CN107151786B - 一种软硬复合涂层木工刀具及其制备方法 - Google Patents

一种软硬复合涂层木工刀具及其制备方法 Download PDF

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CN107151786B
CN107151786B CN201710418581.4A CN201710418581A CN107151786B CN 107151786 B CN107151786 B CN 107151786B CN 201710418581 A CN201710418581 A CN 201710418581A CN 107151786 B CN107151786 B CN 107151786B
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郭晓磊
曹平祥
鲍旭
朱兆龙
丁建文
王宝金
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TAIZHOU RAYARD WOOD INDUSTRY Co.,Ltd.
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Abstract

本发明提供一种软硬复合涂层木工刀具及其制备方法，其中：一种软硬复合涂层木工刀具包括刀具基体以及在该刀具基体外表面设置有刀具涂层，所述刀具涂层由内到外依次为：Cr过渡层、CrN硬涂层、CrCN硬涂层、CrN/WS2中间缓冲层、CrN过渡层、Cr/Ni过渡层和Ni/Al2O3/PTFE复合涂层。本发明的涂层刀具综合了CrN/CrCN硬涂层的高硬度、高耐磨性，CrN/WS2中间缓冲层的自润滑性、良好的结合性能以及Ni/Al2O3/PTFE复合涂层的耐磨、化学稳定性好、摩擦系数低的特点，使木工刀具在切削木材及木质复合材料时表现出更好的切削性能。

Description

一种软硬复合涂层木工刀具及其制备方法
技术领域
本发明涉及木材及木质复合材料切削加工和制造技术领域，特别是涉及一种软硬复合涂层木工刀具及其制备方法。
背景技术
对刀具进行涂层处理是提高刀具切削加工性能的重要途径之一，刀具涂层可分为两大类：硬涂层刀具和软涂层刀具。硬涂层刀具的特点在于提高了刀具的硬度和耐磨性，软涂层刀具的特点在于降低了刀具与切削表面的摩擦系数。如今，刀具涂层技术已广泛应用于金属切削加工领域，应用于木材切削加工领域相对较少。
在木材切削加工领域，刀具切削材料主要采用高速钢和硬质合金。相较于金工刀具，木工刀具旋转速度高，高转速导致刀具切削刃口温度增高，由于刃口温度增高，刀具的强度、韧性和耐磨性会下降，刃口容易发生崩刃现象。其次，由于木工刀具加工对象质地的不均匀性和各向异性，木材中含有的生物碱、有机弱酸以及人造板存在厚度方向的密度差异和胶层等都对木工刀具的化学稳定性和耐磨性提出了更高的要求。
硬质合金刀具由于具有极好的硬度、耐磨性、强度、韧性和耐热、耐腐蚀等一系列优良性能得到了广泛应用，但是其使用成本相对过高，涂层技术应用也相对较少，主要为单一的硬涂层刀具，并且硬涂层剥落后会严重影响加工效率和质量。另外，具有软涂层的刀具广泛应用于金属切削领域，较高的工件表面光洁度是其应用的一个显著特征。而随着各种木质复合材料的出现，对木材加工表面的光洁度也提出了更高的要求。
发明内容
为了解决目前以硬质合金或高速钢为基体的单涂层或复合涂层木工刀具存在的磨损大、涂层剥落、崩刃等问题，本发明提供一种软硬复合涂层木工刀具及其制备方法。
为了达到上述涂层刀具的目的，本发明采用以下技术方案：
本发明提供一种软硬复合涂层木工刀具，包括刀具基体以及在该刀具基体外表面设置有刀具涂层，所述刀具涂层由内到外依次为：Cr过渡层、CrN硬涂层、CrCN硬涂层、CrN/WS2中间缓冲层、CrN过渡层、Cr/Ni过渡层和Ni/nano-Al2O3/PTFE复合涂层。
作为优选，所述刀具基体的材料为硬质合金。
本发明还提供一种软硬复合涂层木工刀具的制备方法，所述刀具涂层由基体到表面依次为：Cr过渡层、CrN/CrCN硬涂层、CrN/WS2中间缓冲层、CrN+Cr/Ni过渡层、Ni/nano-Al2O3/PTFE复合涂层，属于多层结构。该涂层刀具综合了CrN/CrCN硬涂层的高硬度、高耐磨性，CrN/WS2中间缓冲层的自润滑性、良好的结合性能以及Ni/nano-Al2O3/PTFE复合涂层的耐磨、化学稳定性好、摩擦系数低的特点，使木工刀具在切削木材及木质复合材料时表现出更好的切削性能。
本发明中一种软硬复合涂层木工刀具的制备方法，该制备方法是采用多弧离子镀法+中频磁控溅射法共沉积的方法，其具体制备方法步骤如下：
步骤(1)、前处理：将刀具基体(1)硬质合金机械抛光，去除表面污染层，然后依次放入酒精和丙酮中，每次超声清洗15～20min，充分干燥后迅速放入镀膜机真空室，真空室本底气压为6.0×10-3Pa，加热基体至300℃，保温40～50min；
步骤(2)、离子清洗：通入Ar气，气压为1.5Pa，开启脉冲偏压电源，电压为800～900V，占空比0.2，辉光清洗15min，偏压降至300～400V，占空比0.2，气压降至0.5Pa，开启离子源离子清洗10～15min，开启电弧源Cr靶，偏压400V，靶电流调至60A，离子轰击Cr靶0.5min；
步骤(3)、沉积Cr过渡层：调整Ar气压至0.5Pa，偏压降至200V，电弧镀Cr过渡层6min；
步骤(4)、沉积CrN/CrCN硬涂层：调整Ar气压至1.0Pa，偏压180V，Cr靶的靶电流调至80A，开启N2，气压1.8Pa，调整N2流量至150～200sccm，镀制CrN 50～55min；通入乙炔，调整乙炔流量为150～180sccm，镀制CrCN 50～60min；
步骤(5)、沉积CrN/WS2中间缓冲层：关闭乙炔，关闭电弧源Cr靶，调整Ar和N2压力至0.1Pa，基体温度降至200℃，偏压调至250V，开启WS2中频靶，靶电流为0.6A，开启Cr中频靶，靶电流0.6A，中频磁控溅射共沉积CrN/WS260～70min；
步骤(6)、沉积CrN+Cr/Ni过渡层：关闭WS2中频靶和Cr中频靶，开启电弧源Cr靶，沉积CrN 5～7min，关闭N2，开启Ni靶，电流调至50A，镀制Cr/Ni 8～10min；
步骤(7)、沉积Ni/nano-Al2O3/PTFE复合涂层：关闭电弧源Cr靶，调整Ar气压至0.8Pa，开启Al2O3中频靶，靶电流1.2A，开启PTFE中频靶，靶电流1.5A，沉积Ni/nano-Al2O3/PTFE复合涂层80～100min；
步骤(8)、后处理：关闭Al2O3中频靶，PTFE中频靶和Ni靶，关闭离子源及气体源，关闭脉冲偏压，沉积涂层结束。
通过上述工艺制备的交错涂层刀具，由刀具基体表面到刀具表面的涂层依次为Cr过渡层、CrN/CrCN硬涂层、CrN/WS2中间缓冲层、CrN+Cr/Ni过渡层、Ni/nano-Al2O3/PTFE复合涂层。
首先，木材高速切削时，其切削速度高达80m/s，远高于传统切削速度。由于外载荷的作用，木材与刀具之间会发生高速瞬间碰撞，发生超常规的激变，木材的变形量大、应变速率高(可达到105-107s-1)。
其次，由于木工刀具加工对象质地的不均匀性和各向异性(例如刨花板的断面密度分布，胶合板的多层结构等)，刀具受冲击载荷较高。再次，由于木工刀具在高速切削过程中产生大量的切屑会增加对前刀面的磨损并且会使切削刃口产生大量的切削热，此外，胶合板、纤维板等木质复合材料中所含的胶黏剂在切削热作用下会使切屑粘附在刀具表面而影响排屑和切削质量。最后，木材中含有的生物碱，有机弱酸等在切削热的作用下也会加剧对刀具表面涂层材料的腐蚀磨损。
针对木工刀具的切削特点及存在的问题，本专利所述涂层木工刀具表面采用Ni/nano-Al2O3/PTFE复合软涂层，其中PTEF涂层材料具有的低摩擦系数和“不粘”特性可有效降低刀具/工件以及刀具/切屑之间摩擦，从而降低刃口切削力、抑制切削温度的上升并提高刀具的排屑性能；PTEF涂层材料具有的抗酸抗碱的特性可有效降低木材中生物碱和有机弱酸对刀具刃口的腐蚀；为了最大程度发挥PTEF涂层材料的上述优势，添加金属Ni可减小Ni/nano-Al2O3/PTFE复合涂层的摩擦系数，进一步减小刀具切削力，降低切削热；添加nano-Al2O3可大幅提高Ni/nano-Al2O3/PTFE复合涂层的抗磨损性能和热硬性，其较低的热导率可减少切削热传递到刀具的切削刃，防止切削刃受热发生塑性变形而使涂层剥落。
本专利所述CrN/WS2中间缓冲层具有抗冲击载荷的作用，在高速切削过程中可有效应对木材及木质复合材料的不均匀性(如木材节子、人造板多层结构、刨花板断面密度分布)对切削刃口的冲击，提高刀具的抗崩刃性；同时CrN/WS2中间缓冲层可增强自身与CrCN+CrN硬涂层之间的结合强度，提高不同涂层之间的结合力。
鉴于金属切削领域常采用的钛基合金材料涂层，本专利采用铬基合金材料涂层，其优势在于：铬基合金材料的涂层具有更优异的耐化学腐性和抗氧化性，可以更有效地应对木材中的生物碱、有机弱酸和胶黏剂；铬基合金材料涂层具有更低的导热系数，在高速切削过程中，可在工件及切屑与刀具涂层之间形成一道隔热屏障，有效阻止切削热传递到刀具，防止刀具涂层和基体的温度升高，降低基体与涂层界面之间由于受热膨胀而产生的热变形差，减小了界面应力集中，避免涂层从基体上剥落，从而可以减少刀具磨损，提高整个涂层的切削性能。本发明专利中，所述CrCN+CrN硬涂层的高硬度、高耐磨性以及良好的热稳定性配合Ni/nano-Al2O3/PTFE复合软涂层可使所述涂层刀具表现出更好的切削性能并提高刀具的使用寿命。
关于本专利中过渡层的选择，其中Cr过渡层主要作用是提高涂层与刀具基体之间的结合性能；CrN+Cr/Ni过渡层可提高CrN/WS2中间缓冲层和Ni/nano-Al2O3/PTFE复合涂层的结合强度，防止涂层因成分突变而剥落。
附图说明
图1为本发明的一种软硬复合涂层木工刀具的涂层结构示意图。
附图标记：1为刀具基体，2为Cr过渡层，3为CrN硬涂层，4为CrCN硬涂层，5为CrN/WS2中间缓冲层，6为CrN过渡层，7为Cr/Ni过渡层，8为Ni/nano-Al2O3/PTFE复合涂层。
具体实施方式
下面结合说明书附图对本发明的技术方案作进一步说明：
实施例1：
参照附图1，本发明的一种软硬复合涂层木工刀具为木工铣刀，刀具基体材料为硬质合金YG8N；由刀具基体到刀具表面依次为：Cr过渡层、CrCN+CrN硬涂层、CrN/WS2缓冲涂层、CrN+Cr/Ni过渡层、Ni/nano-Al2O3/PTFE复合涂层。采用多弧离子镀+中频磁控溅射的方法制备，其具体步骤如下：
1.前处理：将刀具基体硬质合金机械抛光，去除表面污染层，然后依次放入酒精和丙酮中，每次超声清洗15min，充分干燥后迅速放入镀膜机真空室，真空室本底气压为6.0×10-3Pa，加热基体至300℃，保温40min；
2.离子清洗：通入Ar气，气压为1.5Pa，开启脉冲偏压电源，电压为900V，占空比0.2，辉光清洗15min，偏压降至400V，占空比0.2，气压降至0.5Pa，开启离子源离子清洗10min，开启电弧源Cr靶，偏压400V，靶电流调至60A，离子轰击Cr靶0.5min；
3.沉积Cr过渡层：调整Ar气压至0.5Pa，偏压降至200V，电弧镀Cr过渡层6min；
4.沉积CrCN/CrN硬涂层：调整Ar气压至1.0Pa，偏压180V，Cr靶的靶电流调至80A，开启N2，气压1.8Pa，调整N2流量至180sccm，镀制CrN 55min；通入乙炔，调整乙炔流量为150sccm，镀制CrCN60min；
5.沉积CrN/WS2中间缓冲层：关闭乙炔，关闭电弧源Cr靶，调整Ar和N2压力至0.1Pa，基体温度降至200℃，偏压调至250V，开启WS2中频靶，靶电流为0.6A，开启Cr中频靶，靶电流0.6A，中频磁控溅射共沉积CrN/WS2 70min；
6.沉积CrN+Cr/Ni过渡层：关闭WS2中频靶和Cr中频靶，开启电弧源Cr靶，沉积CrN5min，关闭N2，开启Ni靶，电流调至50A，镀制Cr/Ni 8min；
7.沉积Ni/nano-Al2O3/PTFE复合涂层：关闭电弧源Cr靶，调整Ar气压至0.8Pa，开启Al2O3中频靶，靶电流1.2A，开启PTFE中频靶，靶电流1.5A，沉积Ni/nano-Al2O3/PTFE复合涂层90min；
8.后处理：关闭Al2O3中频靶，PTFE中频靶和Ni靶，关闭离子源及气体源，关闭脉冲偏压，沉积涂层结束。
对照品仍然是以上述所采用的硬质合金YG8N作为刀具基体，按通常所用的物理气相沉积方法分别沉积CrN涂层，然后用本实施例1中所制得的复合涂层刀具A和对照例x进行车削中密度纤维板的对比实验，并且分别对车削过程中刀具切削刃口的温度和切削力进行测量，两组对比实验切削条件同为：中密度纤维板密度为0.75g/cm3，主轴转速n＝1600r/min，进给量f＝0.2mm/r，工件直径100mm。其中：切削温度为切削刃口的最高温度，切削力对比实验结果如下表1所示。
表1：实施例1的本发明涂层刀具与对照品的对比实验结果
由上表1可见，在刀具基体相同、切削条件相同的情况下，本发明的复合涂层刀具在车削中密度纤维板过程中的切削刃口温度比CrN单涂层刀具降低了20.6％，本发明的复合涂层刀具在车削中密度纤维板过程中的平均切削力比CrN单涂层刀具降低了21.2％，本发明的复合涂层刀具在车削中密度纤维板过程中的排屑效果明显优于CrN单涂层刀具。由此可见，发明复合涂层木工刀具的切削性能有显著提高。
实施例2：
参照附图1，本发明的一种软硬复合涂层木工刀具为木工铣刀，刀具基体材料为硬质合金YG8N；由刀具基体到刀具表面依次为：Cr过渡层、CrCN+CrN硬涂层、CrN/WS2缓冲涂层、CrN+Cr/Ni过渡层、Ni/nano-Al2O3/PTFE复合涂层。采用多弧离子镀+中频磁控溅射的方法制备，其具体步骤如下：
1.前处理：将刀具基体硬质合金机械抛光，去除表面污染层，然后依次放入酒精和丙酮中，每次超声清洗18min，充分干燥后迅速放入镀膜机真空室，真空室本底气压为6.0×10-3Pa，加热基体至300℃，保温50min；
2.离子清洗：通入Ar气，气压为1.5Pa，开启脉冲偏压电源，电压为800V，占空比0.2，辉光清洗15min，偏压降至350V，占空比0.2，气压降至0.5Pa，开启离子源离子清洗12min，开启电弧源Cr靶，偏压400V，靶电流调至60A，离子轰击Cr靶0.5min；
3.沉积Cr过渡层：调整Ar气压至0.5Pa，偏压降至200V，电弧镀Cr过渡层6min；
4.沉积CrCN/CrN硬涂层：调整Ar气压至1.0Pa，偏压180V，Cr靶的靶电流调至80A，开启N2，气压1.8Pa，调整N2流量至200sccm，镀制CrN 50min；通入乙炔，调整乙炔流量为180sccm，镀制CrCN 50min；
5.沉积CrN/WS2中间缓冲层：关闭乙炔，关闭电弧源Cr靶，调整Ar和N2压力至0.1Pa，基体温度降至200℃，偏压调至250V，开启WS2中频靶，靶电流为0.6A，开启Cr中频靶，靶电流0.6A，中频磁控溅射共沉积CrN/WS2 60min；
6.沉积CrN+Cr/Ni过渡层：关闭WS2中频靶和Cr中频靶，开启电弧源Cr靶，沉积CrN7min，关闭N2，开启Ni靶，电流调至50A，镀制Cr/Ni 10min；
7.沉积Ni/nano-Al2O3/PTFE复合涂层：关闭电弧源Cr靶，调整Ar气压至0.8Pa，开启Al2O3中频靶，靶电流1.2A，开启PTFE中频靶，靶电流1.5A，沉积Ni/nano-
Al2O3/PTFE复合涂层90min；
8.后处理：关闭Al2O3中频靶，PTFE中频靶和Ni靶，关闭离子源及气体源，关闭脉冲偏压，沉积涂层结束。
对照品仍然是以上述所采用的硬质合金YG8N作为刀具基体，按通常所用的物理气相沉积方法分别沉积CrN涂层，然后用本实施例1中所制得的复合涂层刀具A和对照例x进行铣削纤维板的对比实验，用本实施例1中所制得的复合涂层刀具B和对照例x进行车削中密度纤维板的对比实验，并且分别对车削过程中刀具切削刃口的温度和切削力进行测量，两组对比实验切削条件同为：中密度纤维板密度为0.75g/cm3，主轴转速n＝1600r/min，进给量f＝0.2mm/r，工件直径100mm。其中：切削温度为切削刃口的最高温度，切削力
对比实验结果如下表2所示。
表2：实施例2的本发明涂层刀具与对照品的对比实验结果
由上表2可见，在刀具基体相同、切削条件相同的情况下，本发明的复合涂层刀具在车削中密度纤维板过程中的切削刃口温度比CrN单涂层刀具降低了23.8％，本发明的复合涂层刀具在车削中密度纤维板过程中的平均切削力比CrN单涂层刀具降低了26.4％，本发明的复合涂层刀具在车削中密度纤维板过程中的排屑效果明显优于CrN单涂层刀具。由此可见，本发明复合涂层木工刀具的切削性能有显著提高。
上述实施例是对本发明的说明，不是对本发明的限定，任何对本发明简单变换后的方案均属于本发明的保护范围。

Claims (3)

1.一种软硬复合涂层木工刀具，其特征在于，包括刀具基体(1)以及在该刀具基体(1)外表面设置有刀具涂层，所述刀具涂层由内到外依次为：Cr过渡层(2)、CrN硬涂层(3)、CrCN硬涂层(4)、CrN/WS2中间缓冲层(5)、CrN过渡层(6)、Cr/Ni过渡层(7)和Ni/nano-Al2O3/PTFE复合涂层(8)。
2.根据权利要求1中所述的一种软硬复合涂层木工刀具，其特征在于，所述刀具基体(1)的材料为硬质合金。
3.一种软硬复合涂层木工刀具的制备方法，其特征在于，该制备方法是采用多弧离子镀法+中频磁控溅射法共沉积的方法，其具体制备方法步骤如下：
步骤(1)、前处理：将刀具基体(1)硬质合金机械抛光，去除表面污染层，然后依次放入酒精和丙酮中，每次超声清洗15～20min，充分干燥后迅速放入镀膜机真空室，真空室本底气压为6.0×10-3Pa，加热基体至300℃，保温40～50min；
步骤(2)、离子清洗：通入Ar气，气压为1.5Pa，开启脉冲偏压电源，电压为800～900V，占空比0.2，辉光清洗15min，偏压降至300～400V，占空比0.2，气压降至0.5Pa，开启离子源离子清洗10～15min，开启电弧源Cr靶，偏压400V，靶电流调至60A，离子轰击Cr靶0.5min；
步骤(3)、沉积Cr过渡层(2)：调整Ar气压至0.5Pa，偏压降至200V，电弧镀Cr过渡层6min；
步骤(4)、沉积CrN/CrCN硬涂层：调整Ar气压至1.0Pa，偏压180V，Cr靶的靶电流调至80A，开启N2，气压1.8Pa，调整N2流量至150～200sccm，镀制CrN 50～55min；通入乙炔，调整乙炔流量为150～180sccm，镀制CrCN 50～60min；
步骤(5)、沉积CrN/WS2中间缓冲层(5)：关闭乙炔，关闭电弧源Cr靶，调整Ar和N2压力至0.1Pa，基体温度降至200℃，偏压调至250V，开启WS2中频靶，靶电流为0.6A，开启Cr中频靶，靶电流0.6A，中频磁控溅射共沉积CrN/WS260～70min；
步骤(6)、沉积CrN+Cr/Ni过渡层：关闭WS2中频靶和Cr中频靶，开启电弧源Cr靶，沉积CrN 5～7min，关闭N2，开启Ni靶，电流调至50A，镀制Cr/Ni 8～10min；
步骤(7)、沉积Ni/nano-Al2O3/PTFE复合涂层(8)：关闭电弧源Cr靶，调整Ar气压至0.8Pa，开启Al2O3中频靶，靶电流1.2A，开启PTFE中频靶，靶电流1.5A，沉积Ni/nano-Al2O3/PTFE复合涂层80～100min；
步骤(8)、后处理：关闭Al2O3中频靶，PTFE中频靶和Ni靶，关闭离子源及气体源，关闭脉冲偏压，沉积涂层结束。
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CN103045998A (zh) * 2012-12-06 2013-04-17 浙江工业大学 一种含有CrNiTiAlN五元涂层的制品及制备方法
CN103143761A (zh) * 2013-03-22 2013-06-12 武汉大学 一种AlTiN-MoN纳米多层复合涂层铣刀及其制备方法
CN104029435A (zh) * 2014-06-10 2014-09-10 上海理工大学 一种具有高硬度和低摩擦系数的NbN/WS2多层涂层及其制备方法
CN105862004A (zh) * 2016-06-15 2016-08-17 济宁学院 TiAlCrN&MoS2/Ti/Al/Cr多元叠层润滑涂层刀具及其制备工艺

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