CN1854335A - 涂层刀具刀片 - Google Patents

涂层刀具刀片 Download PDF

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CN1854335A
CN1854335A CNA2006100736665A CN200610073666A CN1854335A CN 1854335 A CN1854335 A CN 1854335A CN A2006100736665 A CNA2006100736665 A CN A2006100736665A CN 200610073666 A CN200610073666 A CN 200610073666A CN 1854335 A CN1854335 A CN 1854335A
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卡尔·比约恩曼德
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
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    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
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Abstract

一种制造涂层刀具刀片的方法，其通过CVD向烧结碳化物的、钛基的或陶瓷的基底上沉积下列物质：总厚度为约2－50μm的硬层体系，其包括选自碳化钛、氮化钛、碳氮化钛、羰基化钛和氧化铝的至少一种层，和外面的1－15μm厚的氧化铝层或(Al2O3+ZrO2)*N多层；TiOx的倒数第二最外层，其中X的范围为1至2；和0.3－2μm厚的TiCxNyOz最外层，其中x+y+z＝1，x≥0，y≥0且z≥0；然后后处理以至少除去刃线上和倾斜面上的所述最外层。

Description

涂层刀具刀片
本发明涉及适于金属的切削成型加工(chip forming machining)的涂层刀具及其生产方法。本发明提供了可靠的方法，用以在涂层后处理过程中除去切削刀片的选定面上的涂层。
现代高生产率的金属切削成型加工需要具有出色的耐磨损性能的可靠工具。这通过使用涂有耐磨损涂层的烧结碳化物刀体(cementedcarbide tool body)来实现，该耐磨损涂层为单层或多层类型，最常见包括TiC、TiN、TiCN和Al2O3的耐磨层。使用CVD、PVD或类似的涂层技术以向烧结碳化物刀体上沉积不同的层。
EP-A-693574描述了在机械加工过程中工具的不同部位怎样经受了不同类型的磨损。因为不同的涂层具有承受不同类型磨损的能力，所以建议在倾斜面(rake face)上有Al2O3最外层，因为其具有承受扩散类型的磨损的能力；并且建议在余隙(clearance)侧面上有MeCxNyOz类型的最外层，因为其具有对侧面磨损的高度耐受性，其中Me是选自元素周期表的IVB、VB、VIB族的金属。TiCxNyOz顶层，或特别地，金色的TiN、ZrN或HfN顶层也使肉眼容易区分用过的与没用过的切削刃。因此，仅从刃线(edge line)上或从倾斜面和刃线上机械除去TiCxNyOz层以暴露Al2O3层。通常这通过对涂层刀片的后处理如喷砂(blasting)或刷光来实现。
在后处理过程中，非常重要的是不要减小沿刃线的Al2O3层的厚度。因此所用方法必须很柔和，从而仅除去TiCxNyOz顶层，尽可能不要触及刃线处的Al2O3。但是，所述的后处理方法难以令人满意，因为经过喷砂工序后TiCxNyOz残余物有时会出现在Al2O3表面上。因为TiCxNyOz残余物被焊接(welding)到工件上，被焊接到工件上，导致涂层拉出(withdrawal)和较低的刀片寿命，所以在Al2O3表面上的TiCxNyOz残余物降低了耐剥落性(flaking resistance)。经过喷砂工序后这些残余物的又一影响是肉眼可见的Al2O3表面的变色。在生产中，通常重复或调整喷砂工序以除去残余的TiCxNyOz，但是这经常造成损坏，例如切削刃线处涂层的剥落。因此找到解决该问题的方法是很重要的，尤其是对薄的Al2O3涂层而言，其中通常使用较低的喷砂压力以避免损坏切削刃处的涂层，因而使得喷砂工序后残留TiCxNyOz的危险性更高。
在美国专利第6,426,137号中，使用氧化钛层以减少向切削刃上污染(smearing)。在该情况下氧化钛层完全覆盖Al2O3表面，充当厚度为0.1-3μm的顶层。在另一实施方案中以TiN层来对所述的氧化钛层进行涂层。
本发明的目的是解决经后处理的刃线和倾斜面上残余TiCxNyOz的问题。
图1A-1C为200X光学显微镜显微照片，其中显示了根据本发明的刀片的Al2O3最外层，其具有经过喷砂工序后各种量的氮化钛残余物，其中在图1A中：
A-TiN残余物，和
B-Al2O3
图2A-2C为500X扫描电子显微镜显微照片，其中显示了根据本发明的刀片的Al2O3最外层，其具有经过喷砂工序后各种量的氧化钛残余物，其中在图2A中：
A-Ti2O3残余物，和
B-Al2O3
图3为200X光学显微镜显微照片，其中显示了根据现有技术的刀刃(insert edge)的Al2O3最外层，其具有经过喷砂工序后的氮化钛，其中：
A-TiN残余物，和
B-Al2O3。
本发明提供了制造涂层刀具刀片的方法，该涂层刀具刀片具有顶面(upper face)(倾斜面)、反面和至少一个余隙面，该余隙面与所述的顶面及反面相交形成切削刃，所述方法包括使用已知的CVD方法向烧结碳化物的、钛基的或陶瓷的基底上沉积下列物质：
-总厚度为2-50μm的硬层体系，包括选自碳化钛、氮化钛、碳氮化钛、羰基化钛(titanium carboxide)和氧化铝的至少一种层，和外面的1-15μm厚的氧化铝层或(Al2O3+ZrO2)*N多层，-TiOx的倒数第二最外层，其中X的范围为1至2，优选为1.3至1.9，厚度优选为0.05-3μm，最优选为0.1-1.0μm，以及-0.3-2μm厚的TiCxNyOz最外层，其中x+y+z＝1，x≥0，y≥0且z≥0，优选TiN、TiC或TiCxNy的单层或多层，其中x+y＝1，x≥0且y≥0，
然后进行后处理，优选喷砂或刷光，至少除去刃线上和倾斜面上所述的最外层。为保证刀片的性能并确保不会因为TiN残余物而有任何变色(discoloration)，优选地，就表面覆盖度而言，所述的后处理还至少除去50％的TiOx层，即，优选暴露所述硬层体系的至少50％的外层表面。
使用具有所提议的厚度的TiOx，其硬度为Al2O3硬度的20％，将TiCxNyOz层提到粗糙的Al2O3表面的上方(above)，从而可以通过喷砂介质(blasting media)将它完全除去。另外，与例如TiN的情况一样，TiOx是透明的氧化物，这意味着留在Al2O3表面上的任何残余物是肉眼不可见的。
本发明还涉及由烧结碳化物、钛基碳氮化物或陶瓷制成的涂层刀具刀片，其具有顶面(倾斜面)、反面和至少一个余隙面，该余隙面和所述的顶面与反面相交形成切削刃。以硬层体系涂层所述刀片，该硬层体系的总厚度为2-50μm，包括选自碳化钛、氮化钛、碳氮化钛、羰基化钛和氧化铝的至少一种层，和外面的1-15μm厚的氧化铝层或(Al2O3+ZrO2)*N多层，所述氧化铝优选为晶粒细化的晶粒粒度为0.5至3μm的α-Al2O3，在所述硬层体系上提供了TiOx层，其中X的范围为1至2，优选1.3至1.9，厚度优选为0.05-3μm，最优选为0.1-1.0μm，所述TiOx层为切削刃线和倾斜面上的最外层，并且在余隙侧面上的所述TiOx层上提供了0.3-2μm厚的TiCxNyOz最外层，其中x+y+z＝1，x≥0，y≥0且z≥0，优选TiN、TiC或TiCxNy的单层或多层，其中x+y＝1，x≥0且y≥0。
以5000X放大沉积态(as deposited)的Al2O3层表面，由SEM顶视显微照片确定Al2O3层的晶粒粒度。以随机方向划三条直线，采用沿所述线的晶界间的平均距离来作为晶粒粒度测定值。
在一个优选实施方案中，刃线和倾斜面上的所述TiOx层覆盖了所述硬层体系的小于50％的表面。
实施例1
A(发明)：通过CVD技术按照下列顺序来涂层烧结碳化物切削刀片CNMG120408-PM，其组分为5.5wt-％Co、8.6wt-％立方体碳化物(TiC+TaC+NbC)和余量WC，所述顺序为0.7μm TiN、4.0μmTi(CN)、5.0μm α-Al2O3、0.7μm氧化钛(Ti2O3)和0.7μm TiN。
通过CVD技术沉积Ti2O3层，其中将待涂层的基底保持在1010℃的温度下并与含TiCl4、CO2和HCl的氢载体气体接触。以下列顺序开始成核：反应气体HCl和CO2在氢气气氛中首先进入反应器，然后是TiCl4。以CVD方法以下列工艺参数沉积氧化钛层：
    气流(％)，T＝1010℃，P＝55mbar     Ti2O3
    H2(％)     88.0
    HCl(％)     7.6
    CO2(％)     2.1
    TiCl4(％)     2.3
    沉积速度(μm/hrs)     1.5
通过已知的CVD方法沉积其它层。
通过使用Al2O3砂粒，在不同的喷砂压力即1.8、2.0和2.2巴下喷砂来后处理所述的涂层刀片。
B(现有技术)：通过CVD技术按照下列顺序涂层烧结碳化物切削刀片CNMG120408-PM，其组分为5.5wt-％Co、8.6wt-％立方碳化物(TiC+TaC+NbC)和余量WC，所述顺序为0.7μm TiN、4.0μmTi(CN)、5.0μm α-Al2O3和0.7μm TiN。
通过使用Al2O3砂粒在喷砂压力2.4巴下喷砂来后处理所述的涂层刀片。
用光学显微镜(200X)研究A型和B型刀片以发现Al2O3表面上的任何TiN残余物，并进一步用扫描电子显微镜(500X)来检测Ti2O3残余物。采用图像分析(Leica Quantimet 500)确定残余Ti2O3的量。结果总结于下表中。
样品A，在1.8巴下喷砂(本发明) 通过光学显微镜观察到Al2O3表面上有一些量的TiN残余物(图1A)。肉眼观察发现刀片表面稍微变色。 ＜75％的Al2O3表面被残余的Ti2O3覆盖(图2A)。
样品A，在2.0巴下喷砂(本发明) ＜1％的Al2O3表面被残余的TiN覆盖(图1B)。刀片表面没有变色。 ＜50％的Al2O3表面被残余的Ti2O3覆盖(图2B)。
样品A，在2.2巴下喷砂(本发明) 无TiN残余物(图1C)。刀片表面没有变色。 ＜30％的Al2O3表面被残余的Ti2O3覆盖(图2C)。
样品B，在2.4巴下喷(现有技术) 通过光学显微镜观察到Al2O3表面上有大量的TiN残余物(图2)。肉眼观察发现刀片表面变色。

Claims (6)

1.一种制造涂层刀具刀片的方法，该涂层刀具刀片具有顶面(倾斜面)、反面和至少一个余隙面，该余隙面与所述的顶面及反面相交形成切削刃，其特征在于通过CVD向烧结碳化物的、钛基的或陶瓷的基底上沉积下列物质：
—总厚度为约2-50μm的硬层体系，包括选自碳化钛、氮化钛、碳氮化钛、羰基化钛和氧化铝的至少一种层，和外面的1-15μm厚的氧化铝层或(Al2O3+ZrO2)*N多层，
—TiOx的倒数第二最外层，其中X的范围为1至2，优选为1.3至1.9，和
—0.3-2μm厚的TiCxNyOz最外层，其中x+y+z＝1，x≥0，y≥0且z≥0，优选TiN、TiC或TiCxNy的单层或多层，其中x+y＝1，x≥0且y≥0，
然后进行后处理，优选喷砂或刷光，至少除去刃线上和倾斜面上所述的最外层。
2.如权利要求1所述的制造涂层刀具刀片的方法，其特征在于，就表面覆盖度而言，所述后处理还至少除去50％的TiOx层。
3.如权利要求1-2所述的制造涂层刀具刀片的方法，其特征在于所述沉积的TiOx层的厚度为0.05-3μm。
4.一种由烧结碳化物、钛基碳氮化物或陶瓷制成的涂层刀具刀片，其具有顶面(倾斜面)、反面和至少一个余隙面，该余隙面和所述的顶面与反面相交形成切削刃，其特征在于以硬层体系涂层所述刀片，该硬层体系的总厚度为约2-50μm，包括选自碳化钛、氮化钛、碳氮化钛、羰基化钛和氧化铝的至少一种层，和外面的1-15μm厚的氧化铝层或(Al2O3+ZrO2)*N多层，所述氧化铝优选为晶粒细化的α-Al2O3，在所述硬层体系上提供TiOx层，其中X的范围为1至2，厚度优选为0.05-3μm，所述TiOx层为切削刃线和倾斜面上的最外层，并且在余隙侧面上的所述TiOx层上提供0.3-2μm厚的TiCxNyOz最外层，其中x+y+z＝1，x≥0，y≥0且z≥0，优选TiN、TiC或TiCxNy的单层或多层，其中x+y＝1，x≥0且y≥0。
5.如权利要求4所述的刀具刀片，其特征在于在刃线和倾斜面上的所述TiOx层覆盖所述硬层体系的小于50％的表面。
6.如权利要求4-5所述的刀具刀片，其特征在于所述的TiOx层的厚度为0.05-3μm。
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