CN108778584A - 表面包覆切削工具 - Google Patents
表面包覆切削工具 Download PDFInfo
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Abstract
本发明提供一种表面包覆切削工具,在碳钢或合金钢等的切削加工中,耐熔敷性及耐缺损性优异,尤其在断续切削等中的耐崩刀性、耐缺损性也优异。一种表面包覆切削工具,在由WC基硬质合金或TiCN基金属陶瓷构成的工具基体的表面形成有至少包括下部层和上部层的硬质包覆层,所述表面包覆切削工具的特征在于,(a)所述硬质包覆层的下部层由TiC层、TiN层、TiCN层、TiCO层及TiCNO层(以下,统称为Ti化合物层)中的一层或两层以上构成,在该下部层的表面形成有作为所述硬质包覆层的上部层的Al2O3层,(b)至少在所述表面包覆切削工具的前刀面的该上部层的最表面,以面积率30~70%形成氧化锆层,所述前刀面中的Al2O3层具有10~200MPa的拉伸残余应力,表面粗糙度Ra为0.25μm以下。
Description
技术领域
本发明涉及一种表面包覆切削工具(以下,简称为“包覆工具”),其中在碳钢或合金钢等的切削加工中,耐熔敷性及耐缺损性优异,尤其在断续切削等中的耐崩刀性、耐缺损性也优异。
背景技术
以往,已知有一种包覆工具,其在由碳化钨(以下,以WC表示)基硬质合金或碳氮化钛(以下,以TiCN表示)基金属陶瓷构成的基体(以下,称为工具基体)的表面设置有硬质包覆层,该硬质包覆层将Ti化合物层作为下部层且将具有α型晶体结构的Al2O3层作为其上部层而构成,其中,Ti化合物层由Ti的碳化物(以下,以TiC表示)层、氮化物(以下,同样地以TiN表示)层、碳氮化物(以下,以TiCN表示)层、碳氧化物(以下,以TiCO表示)层及碳氮氧化物(以下,以TiCNO表示)层中的一层或两层以上构成。而且,为了提高形成有所述硬质包覆层的包覆工具的切削性能,从以往提出了各种方案。
例如,根据专利文献1的方案可得到如下包覆工具,即在基材表面形成有由包含TiN、TiCN和/或TiAlCNO的硬质材料层构成的下部层和由具有特定的择优取向组织的α-Al2O3层构成的上部层,其中,对于作为所述上部层的α-Al2O3层,通过化学蒸镀形成由TiN层、TiC层、TiCN层或它们的组合所组成的层构成的磨损识别层之后,对于前刀面,使用硬度比以往所使用的高硬度的刚玉(α-Al2O3)制粒状喷砂材料低的钢、玻璃、ZrO2制喷砂材料进行喷砂处理,由此在去除了磨损识别层之后的α-Al2O3层中,实现拉伸应力的松弛,并且α-Al2O3层的表面被平滑化,且耐缺损性优异。
专利文献1:日本特开2014-530112号公报
所述专利文献1所示的包覆工具中,认为使用硬度比以往所使用的高硬度的刚玉(α-Al2O3)制粒状喷砂材料低的ZrO2制喷砂材料(平均粒径20~450μm)进行喷砂处理,由此对存在于α-Al2O3层的表面的凸部(即,α-Al2O3层的表面的粒子顶部)及凹部(即,α-Al2O3层的表面的粒子间部)中的凸部进行了平滑化。
然而,所述ZrO2制喷砂材料的硬度低,且磨削加工能力差,因此至少在覆膜表面的凹部(即,所述α-Al2O3层的表面的粒子间部),未进行充分的研磨,且未进行平滑化,从而以所述α-Al2O3层的表面的粒子间部即凹部为起点产生了崩刀,尤其认为当在所述切削初期产生的崩刀增大时,会产生致命的缺损。
于是,作为包覆工具,要求一种在覆膜表面具有更优异的平滑性,且耐熔敷性、耐崩刀性、耐缺损性更优异的包覆工具。
发明内容
本发明人等对在包覆工具中,具有更优异的平滑性,且耐熔敷性、耐崩刀性、耐缺损性更优异的硬质包覆层的结构进行了深入研究的结果,得到了如下见解。
即,发现了如下事实:在工具基体表面作为硬质包覆层至少包覆形成有Al2O3层的包覆工具中,对前刀面的α-Al2O3层最表面的存在所述课题的粒子间部即凹部,导入氧化锆,且在该α-Al2O3层的最表面形成有面积率为30~70%的氧化锆层的情况下,进一步改善了覆膜表面的平滑性,且耐熔敷性、耐崩刀性、耐缺损性也更优异。
而且,具体而言,例如能够通过如下而得到,即,在工具基体的前刀面及后刀面形成作为下部层的TiC、TiN、TiCN中的任意一层或两层以上,在该下部层上形成作为上部层的Al2O3层,接着,针对前刀面,形成30~70%的面积率的锆层。
另外,根据需要,在该Al2O3层的最表面形成由TiN层、TiC层、TiCN层或TiNO层构成的磨损识别层,且去除所述前刀面中的磨损识别层的同时在前刀面最表面形成氧化锆层。
而且,在此所得到的本发明所涉及的包覆工具中,针对前刀面,调整喷砂条件,由此能够在Al2O3层的表面形成30~70%的面积率的锆层而排除Al2O3层最表面的缺陷的影响的同时进一步提高表面平滑性,且提高耐熔敷性,并且能够实现残余应力的减少,因此耐崩刀性、耐缺损性优异。
本发明基于上述见解而成,且具有如下特征:
“(1)一种表面包覆切削工具,在由WC基硬质合金或TiCN基金属陶瓷构成的工具基体的表面形成有至少包括下部层和上部层的硬质包覆层,该表面包覆切削工具的特征在于,(a)所述硬质包覆层的下部层由TiC层、TiN层、TiCN层、TiCO层及TiCNO层(以下,统称为Ti化合物层)中的两层以上构成,其中至少一层由TiCN层构成,在该下部层的表面形成有作为所述硬质包覆层的上部层的Al2O3层,(b)至少在所述表面包覆切削工具的前刀面的该上部层的最表面,以面积率30~70%形成氧化锆层,所述前刀面中的Al2O3层具有10~200MPa的拉伸残余应力,且表面粗糙度Ra为0.25μm以下。
(2)根据所述(1)所述的表面包覆切削工具,其特征在于,所述前刀面中的TiCN层的拉伸残余应力为10~250MPa。
(3)根据所述(1)或(2)所述的表面包覆切削工具,其特征在于,在作为后刀面的上部层的所述Al2O3层的最表面形成有TiN层、TiC层、TiCN层或TiNO层。”
以下,对本发明的包覆工具进行详细说明。
下部层;
由Ti化合物层构成的下部层基本上设置在由Al2O3层构成的上部层的下部,与工具基体和上部层均牢固密接,具有有助于提高硬质包覆层与工具基体的密接性的作用,通过下部层自身的特性的高硬度而使硬质包覆层具备耐磨损性,尤其具备优异的耐后刀面磨损性。
作为对这种下部层适合的膜种类,能够举出TiC层、TiN层、TiCN层、TiCO层及TiCNO层中的两层以上的Ti化合物层,其中至少一层为TiCN层而构成下部层。
并且,对于下部层的平均层厚并无特别限定,该平均层厚小于3μm时,无法充分发挥所述作用,另一方面,该平均层厚大于20μm时,会对耐缺损性带来不良影响,因此优选将下部层的平均层厚设为3~20μm。
上部层:
由Al2O3层构成的上部层中,根据其硬度、耐热性、耐氧化性而提高包覆工具的耐磨损性。本发明中,上部层的层厚并无特别限制,Al2O3层的平均层厚小于1μm时,在长期使用中无法发挥优异的耐磨损性,另一方面,该平均层厚大于15μm时,容易发生崩刀、缺损、剥离等异常损伤。因此,优选将由Al2O3层构成的上部层的平均层厚设为1~15μm。
前刀面的硬质包覆层:
形成于前刀面的硬质包覆层由如下构成,即,由Ti化合物层构成的下部层、由Al2O3层构成的上部层及在最表面以面积率30~70%形成的氧化锆层。
根据后述的本发明的包覆工具的制造方法的一例,首先,在工具基体的前刀面及后刀面形成作为下部层的Ti化合物层,接着,在下部层表面形成作为上部层的Al2O3层,然后,对于前刀面,进行用于提高前刀面的Al2O3层的表面平滑性,同时实现残余应力的减少的喷砂处理,由此形成以面积率30~70%覆盖Al2O3层的表面的氧化锆层,同时将表面粗糙度Ra调整为0.25μm以下,优选调整为0.20μm以下,从而提高耐崩刀性和耐熔敷性。
并且,在喷砂处理之后,Al2O3层内的残余应力得以松弛,将拉伸残余应力的值设为10~200MPa,优选设为10~150MPa,由此提高作为硬质包覆层整体的耐崩刀性、耐缺损性、耐剥离性。
而且,将TiCN层的拉伸残余应力的值设为10~250MPa,优选设为10~150MPa,由此提高作为硬质包覆层整体的耐崩刀性、耐缺损性、耐剥离性。
另外,关于前刀面的Al2O3层的最表面上的氧化锆层的面积率,指的是针对前刀面进行SEM观察及EDS分析而测量得到的面积率。
关于前刀面的表面粗糙度Ra,按照JIS B0601:2001,以截止值:0.08mm、基准长度:0.8mm、扫描速度:0.1mm/秒使用触针式表面粗糙度测量仪进行了测量。
并且,上部层的Al2O3层的残余应力利用sin2Ψ法,且使用利用了Cuκα的X射线衍射装置进行测量。测量中,关于α-Al2O3,使用(13_10)面的衍射峰,作为杨氏模量使用384GPa,作为泊松比使用0.232来实施计算。
同样地,下部层的TiCN层的残余应力使用(422)面的衍射峰,作为杨氏模量使用480GPa,作为泊松比使用0.2来实施计算。
后刀面的硬质包覆层:
形成于后刀面的硬质包覆层由如下构成,即,由Ti化合物层构成的下部层、由Al2O3层构成的上部层及根据需要由形成于Al2O3层的最表面的TiN层、TiC层、TiCN层或TiNO层构成的磨损识别层。
硬质包覆层的制作方法:
本发明的硬质包覆层例如能够通过以下方法进行制作。
首先,在工具基体表面,通过通常的化学蒸镀法,以规定的平均层厚形成作为下部层的Ti化合物层及作为上部层的Al2O3层。
接着,在上部层的Al2O3层的最表面,通过通常的化学蒸镀法,以平均层厚成为0.1~1μm左右的层厚的方式形成TiN层、TiC层、TiCN层或TiNO层。
接着,对前刀面实施湿式喷砂处理,在前刀面形成有TiN层、TiC层、TiCN层、TiNO层的情况下,去除所形成的TiN层、TiC层、TiCN层、TiNO层的同时对Al2O3层的最表面形成以面积率30~70%覆盖的氧化锆层的方式进行处理,由此来制作。
喷砂处理:
关于喷砂处理,若对更具体的条件进行说明,则例如在如下条件下,对前刀面实施喷砂处理,尤其通过调整磨粒形状及磨粒尺寸、喷砂压力、投射角度等,能够调整上部层的Al2O3层的残余应力及Al2O3层的表面层的氧化锆层的面积率。
喷砂处理液:磨粒+水、
磨粒:ZrO2粒、
磨粒形状:球形和/或多边形、
磨粒尺寸(粒径):125-425μm(球形)/<125μm(多边形)
磨粒比例:70-90质量%(球形)/10-30质量%(多边形)
磨粒浓度:20体积%以下、
喷砂压力:0.10-0.35MPa
相对于前刀面的法线的投射角度:0-20度
投射时间:5-30秒
关于本发明的包覆工具,在前刀面,通过在作为上部层的Al2O3层的最表面设置面积率30~70%的氧化锆层,实现了最表面的更优异的平滑化,因此耐熔敷性及耐缺损性优异,尤其在断续切削等的耐崩刀性、耐缺损性方面也优异,且在长期使用中发挥优异的切削性能。
具体实施方式
接着,通过实施例对本发明的包覆工具进行具体的说明。
另外,在此,作为工具基体,示出使用了WC基硬质合金的例子,但作为工具基体,使用了TiCN基金属陶瓷的情况也相同。
[实施例1]
作为原料粉末,准备均具有1~3μm的平均粒径的WC粉末、TiC粉末、TiN粉末、TaC粉末、NbC粉末、Cr3C2粉末及Co粉末,将这些原料粉末配合成表1所示的配合组成,添加蜡在丙酮中球磨混合24小时,并减压干燥之后,以98MPa的压力冲压成型为规定形状的压坯,将该压坯在5Pa的真空中,在以1370~1470℃的范围内的规定温度保持1小时的条件下进行真空烧结,烧结之后,对切削刃部实施R:0.05mm的刃口修磨加工,由此制造了由ISO·CNMG120408规定的刀片形状的WC基硬质合金制工具基体A~工具基体C。
接着,将该工具基体装入通常的化学蒸镀装置。
首先,在表2(表2中的l-TiCN表示具有日本特开平6-8010号公报中所记载的纵向生长的晶体组织的TiCN层的形成条件,除此以外,表示通常的粒状晶体组织的形成条件)所示的条件下,作为硬质包覆层的下部层蒸镀形成了表3所示的目标层厚的Ti化合物层。
接着,在所述下部层的表面,在表2所示的条件下蒸镀形成了表3所示的目标层厚的Al2O3层及TiN层。
接着,作为磨粒使用ZrO2粒,在表4所示的条件下对前刀面实施湿式喷砂处理,从而制作了表5所示的前刀面具有Al2O3层及氧化锆层的本发明的包覆工具1~包覆工具3。
用扫描型电子显微镜对上述本发明的包覆工具1~包覆工具3的下部层、上部层的厚度进行了测量(纵截面测量)的结果,均示出与目标层厚实质上相同的平均层厚(测量5个部位的平均值)。
并且,对上述本发明的包覆工具1~包覆工具3的Al2O3层的最表面进行SEM观察及EDS分析,由此对存在于前刀面的Al2O3层的表面的氧化锆层的面积率进行了测量。
表5中示出所测量的氧化锆层的面积率。
并且,关于以上述所制作的本发明的包覆工具1~包覆工具3,对前刀面的表面粗糙度Ra进行了测量。
另外,表面粗糙度Ra的测量按照JIS B0601:2001,以截止值:0.08mm、基准长度:0.8mm、扫描速度:0.1mm/秒用触针式表面粗糙度测量仪进行了测量。
表5中示出其结果。
而且,关于在上述中所制作的本发明的包覆工具1~包覆工具3,对Al2O3层及TiCN层的残余应力进行了测量。
残余应力利用sin2Ψ法,且使用利用了Cuκα的X射线衍射装置进行了测量。测量中,关于α-Al2O3,使用(13_10)面的衍射峰,作为杨氏模量使用384GPa,作为泊松比使用0.232来实施了计算,关于TiCN,使用(422)面的衍射峰,作为杨氏模量使用480GPa,作为泊松比使用0.2来实施了计算。表5中示出其结果。
[表1]
[表2]
[表3]
[表4]
[表5]
以比较的目的,对于以上述所制作的WC基硬质合金制工具基体A~工具基体C,在表2所示的条件下,作为硬质包覆层的下部层蒸镀形成表6所示的目标层厚的Ti化合物层之后,接着,在该下部层的表面,在表2所示的条件下,蒸镀形成了表6所示的目标层厚的Al2O3层及TiN层。
接着,在表7所示的条件下,对前刀面实施喷砂处理而制作了表8所示的在前刀面具有Al2O3层的比较例的包覆工具1~包覆工具3。
并且,对上述比较例的包覆工具1~包覆工具3的Al2O3层的最表面进行SEM观察及EDS分析,由此对存在于前刀面的Al2O3层的表面的氧化锆层的面积率进行了测量。
表8中示出所测量的氧化锆层的面积率。
并且,关于在上述中所制作的比较例的包覆工具1~包覆工具3,通过与本发明的包覆工具1~包覆工具3相同的方法,对前刀面的表面粗糙度Ra进行测量,进而对Al2O3层及TiCN层的残余应力进行了测量。
表8中示出其结果。
[表6]
[表7]
[表8]
接着,关于上述本发明的包覆工具1~包覆工具3及比较例的包覆工具1~包覆工具3,均以利用固定夹具紧固在工具钢制车刀的前端部的状态,且在以下切削条件A及切削条件B下实施了切削试验。
《切削条件A》
被切削材料:JIS·S45C的圆杆、
切削速度:250m/min、
切削深度:1.5mm、
进给量:0.25mm/rev、
切削时间:10分钟
这一条件下的碳钢的干式切削试验。
《切削条件B》
被切削材料:JIS·SNCM439的长边方向上等间隔的4个凹槽圆杆、
切削速度:150m/min、
切削深度:3.0mm、
进给量:0.25mm/rev、
切削时间:6分钟
这一条件下的合金钢的干式断续切削试验。
上述切削试验中,观察了有无发生熔敷,有无发生崩刀,有无发生缺损。表9中示出切削试验结果。
[表9]
从表5、表8、表9所示的结果,能够理解到本发明的包覆工具在作为前刀面的上层的Al2O3层的最表面以面积率30~70%具有氧化锆层,且耐熔敷性、耐崩刀性及耐缺损性优异。
相对于此,比较例的包覆工具中,均未在作为前刀面的上层的Al2O3层的最表面形成氧化锆层,即使形成有氧化锆层,面积率也小于30%,其结果,关于耐熔敷性、耐崩刀性及耐缺损性,不能说具有充分的切削性能。
产业上的可利用性
如上,本发明所涉及的包覆工具的切削性能优异,因此能够实现切削装置的高性能化以及切削加工的省力化及节能化带来的低成本化及高操作性。
Claims (3)
1.一种表面包覆切削工具,在由WC基硬质合金或TiCN基金属陶瓷构成的工具基体的表面形成有至少包括下部层和上部层的硬质包覆层,所述表面包覆切削工具的特征在于,
(a)所述硬质包覆层的下部层由TiC层、TiN层、TiCN层、TiCO层及TiCNO层中的两层以上构成,其中至少一层由TiCN层构成,在该下部层的表面形成有作为所述硬质包覆层的上部层的Al2O3层,以下,将TiC层、TiN层、TiCN层、TiCO层及TiCNO层统称为Ti化合物层,
(b)至少在所述表面包覆切削工具的前刀面的该上部层的最表面,以面积率30~70%形成氧化锆层,所述前刀面中的Al2O3层具有10~200MPa的拉伸残余应力,且表面粗糙度Ra为0.25μm以下。
2.根据权利要求1所述的表面包覆切削工具,其特征在于,
所述前刀面中的TiCN层的拉伸残余应力为10~250MPa。
3.根据权利要求1或2所述的表面包覆切削工具,其特征在于,
在作为后刀面的上部层的所述Al2O3层的最表面形成有TiN层、TiC层、TiCN层或TiNO层。
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CN108778584B (zh) | 2020-10-20 |
JP2017177292A (ja) | 2017-10-05 |
EP3437772A4 (en) | 2019-10-09 |
WO2017170687A1 (ja) | 2017-10-05 |
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