C-层和B-层,与本发明相同。然而,B-层和C-层的组成彼此转换(即,B-层包含Ti46~49Al51~54N,而C-层包含Τi34~38Al62~66Ν)。对比实施例的多层涂层仅包含A-层。
该实验证实,即使沉积组成彼此转换的B-层和C-层,本发明的实施仍好于排除B-层和C-层的对比实施例。
如在上述实验结果中证实的,通过调节在A-层的附属层中的组成差异,本发明成功地使由层之间的相互作用引起的硬度增强最大化。同时,通过非周期性沉积A-层的附属层,本发明还增强A-层的韧性。通过控制B-层与A-层的总厚度比率为小于0.3,整个涂层的耐磨性可保持,同时抗冲击性增强。此外,通过加入有助于B-层均匀形成的C-层,B-层的均匀性可增强,并且B-层的韧性增强效果可最大化。因此,本发明成功地保持耐磨性和抗冲击性两者均良好,由此提供可广泛用于各种目的并且具有显著提高的寿命的切削工具。
到目前为止,使用优选的实施方案说明了本发明。然而,这些实施方案仅为举例,并且本发明不局限于此。本领域技术人员将理解,可伴随在本发明的范围内的各种变更来实践本发明。
Claims (4)
1. 一种切削工具,其包含:
基底材料和在所述基底材料的表面上形成的多层涂层,所述多层涂层包含从基底材料朝向所述多层涂层的外表面以A-层、C-层和B-层的顺序重复沉积的A-层、C-层和B-层;
A-层的厚度为0.5~2.0μm并且包含a1层和a2层,a1层的厚度为4nm~30nm并且包含Ti46~49Al51~54N,而a2层的厚度为2nm~25nm并且包含Ti34~38Al62~66N,其中每100nm非周期性沉积8~20层的所述a1层和a2层;
B-层的厚度为0.1μm~0.5μm并且包含Τi34~38Al62~66Ν;
C-层的厚度为55~95nm并且包含Ti46~49Al51~54N;
其中,在多层涂层中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)小于0.3。
2. 一种切削工具,其包含:
基底材料和在所述基底材料的表面上形成的多层涂层,所述多层涂层包含从基底材料朝向所述多层涂层的外表面以A-层、C-层和B-层的顺序重复沉积的A-层、C-层和B-层;
A-层的厚度为0.5~2.0μm并且包含a1层和a2层,a1层的厚度为4nm~30nm并且包含Ti46~49Al51~54N,而a2层的厚度为2nm~25nm并且包含Ti34~38Al62~66N,其中每100nm非周期性沉积8~20层的所述a1层和a2层;
B-层的厚度为0.1μm~0.5μm并且包含Ti46~49Al51~54N;
C-层的厚度为55~95nm并且包含Τi34~38Al62~66Ν;
其中,在多层涂层中B-层与A-层的总厚度比率(总B-层厚度/总A-层厚度)小于0.3。
3. 权利要求1或2的切削工具,其中在A-层中a1层相比a2层的总厚度(总a1层厚度/总a2层厚度)为1.1~2.1。
4. 权利要求1或2的切削工具,其中所述A-层具有调节至27~32 GPa的硬度,其中所述B-层具有调节至22~24 GPa的硬度,并且其中所述C-层具有调节至26~30 GPa的硬度。
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Also Published As
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KR20110093118A (ko) | 2011-08-18 |
EP2534275B1 (en) | 2016-08-31 |
KR101190324B1 (ko) | 2012-10-11 |
US8889252B2 (en) | 2014-11-18 |
US20120308845A1 (en) | 2012-12-06 |
WO2011099683A1 (en) | 2011-08-18 |
JP2013518734A (ja) | 2013-05-23 |
EP2534275A1 (en) | 2012-12-19 |
JP5694381B2 (ja) | 2015-04-01 |
EP2534275A4 (en) | 2014-02-19 |
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