CN106141180A - 通过增材制造制备的切削工具 - Google Patents

通过增材制造制备的切削工具 Download PDF

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CN106141180A
CN106141180A CN201610307789.4A CN201610307789A CN106141180A CN 106141180 A CN106141180 A CN 106141180A CN 201610307789 A CN201610307789 A CN 201610307789A CN 106141180 A CN106141180 A CN 106141180A
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cutting element
internal cavity
cutting
band coating
rake face
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CN106141180B (zh
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P.斯托亚诺夫
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Kennametal Inc
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Abstract

本发明公开了一种由增材制造工艺制备的切削工具。所述切削工具具有外表面以及由一个或多个朝内的表面限定的封闭的内部腔体。所述内部腔体可具有内部支撑件，诸如晶格或蜂窝结构。所述切削工具可为具有冷却剂孔的刀片、钻头或端铣刀。

Description

通过增材制造制备的切削工具
技术领域
本发明涉及金属切削工具的制备和设计。
背景技术
金属切削工具通常由烧结碳化钨或另一种合适的材料(诸如PCD、PcBN、高速钢和其他金属陶瓷)制成。烧结碳化钨部件通过将WC、Co以及可能的其他材料的共混物压制或挤压成生坯形状而制成。然后烧结生坯形状以将粉末压实并熔化在一起。烧结碳化物是金属基质复合材料，该复合材料包含一种或多种过渡金属的碳化物，所述碳化物作为硬颗粒分散并固结在诸如钴、镍和/或铁(或这些金属的合金)的粘结剂中。这样，硬颗粒形成分散相，而粘结剂形成成连续相。对于用作切削工具(包括例如车削刀片和铣削刀片)，烧结碳化物提供强度、韧性和耐磨损性/耐腐蚀性(即，耐磨性)的有吸引力的组合。在可能的不同硬颗粒组合中，由碳化钨作为硬颗粒以及钴作为粘结剂相而组合的烧结碳化物普遍用作对难加工材料(诸如钛和钛合金、镍和镍合金、超合金、不锈钢和球墨铸铁)进行金属加工操作的切削工具。
压制和烧结技术或挤压和烧结技术将最终部件的设计仅限为可被压制或挤压的那些几何形状。这可能导致含有更多材料的烧结碳化物部件中掺入次等或不必要的特征。一个不必要的特征通常是使用比所需更多的材料来制备部件。烧结碳化钨是昂贵的材料。在不损害切削工具质量或性能的情况下需要不断减少烧结碳化钨的使用。
发明内容
在本发明的一种形式中，本发明为切削工具，该切削工具包括外表面以及由一个或多个朝内的表面限定的封闭的内部腔体。内部腔体可具有内部支撑件，诸如晶格或蜂窝结构。
在本发明的另一种形式中，本发明为制备切削工具的方法，该方法包括使用粘结剂喷射工艺由起始粉末制备具有内部腔体的生坯切削工具，然后使切削工具脱粘并烧结。
在本发明的另一种形式中，本发明为制备切削工具的方法，该方法包括使用选择性激光烧结工艺由起始粉末制备具有内部腔体的工具的步骤。
根据本发明制备的工具可具有改善的机械性能和耐磨性、通过消除不必要的材料而降低的总重量，以及节省的制造时间和成本。此外，工具的轻重量设计将由于机械的更快反应而允许高速操作中更精确的工具路径。该设计的另外的益处包括设计灵活性增加的更高质量成品。
这些和其他实施例在下文的具体实施方式中更详细地描述。
附图说明
图1为根据本发明的一个实施例的切削刀片的透视图。
图2为图1的切削刀片的剖视图。
图3为根据本发明的另一个实施例的切削刀片的剖视图。
图4为根据本发明的另一个实施例的钻头的透视图。
图5为图4的钻头的剖视图。
具体实施方式
参考以下具体实施方式和实例以及前述和下述内容可更容易地理解本文所述的实施例。然而，本文所述的元素、设备和方法并不限于具体实施方式和实例中所述的具体实施例。应当认识到，这些实施例仅示例性地说明本发明的原理。在不脱离本发明精神和范围的情况下，多种修改和变更对于本领域技术人员而言将是显而易见的。如本文所用，术语切削工具是指用于从工件移除材料的硬组件。
图1示出根据本发明的一个实施例的切削刀片10。在该实施例中，切削刀片呈大致矩形形式，但是该切削刀片可为适用于金属切削的任何所需形状，例如另一种刀片类型、端铣刀或钻头。此外，该切削刀片10可在其一个或多个表面上具有类似断屑槽或孔之类的另外几何形状。切削刀片10具有在前刀面12与后刀面13的交汇处的切削刃11。切削工具10的外表面14包括前刀面12、后刀面13和切削刃11。该类型的切削刀片通常可根据车削或铣削操作在刀架上转位，并且可以从刀架上拆卸。
图2为图1的切削刀片10的剖视图。该剖面展示了刀片10内的内部腔体15。内部腔体15由一个或多个朝内的表面19限定。结合晶格结构17以改善切削刀片10的机械性能。晶格结构17可以是维持工具的机械强度和完整性的任何合适设计，例如，可加入一个或多个内壁或者可结合蜂窝结构。如本文所用，术语“腔体”是指工具内由朝内的表面在所有侧面上限定的内部空间。
现在参见图3，根据本发明的另一个实施例示出了切削刀片20的剖视图。切削刀片20具有带有支撑晶格结构22的内部腔体21。切削刀片20具有在后刀面24与前刀面25的交汇处的切削刃23。在前刀面25内并且邻近切削刃23的是冷却剂排放孔26，该冷却剂排放孔从内部腔体21延伸至前刀面25。在该实施例中，冷却剂(例如水或切削液)通过刀架(未示出)递送进入到冷却剂入口(未示出)中，该冷却剂入口结合到切削刀片20的底部。刀片的底部是与前刀面25相对的侧面。其他实施例可具有位于后刀面或前刀面的冷却剂入口。
图4和图5示出根据本发明的另一个实施例的钻头30。图5为钻头30的中心部分的剖视图。该剖面沿着与钻头30的纵向轴线相交的平面。该钻头具有在切削刀头32的一端处的柄部31以及在相对端处的切削刃33。如图5所示，钻头30具有由一个或多个朝内的表面35限定的内部腔体34。晶格结构36为钻头30提供机械支撑。
本发明的切削工具通过增材制造(例如粘结剂喷射、选择性激光烧结(SLS)、或选择性激光熔化(SLM))来制造。如本文所用，“粘结剂喷射”是指生产部件的以下方法：将液体粘结剂选择性地喷射到基于部件3D模型的粉末床上，将粘结剂和粉末凝固成剖面，接着依次放置额外的粉末和粘合剂以形成物件的下一层，然后重复该过程直到完成生坯部件。在粘结剂喷射之后，将部件脱粘并烧结。在一些实施例中，将切削工具在介于2000至3000℉之间的温度以及10,000至30,000psi的压力下热等静压(HIP)30至500分钟之间的时间段以获得高度致密和可靠的结构。工具的最终密度为>95％，例如>99.5％。
合适的粉末包括水雾化和气雾化的粉末，该雾化粉末包含硬颗粒组分和金属粘结剂组分。现在转到特定组分，硬颗粒相可以不违背本发明目的的任何量存在于烧结硬质碳化物制品中。在一些实施例中，例如，硬颗粒相以烧结硬质碳化物制品的至少70重量％或至少80重量％的量存在。硬颗粒相还可以选自表I的量存在。
表I-硬颗粒相含量
重量％烧结硬质碳化物制品
70-98
80-98
85-96
88-95
89-98
90-97
如本文所述，硬颗粒相包括碳化钨。在一些实施例中，硬颗粒相仅由碳化钨形成。作为另外一种选择，硬颗粒相还可包括选自周期表的IVB族、VB族和VIB族的一种或多种金属的碳化物、氮化物和/或碳氮化物。例如，在一些实施例中，除了碳化钨以外，硬颗粒相包括碳化钽、碳化铌、碳化钒、碳化铬、碳化锆、碳化铪、碳化钛及其固溶体中的至少一种。另外的金属碳化物、氮化物和/或碳氮化物可以不违背本发明目的的任何量存在于硬颗粒相中。在一些实施例中，另外的金属碳化物、氮化物和/或碳氮化物以最多至硬颗粒相的50重量％的量存在。例如，另外的金属碳化物、氮化物和/或碳氮化物可以硬颗粒相的1-10重量％的量存在。另外，硬颗粒相可通常表现出小于30μm的平均粒径。例如，硬颗粒相的平均粒径可小于10μm，诸如0.5-3μm。
如本文所述，烧结硬质碳化物制品包括金属粘结剂相，所述金属粘结剂相包括一种或多种合金化添加剂以及余量的钴、镍和/或铁。如本文所用，“金属粘结剂”是指金属组分，该金属组分在烧结期间软化并且将硬颗粒固结在一起。金属粘结剂是粉末共混物的一部分，该粉末共混物用于形成生坯部件。一般来讲，金属粘结剂相以烧结硬质碳化物制品的1-30重量％的量存在。在一些实施例中，金属粘结剂相以选自表II的量存在。
表II–金属粘结剂相含量
金属粘结剂相的合金化添加剂包括一种或多种金属元素、非金属元素或其固溶体。适于用作合金化添加剂的金属元素包括过渡金属和铝。在一些实施例中，过渡金属合金化添加剂选自周期表的IIIB族-VIIm族。例如，合金化添加剂可包括钨、钌、锰、铜、铼、铬、锇和钼中的一种或多种。在一些实施例中，金属合金化添加剂表现出六方紧密堆积(hcp)晶体结构。在其他实施例中，金属合金化添加剂具有立方晶体结构，诸如面心立方(fcc)或体心立方(bcc)。合金化添加剂还可包括一种或多种非金属元素。非金属合金元素可选自周期表的IlIA族-VA族，诸如硼、硅、碳和/或氮。一般来讲，合金化添加剂以最多至金属粘结剂相的50重量％的量存在。在一些实施例中，例如，合金化添加剂以金属粘结剂相的10-30重量％或30-50重量％的量存在。
在一些实施例中，本文所述的烧结硬质碳化物制品还包括合金粘结剂富集的表面区，其具有大于烧结制品本体中合金粘结剂含量的最大合金粘结剂含量。粘结剂富集区可从烧结制品表面向内延伸。在一些实施例中，富集区的合金粘结剂分层，从而表现出不同的合金粘结剂层。在其他实施例中，合金粘结剂是不分层的。烧结硬质碳化物制品可在一个或多个表面上表现出合金粘结剂富集的表面区。
可与本发明的悬浮液一起使用的粘结剂的非限制性例子包括诸如乙二醇单甲醚、聚乙二醇、聚乙烯醇(PVA)、聚乙烯醇缩丁醛(PVB)、聚乙烯吡咯烷酮(PVP)和蜡之类的粘结剂。粘结剂的浓度可为约5至约10重量％粘结剂。工具可使用如上所述的合适的粘结剂和粉末组合用ExOne粘结剂喷射打印机来制备。
在一些实施例中，通过PVD和/或CVD将本文所述的切削工具涂覆一种或多种耐火材料。在一些实施例中，耐火涂层包括选自铝和周期表IVB族、VB族和VIB族的金属元素中的一种或多种金属元素以及选自周期表IIIA族、IVA族、VA族和VIA族中的一种或多种非金属元素。例如，耐火涂层可包括选自铝和周期表IVB族、VB族和VIB族中的一种或多种金属元素的一种或多种碳化物、氮化物、碳氮化物、氧化物或硼化物。另外，涂层可为单层或多层。
另外，本文所述的切削工具可经受一种或多种处理，诸如抛光、喷射和/或蚀刻。表面处理的烧结硬质碳化物制品可保持未涂布状态，或者可将本文所述的耐火涂层施加到处理过的表面。此外，耐火涂层的一个或多个层可经受涂布后处理，诸如抛光和/或喷射。
增材制造技术使完全封闭的腔体能够被设计成切削工具。腔体可设计成在工具中额外具有晶格或其他支撑件以增加工具的强度。现有技术的压制和烧结技术不能够产生完全封闭的内部腔体。具有晶格支撑件的封闭腔体允许以最少用料设计切削工具，同时保持工具的机械强度。
针对实现本发明多个目的，现已描述了本发明的多个实施例。应当认识到，这些实施例仅示例性地说明本发明的原理。在不脱离本发明精神和范围的情况下，其多种修改和变更对于本领域技术人员而言将是显而易见的。

Claims (12)

1.一种切削工具，所述切削工具包括：
外表面，以及
封闭的内部腔体，所述封闭的内部腔体由一个或多个朝内的表面限定。
2.根据权利要求1所述的带涂层的切削工具，还包括位于所述内部腔体内部并且支撑所述内部腔体的一个或多个晶格结构。
3.根据权利要求2所述的带涂层的切削工具，其中所述切削工具包括烧结碳化钨。
4.根据权利要求1所述的带涂层的切削工具，还包括：
前刀面；
后刀面；以及
在所述前刀面和所述后刀面的交汇处的切削刃。
5.根据权利要求4所述的带涂层的切削工具，所述前刀面、后刀面或另一个包含冷却剂入口的表面，并且其中所述前刀面包括邻近所述切削刃的冷却剂排放孔。
6.根据权利要求1所述的带涂层的切削工具，还包括至少在所述前刀面或所述后刀面上的PVD或CVD涂层。
7.根据权利要求1所述的带涂层的切削工具，其中所述切削工具为切削刀片、钻头、扩孔钻或端铣刀。
8.一种制备切削工具的方法，所述方法包括：
使用粘结剂喷射工艺由起始粉末制备具有内部腔体的生坯切削工具；以及
将所述切削工具脱粘并烧结。
9.根据权利要求8所述的制备切削工具的方法，其中所述起始粉末包含碳化钨和钴。
10.根据权利要求8所述的方法，还包括在烧结之后热等静压(HIP)所述切削工具。
11.一种制备切削工具的方法，所述方法包括：
使用选择性激光烧结工艺由起始粉末制备具有内部腔体的工具。
12.根据权利要求11所述的制备切削工具的方法，其中所述起始粉末包含碳化钨和钴。
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