CN110653432B - 一种自润滑挤压丝锥 - Google Patents

一种自润滑挤压丝锥 Download PDF

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CN110653432B
CN110653432B CN201910953276.4A CN201910953276A CN110653432B CN 110653432 B CN110653432 B CN 110653432B CN 201910953276 A CN201910953276 A CN 201910953276A CN 110653432 B CN110653432 B CN 110653432B
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李士鹏
秦旭达
武卫洲
刘文韬
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Hangzhou Zhenjiang Precision Tools Co ltd
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    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
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Abstract

本发明公开了一种自润滑挤压丝锥，属于机械切削加工领域。该丝锥基体材料为高速钢，丝锥基体表面有彼此交错分布的微米级沟槽，并涂覆多层涂层，该涂层结构由基体向外依次为Cr‑CrN过渡层、AlCrN涂层、CrN‑Cr过渡层、高Cr含量WS2/Cr复合涂层、低Cr含量WS2/Cr复合涂层和WS2涂层，该涂层结合了AlCrN涂层高硬度和WS2涂层减摩性，且Cr元素的梯度变化提高了每一层间的结合强度和涂层承载能力；而基体表面微米级沟槽可储存WS2，有效延长丝锥的润滑性。该丝锥显著减小螺纹挤压过程中扭矩和丝锥的粘结，明显提高丝锥性能。

Description

一种自润滑挤压丝锥
技术领域
本发明属于机械加工制造技术领域，特别涉及一种适合高塑性金属内螺纹加工过程中兼具耐磨性与减摩性的自润滑丝锥。
背景技术
攻丝是加工效率较低的一道工序，内螺纹加工中，相比于切削丝锥，挤压丝锥具有无切屑、螺纹强度高、精度高等优点，在铝合金、低碳钢、不锈钢等具有良好塑性的材料中应用广泛，近年来在钛合金、高温合金等特殊结构中也有应用。但在螺纹挤压过程中，丝锥与工件间发生严重的摩擦，存在润滑不充分、易粘结、扭矩大等问题。
目前挤压丝锥应用最广的涂层为耐磨涂层，可以有效提高丝锥耐磨性，但摩擦系数还是较高。随着涂层技术的发展，多元化、多层化、复合化成为发展的趋势，使涂层能够整合多种涂层材料的优点，显著提升涂层刀具的综合性能，满足不同应用环境的需要。二硫化钨(WS2)具有减摩性好(摩擦系数很低<0.1)、粘附性高等优点，已在汽车、卫星等摩擦件中得到应用，但其耐磨性低、可持续性差，导致无法在切削加工领域广泛应用。
申请号为201310141014.0的中国专利公开了“一种应用于挤压丝锥的涂层”，该涂层有TiAlCrN、CrN交替组成的耐磨层和WC/C润滑层，该涂层有较好的耐磨性和抗粘着性，但WC/C层摩擦系数在0.2左右，且由于含碳元素，其与耐磨层TiAlCrN结合强度不易保证。
申请号为200910256536.9的中国专利公开了“ZrN+MoS2软硬涂层刀具及其制备方法”，该涂层刀具表面为MoS2层，MoS2层与刀具基体之间为Ti过渡层和ZrN硬涂层。该涂层刀具综合了ZrN涂层的高硬度、高耐磨性及MoS2涂层的润滑性，一定程度上改善了刀具在干切削过程中的性能，但由于MoS2涂层耐磨性低，很快发生磨损，其减摩作用时间较短。
申请号为201110089826.6的中国专利公开了“一种微织构自润滑钻头及其制备方法”，该钻头前刀面刀-屑接触区带有多个存储固体润滑剂的微织构，沟槽中填充润滑剂，该钻头利用微织构延长润滑剂的作用时间，较好提高了钻头切削性能，但该技术无法应用于螺纹挤压过程，挤压丝锥对于微沟槽的位置、深度等有较高要求，选用不当会降低挤压丝锥结构强度，造成牙型的破坏。
发明内容
本发明的目的在于克服现有技术的不足，提供一种自润滑挤压丝锥，该丝锥在保证丝牙强度的同时，还兼具耐磨性和减摩性，可有效减小螺纹挤压过程中扭矩和丝锥的粘结，明显提高了丝锥性能。
本发明的一种自润滑挤压丝锥，包括丝锥基体，所述的丝锥基体材料为高速钢，在所述的丝锥基体的螺纹牙的每个牙型面的下部开有多个微米级沟槽，每个螺纹牙的两个牙型面上的多个沟槽彼此交错分布，每个沟槽与丝锥轴线在牙型面上投影的夹角为0～20°，每个沟槽长度为800～1500μm，每个沟槽宽度为20～60μm，沟槽深度为30～80μm，每个沟槽与牙顶保持设定距离，所述的设定距离的最小值为200～600μm，同一牙型面前后相邻的两个沟槽之间的距离为800～2000μm；
所述的丝锥基体的表面为渗Cr层，在所述的渗Cr层上依次涂覆有Cr-CrN过渡层、AlCrN涂层、CrN-Cr过渡层、含有WS2和Cr且Cr原子百分比为20～30％的高Cr含量WS2/Cr复合涂层、含有WS2和Cr且Cr原子百分比为5～15％的低Cr含量WS2/Cr复合涂层和WS2涂层。
本发明与现有发明相比，本发明具有以下优势：
本发明的自润滑挤压丝锥，AlCrN层可保证丝锥耐磨性，WS2/Cr层及WS2层赋予丝锥自润滑功能。螺纹牙之间有特殊结构微沟槽，在丝锥工作过程中可贮存WS2及加工过程中的润滑油，延长润滑减摩作用时间；同时，微沟槽不过牙顶、距牙顶200～600μm的安全距离可保证丝牙强度，不会使其在挤压过程中发生破坏。该丝锥可有效减小螺纹挤压过程中的摩擦系数和扭矩，降低粘结磨损，提高丝锥寿命。该自润滑丝锥可广泛应用于钛合金、铝合金、不锈钢及其他金属螺纹加工中。
附图说明
图1是本发明的一种自润滑挤压丝锥的结构示意图；
图2是图1所示的丝锥的A处结构放大示意图；
图3为图2所示的沟槽的B-B截面即横截面形状示意图；
图4为自润滑挤压丝锥的软硬多层复合涂层的涂层结构示意图。
具体实施方式
下面结合附图和具体实施例对本发明加以详细说明。
如附图所示本发明的一种自润滑挤压丝锥，包括丝锥基体1，所述的丝锥基体1材料为高速钢，在所述的丝锥基体1的螺纹牙的每个牙型面的下部3开有多个微米级沟槽2，每个螺纹牙的两个牙型面上的多个沟槽2彼此交错分布(也即同一个螺纹牙的两个牙型面上的多个沟槽2彼此位置不同)，每个沟槽与丝锥轴线在牙型面上投影的夹角7为0～20°，每个沟槽长度8为800～1500μm，每个沟槽宽度9为20～60μm，沟槽深度10为30～80μm，每个沟槽与牙顶4保持设定距离，所述的设定距离6的最小值为200～600μm，同一牙型面前后相邻的两个沟槽之间的距离5为800～2000μm；所述的沟槽加工后在丝锥表面无毛刺、凸起；。
所述的丝锥基体1的表面为渗Cr层，加工方法为：加工沟槽2后，所述的丝锥基体1通过Cr离子在-800V～-1000V偏压下轰击，形成渗Cr层。
在所述的渗Cr层上依次涂覆Cr-CrN过渡层11、AlCrN涂层12、CrN-Cr过渡层13、含有WS2和Cr且Cr原子百分比为20～30的高Cr含量WS2/Cr复合涂层14、含有WS2和Cr且Cr原子百分比为5～15的低Cr含量WS2/Cr复合涂层15和WS2涂层16。此涂层结构，可在丝锥基体1与AlCrN涂层12间、AlCrN涂层12与WS2涂层16间实现元素的梯度变化，提高各层间的结合强度，增强减摩性和耐磨性。
进一步优选的，其中AlCrN涂层12的厚度2～3μm，高Cr含量WS2/Cr涂层14厚度为1～2μm、低Cr含量的WS2/Cr涂层15的厚度为2～3μm，WS2涂层16的厚度为3～6μm。此涂层厚度可保证AlCrN涂层具有高的硬度和耐磨性以及WS2/Cr和WS2层有较好的润滑性和持久性。
下面给出本发明的最佳实施例：
实施例1
M12挤压丝锥加工铝合金螺纹，该丝锥的基体为W2Mo9Cr4VCo8高速钢，在螺纹牙部分，有微米级沟槽，沟槽与丝锥轴线夹角为0°-10°，长度1200μm，沟槽宽度50μm，深度70μm；沟槽不过牙顶，相错分布于牙顶两侧，沟槽与牙顶最小距离为600μm，沟槽与沟槽间距离为1500μm；沟槽加工后，丝锥经流体抛光5min，平滑化沟槽边缘，去除沟槽表面的凸起、毛刺，以免沟槽边缘对工件产生切削作用。随后经过酒精+丙酮20min超声清洗后，充分干燥，在真空室中-1000V偏压下Cr离子轰击表面10min，形成表面渗Cr层。采用多弧离子镀方法在丝锥表面依次涂覆Cr-CrN过渡层、AlCrN涂层、CrN-Cr过渡层，其中AlCrN层厚度2μm，过渡层厚度均为0.3μm；然后采用射频磁控溅射再继续涂覆WS2/Cr层，分为2层，高Cr含量WS2/Cr层厚1μm、Cr原子含量30at.％，低Cr含量WS2/Cr层厚2μm、Cr原子含量为8at.％；再用射频磁控溅射法沉积WS2涂层，厚度4μm。该丝锥在铝合金螺纹挤压加工过程中，能显著降低丝锥表面粘结、减小扭矩、提高丝锥寿命。
实施例2
M8挤压丝锥加工不锈钢螺纹，该丝锥的基体为W2Mo9Cr4VCo8高速钢，在螺纹牙部分，有微米级沟槽，沟槽与丝锥轴线夹角为10°-20°，沟槽与沟槽间互相平行，沟槽宽度35μm，深度50μm，长度1000μm；沟槽不过牙顶，相错分布与牙顶两侧，沟槽与牙顶最小距离为500μm，沟槽与沟槽间距离为800μm；沟槽加工后，丝锥经流体抛光3min，平滑化沟槽边缘，去除沟槽表面的凸起、毛刺，以免沟槽边缘对工件产生切削作用。随后经过酒精+丙酮20min超声清洗后，充分干燥，在真空室中-800V偏压下Cr离子轰击表面8min，形成表面渗Cr层。采用多弧离子镀方法在丝锥表面依次涂覆Cr-CrN过渡层、AlCrN涂层、CrN-Cr过渡层，其中AlCrN层厚度2μm，过渡层厚度均为0.3μm；然后采用射频磁控溅射再继续涂覆WS2/Cr层，分为两层，高Cr含量WS2/Cr层厚2μm、Cr原子含量20at.％，低Cr含量WS2/Cr厚3μm、Cr原子含量为5at.％；再用射频磁控溅射法沉积WS2涂层，厚度5μm。该丝锥在不锈钢螺纹挤压过程中，可有效减小扭矩、减少刀具表面粘结、降低丝锥扭断风险。

Claims (2)

1.一种自润滑挤压丝锥，包括丝锥基体，其特征在于：所述的丝锥基体材料为高速钢，在所述的丝锥基体的螺纹牙的每个牙型面的下部开有多个微米级沟槽，每个螺纹牙的两个牙型面上的多个沟槽彼此交错分布，每个沟槽与丝锥轴线在牙型面上投影的夹角为0～20°，每个沟槽长度为800～1500μm，每个沟槽宽度为20～60μm，沟槽深度为30～80μm，每个沟槽与牙顶保持设定距离，所述的设定距离的最小值为200～600μm，同一牙型面前后相邻的两个沟槽之间的距离为800～2000μm；
所述的丝锥基体的表面为渗Cr层，在所述的渗Cr层上依次涂覆有Cr-CrN过渡层、AlCrN涂层、CrN-Cr过渡层、含有WS2和Cr且Cr原子百分比为20～30％的高Cr含量WS2/Cr复合涂层、含有WS2和Cr且Cr原子百分比为5～15％的低Cr含量WS2/Cr复合涂层和WS2涂层。
2.根据权利要求1所述的自润滑挤压丝锥，其特征在于：所述的AlCrN涂层的厚度2～3μm，高Cr含量WS2/Cr复合涂层厚度为1～2μm、低Cr含量的WS2/Cr复合涂层的厚度为2～3μm，WS2涂层的厚度为3～6μm。
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