CN106414371A - 立方晶氮化硼烧结体及切削工具 - Google Patents

立方晶氮化硼烧结体及切削工具 Download PDF

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Publication number
CN106414371A
CN106414371A CN201580027940.2A CN201580027940A CN106414371A CN 106414371 A CN106414371 A CN 106414371A CN 201580027940 A CN201580027940 A CN 201580027940A CN 106414371 A CN106414371 A CN 106414371A
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cbn
boron nitride
cubic boron
ratio
peak
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CN106414371B (zh
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广崎浩司
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Kyocera Corp
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Kyocera Corp
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  • Powder Metallurgy (AREA)

Abstract

本发明提供耐摩耗性高且电阻率小的cBN烧结体以及使用其的加工性良好且耐摩耗性高的切削工具。本发明的立方晶氮化硼烧结体是含有85～97体积％的比例的立方晶氮化硼粒子和3～15体积％的比例的结合相的立方晶氮化硼烧结体，其中，含有相对于该立方晶氮化硼烧结体整体的比率为0.1～5质量％的Al，并且含有使Co相对于Al的质量比(Co/Al)为3～40的量的Co，且具有Al3B6Co20，本发明的切削工具为以上述的立方晶氮化硼烧结体作为切刃部5的切削镶刀1等切削工具。

Description

立方晶氮化硼烧结体及切削工具
技术领域
本发明涉及一种立方晶氮化硼烧结体及切削工具。
背景技术
立方晶氮化硼烧结体(以下，有时简称为cBN烧结体。)具有优异的耐摩耗性，因此被用作例如切削工具，尤其被广泛用于加工铸铁、作为难切削材的烧结合金。例如在专利文献1中公开了一种cBN烧结体，其包含立方晶氮化硼(cBN)相和含有W、Co、Al的结合相，并且以规定的比率含有B6Co21W2作为结合相。另外，在专利文献2中公开了一种cBN烧结体，其含有80重量％以上的cBN粒子，并且在结合相中添加了Co以及含有比率超过50重量％的Al。
现有技术文献
专利文献
专利文献1：日本特开2004－331456号公报
专利文献2：日本特开2013-538937号公报
发明内容
发明要解决的课题
然而，即使为上述专利文献1、2中记载的cBN烧结体，cBN粒子的脱粒也容易进行而使耐摩耗性降低，例如用作切削工具时的耐摩耗性称不上充分。
用于解决课题的手段
本实施方式的立方晶氮化硼烧结体是含有85～97体积％的比例的立方晶氮化硼粒子和3～15体积％的比例的结合相的立方晶氮化硼烧结体，该立方晶氮化硼烧结体中的Al含量为0.1～5质量％，Co含量相对于Al含量之比以质量比(Co/Al)计为3～40，且具有Al3B6Co20。
发明效果
根据本实施方式的立方晶氮化硼烧结体，结合相与立方晶氮化硼粒子的密合性提高，抑制立方晶氮化硼粒子的脱粒，从而使耐摩耗性高。其结果为：若将该立方晶氮化硼烧结体用于切削工具的切刃部，则可以提供耐摩耗性高且寿命更长的切削工具。
附图说明
图1为本实施方式的立方晶氮化硼烧结体的一例的X射线衍射数据。
图2为以本实施方式的立方晶氮化硼烧结体作为切刃部的切削工具的一例的概略立体图。
具体实施方式
立方晶氮化硼烧结体(cBN烧结体)含有85～97体积％的比例的立方晶氮化硼粒子(cBN粒子)和3～15体积％的比例的结合相，cBN烧结体中的Al含量为0.1～5质量％，Co含量相对于Al含量之比以质量比(Co/Al)计为3～40，且具有Al3B6Co20。
由此，就本实施方式的cBN烧结体而言，结合相与cBN粒子的密合性提高，抑制cBN粒子的脱粒，从而使耐摩耗性较高。因此，在切刃部具有本实施方式的cBN烧结体的切削工具的耐摩耗性高，可以长时间用于切削加工。另外，由于cBN烧结体的电阻率低，因此能够进行线放电加工。因此可以制作容易加工的切削工具。
若cBN粒子少于85体积％或结合相多于15体积％，则cBN烧结体的硬度降低，从而耐摩耗性降低。若cBN粒子多于97体积％或结合相少于3体积％，则结合相的密合力、即cBN粒子的保持力降低而使cBN粒子的脱粒变多，cBN烧结体的耐摩耗性降低。予以说明，就本实施方式中的cBN烧结体的cBN粒子及结合相的体积比率而言，测定cBN烧结体的截面照片中的cBN粒子与结合相的面积比率，并将该二维面积比率视为与三维的体积比率相同来作为cBN粒子与结合相的体积比率。予以说明，在测定中，在3个部位以上的多个部位测定面积比率，计算其平均值。cBN粒子的优选的含有比率为90～96体积％。
在此，若cBN烧结体中的Al含量少于0.1质量％，则不存在Al3B6Co20，结合相的密合力降低，从而烧结体的耐摩耗性降低。若Al含量多于5质量％，则难以进行线放电加工。若Co含量相对于Al含量之比以质量比(Co/Al)计低于3，则不存在Al3B6Co20，且难以进行线放电加工。若Co含量相对于Al含量之比以质量比(Co/Al)计高于40，则结合相的密合性降低，从而使cBN烧结体的耐摩耗性变差。质量比(Co/Al)的优选的范围为5～30。
在本实施方式中，从提高cBN烧结体的耐摩耗性及强度的方面出发，cBN粒子的平均粒径为0.2～10μm、优选为1～5μm、特别优选为1.5μm～2.5μm的范围。若为该范围，则cBN烧结体的硬度变高且可以抑制cBN粒子的脱粒。予以说明，本实施方式中的cBN粒子的粒径的测定依据CIS－019D－2005中规定的超硬合金的平均粒径的测定方法进行测定。
结合相以填埋cBN粒子间的间隙之类的状态存在，处于混杂有多个结晶相、非结晶相的状态。在本实施方式中，除cBN粒子以外的成分均为结合相。
在本实施方式中，如图1的Cu－Kα线的X射线衍射数据所示，在cBN烧结体中的cBN的衍射峰(以下，有时简称为cBN峰。有时对其他峰也同样地进行同样简略。)中，归属于cBN的(111)面的峰(以下，有时简称为cBN(111)峰。有时对其他峰也同样地进行简略。)的峰强度最强。作为归属于结合相的峰，存在Co(200)峰。
而且，根据本实施方式，在2θ＝38.5°、42.2°、45.0°、49.2°、51.3°等存在Al3B6Co20峰。予以说明，在这些峰中，2θ＝38.5°的峰与金属Al的峰重叠。同样，2θ＝49.2°、51.3°的峰与BCo的峰重叠。因此，在本实施方式中，是否存在Al3B6Co20通过有无存在不与其他结晶相的峰重叠的2θ＝42.2°及45.0°的任意峰来判定。另外，Al3B6Co20的最强峰的峰强度为在2θ＝42.2°及45.0°中峰强度高的一方。予以说明，各峰有时还会因固溶状态的若干不同或残留应力等而使衍射角(2θ)的值偏移，只要可以维持Al3B6Co20的晶格而检测到各衍射角的峰，则判断存在Al3B6Co20峰。
若不存在Al3B6Co20，结合相的密合性降低而使cBN粒子容易脱粒，cBN烧结体的耐摩耗性降低。另外，若不存在Al3B6Co20，则有时难以进行cBN烧结体的线放电加工。
在本实施方式中，相对于cBN(111)的峰强度的Al3B6Co20的最强峰(2θ＝42.2°及45.0°的峰中的峰强度较高的一方)的峰强度可以为0.02～0.25。若为该范围，则可以抑制cBN粒子的脱粒。相对于cBN(111)的峰强度的Al3B6Co20的最强峰的峰强度的优选范围为0.1～0.24。
另外，在图1中，仅试样No.7在2θ＝42°附近检测到BCo峰，但若不存在BCo的峰或者BCo的最强峰的峰强度相对于cBN(111)的峰强度的强度比为0.05以下，则可以抑制cBN粒子的脱粒。
进而，若相对于Co(200)的峰强度，Al3B6Co20的最强峰的峰强度为0.01～0.25，则可以抑制cBN粒子的脱粒，并且能够进行线放电加工。另外，若相对于cBN(111)的峰强度，Co(200)的峰强度为0.5～3，则可以优化cBN烧结体的耐摩耗性及电阻率。
在cBN烧结体中，除cBN峰、Co峰、Al3B6Co20峰以外，还可以存在金属Al峰或BCo峰。进而，虽然在图1中并未检测到，但是也可以存在AlN的峰，此时，相对于cBN(111)的峰强度的AlN的最强峰的峰强度优选为0.05以下。若为该范围，则可以抑制cBN粒子的脱粒，并且能够进行线放电加工。
另外，在cBN烧结体中可以进一步含有W。W以金属W、WC、W2B、B6Co21W2等形式存在。金属W、WC、W2B、B6Co21W2等可以通过在X射线衍射数据中检测到各峰来确认。进而，在cBN烧结体中可以含有Ti、除Ti以外的周期表4、5及6族金属成分。
进而，在本实施方式中，Al3B6Co20粒子的平均粒径的优选范围为0.02μm～0.5μm。由此，使Al3B6Co20粒子牢固地结合cBN粒子，从而可以抑制cBN粒子的脱粒。予以说明，本实施方式中的Al3B6Co20粒子的平均粒径作为从TEM观察得到的将各粒子的面积换算为圆时的直径而求得。
基于图2对以上述的cBN烧结体作为切刃部的切削工具的一例进行说明。图2的切削镶刀(以下，简称为镶刀。)1将包含cBN烧结体6的切刃片5经由包含含有WC和Co的超硬合金的衬层11钎焊到工具主体10的前端。切刃片5构成包含前刀面2、后刀面3和作为其交差脊线的切刃4的切刃部。另外，工具主体10包含超硬合金或高速度钢、合金钢等金属。予以说明，图2的镶刀1仅切刃片5包含cBN烧结体6，但是，本实施方式并不限定于该实施方式，也可以使切削镶刀整体由cBN烧结体6构成。
接下来，对于上述cBN烧结体的制造方法进行说明。
例如，将75～88质量％的比率的平均粒径为1.0～4.5μm的cBN原料粉末、10～24.9质量％的比率的平均粒径为1.0～2.5μm的金属Co原料粉末、0.1～5质量％的比率的平均粒径为0.5～1.8μm的金属Al原料粉末和0～20质量％的比率的平均粒径为0.3～1.5μm的WC原料粉末进行调合。在此，在本实施方式中，将cBN原料粉末的平均粒径与Al原料粉末的平均粒径的比(cBN/Al)设为1.0～3.0，并且将Al原料粉末的平均粒径与Co原料粉末的平均粒径的比(Co/Al)设为0.7～1.6。
将上述调合粉末球磨机粉碎混合15～72小时。之后，根据需要形成为规定形状。在成形中可以使用冲压成形、注射成形、浇铸成形、挤压成形等公知的成形手段。
接着，将其与另行准备的超硬合金制的衬底支撑体一起装入超高压加热装置中，在1450～1700℃的范围内的规定的温度且4～7GPa的压力下保持10～60分钟后，以3℃/秒以下的速度进行降温。由此，可以将cBN烧结体中的cBN粒子的存在比率调整为规定的范围内，并且可以存在Al3B6Co20。
即，若原料粉末的调合比率偏离上述范围，则cBN烧结体中的cBN粒子的存在比率偏离规定的范围或者不存在Al3B6Co20。若cBN原料粉末的平均粒径与Al原料粉末的平均粒径的比、以及Al原料粉末的平均粒径与Co原料粉末的平均粒径之比偏离上述范围，则cBN烧结体中的cBN粒子的存在比率偏离规定的范围或者不存在Al3B6Co20。另外，若烧成后的降温速度快于3℃/秒，则不析出Al3B6Co20。
另外，从制作的cBN烧结体利用线放电加工切割规定尺寸的切刃部。本实施方式的cBN烧结体为能够进行线放电加工的电阻率。而且，将该切割的切刃部钎焊到形成在超硬合金制的工具主体的前端角部的切口段部上。之后，对钎焊后的镶刀的上表面进行磨削加工，接着，将切刃部的侧面包括cBN烧结体的渗出部分进行磨削加工。进而，根据需要对切刃前端部实施衍磨加工，由此可以制作本实施方式的切削工具。
实施例
使用表1所示的平均粒径的cBN粉末、金属Co粉末、金属Al粉末、WC粉末，按照表1的组成进行调合，将该粉体利用使用了氧化铝制珠粒的球磨机混合15小时。接着，将混合的粉体在压力98MPa下进行加压成形。将该成形体与衬底支撑体重叠后，放置在超高压加热装置内，以120℃/分钟进行升温，以5GPa的压力在1450℃下保持15分钟后，以表1所示的降温速度降温，得到cBN烧结体。
接着，利用线放电加工从所制作的cBN烧结体及衬层的一体物切割为规定的形状。关于线放电加工的加工性，将良好的情况标记○，将花费时间可以进行加工的情况标记Δ，将无法加工的情况标记×，记载于表3中。然后，在形成于超硬合金制的工具主体的切刃前端部的切口段部，将衬层的下表面钎焊到工具主体的切口段部的表面，将切割的cBN烧结体作为切刃部。然后，使用金刚石轮对该cBN烧结体的切刃部实施刃尖处理(倒棱衍磨及R衍磨)，制作JIS·CNGA120408形状的切削镶刀。
就所得的镶刀而言，对切刃部的cBN烧结体的cBN烧结体的任意截面，通过采用扫描型电子显微镜(SEM)的组织观察，计算出cBN烧结体中的cBN粒子的含有比率。另外，依据CIS－019D－2005中规定的超硬合金的平均粒径的测定方法，测定了cBN粒子的平均粒径。在表1中示出结果。予以说明，在组织照片中，cBN粒子以外的部分设为结合相。
另外，利用ICP分析对cBN烧结体的组成进行确认，并测定Co、Al、W相对于cBN烧结体整体的含有比率。在表2中示出结果。
进而，使用BrukerAXS公司制D8DISCOVER with GADDS Super Speed、射线源：CuKα、准直直径：0.8mmφ，从前刀面及后刀面进行X射线衍射测定，鉴定cBN烧结体中的结晶相，并且将cBN(111)的峰强度设为1时的归属于各结晶相的峰中的最强峰的峰强度示于表3中。予以说明，图1的XRD谱图为试样No.7、9、10、11的XRD谱图。
接着，采用所获得的切削镶刀在以下的切削条件下进行了切削试验。在表3中示出结果。
切削方法：外径旋削加工
被切削材：FC250衬套材
切削速度：700m/分钟
送给：0.2mm/rev
切口：0.2mm
切削状态：湿式(有切削油)
评价方法：评价直至摩耗或缺失为止的切削长度。
【表1】
【表2】
【表3】
根据表1～3所示的结果，cBN粒子的含量少于85体积％且结合相的含有比率多于15体积％的试样No.1中，耐摩耗性降低，切削长度短。cBN粒子的含量多于97体积％且结合相的含有比率少于3体积％的试样No.6中，cBN粒子的脱粒多，耐摩耗性降低，切削长度短。Co与Al的含量的比(Co/Al)小于3的试样No.7及Al含量多于5质量％的试样No.18中，不存在Al3B6Co20，无法进行线放电加工。Co与Al的含量的比(Co/Al)大于40的试样No.13、Al含量少于0.1质量％的试样No.14中，不存在Al3B6Co20，切削长度短。试样No.19～21中，不存在Al3B6Co20，线放电加工性差，且切削长度短。
与此相对，含有85～97体积％的比例的立方晶氮化硼粒子和3～15体积％的比例的结合相、Al含量为0.1～5质量％、Co含量相对于Al含量之比以质量比(Co/Al)计为3～40且具有Al3B6Co20的试样No.2～5、8～12、15～17、22～25中，均能进行线放电加工，并且耐摩耗性高，切削长度长。
试样No.2～5、8～12、15～17、22～25之中，在X射线衍射测定中相对于cBN(111)的峰强度，Al3B6Co20的最强峰的峰强度为0.02～0.25的试样No.2～5、8～12、16、17、22、23均能进行线放电加工，并且切削长度长。另外，相对于cBN(111)的峰强度，Co(200)的峰强度为0.5～3的试样No.2～5、8～12、15～17、23、24均能进行线放电加工，并且切削长度长。
进而，相对于Co(200)的峰强度，Al3B6Co20的最强峰的峰强度为0.01～0.25的试样No.2～5、8～12、15～17、23、24均能进行线放电加工，并且切削长度长。
另外，不存在AlN的峰或者以相对于cBN(111)的峰强度，AlN的最强峰的峰强度为0.05以下的强度比存在的试样No.2～5、8～11、15～17、22～25以及不存在BCo的峰或者相对于cBN(111)的峰强度，BCo的最强峰的峰强度为0.05以下的No.3～5、8～12、15～17、22～25均能够进行线放电加工，并且切削长度长。
进而，cBN粒子的平均粒径为1.5μm～2.5μm且Al3B6Co20粒子的平均粒径为0.02μm～0.5μm的试样No.2～5、8～12、15～17、23、24均能进行线放电加工，并且耐摩耗性高，切削长度长。
符号说明
1 镶刀(切削镶刀)
2 前刀面
3 后刀面
4 切刃
5 切刃部
6 cBN烧结体

Claims (8)

1.一种立方晶氮化硼烧结体，其是含有85～97体积％的比例的立方晶氮化硼粒子和3～15体积％的比例的结合相的立方晶氮化硼烧结体，该立方晶氮化硼烧结体中的Al含量为0.1～5质量％，Co含量相对于Al含量之比以质量比Co/Al计为3～40，且具有Al3B6Co20。
2.根据权利要求1所述的立方晶氮化硼烧结体，在X射线衍射测定中，所述Al3B6Co20的最强峰的峰强度相对于cBN(111)的峰强度之比为0.02～0.25。
3.根据权利要求1或2所述的立方晶氮化硼烧结体，在X射线衍射测定中，所述Al3B6Co20的最强峰的峰强度相对于Co(200)的峰强度之比为0.01～0.25。
4.根据权利要求1～3中任一项所述的立方晶氮化硼烧结体，在X射线衍射测定中，所述Co(200)的峰强度相对于cBN(111)的峰强度之比为0.5～3。
5.根据权利要求1～4中任一项所述的立方晶氮化硼烧结体，在X射线衍射测定中，不存在AlN的峰、或者AlN的最强峰的峰强度相对于cBN(111)的峰强度之比为0.05以下。
6.根据权利要求1～5中任一项所述的立方晶氮化硼烧结体，在X射线衍射测定中，不存在BCo的峰、或者BCo的最强峰的峰强度相对于cBN(111)的峰强度之比为0.05以下。
7.根据权利要求1～6中任一项所述的立方晶氮化硼烧结体，其中，所述立方晶氮化硼粒子的平均粒径为1.5μm～2.5μm，Al3B6Co20粒子的平均粒径为0.02μm～0.5μm。
8.一种切削工具，其以权利要求1～7中任一项所述的立方晶氮化硼烧结体作为切刃部。
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