CN1927513A - Pvd涂覆切削工具 - Google Patents

Pvd涂覆切削工具 Download PDF

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CN1927513A
CN1927513A CNA2006101516802A CN200610151680A CN1927513A CN 1927513 A CN1927513 A CN 1927513A CN A2006101516802 A CNA2006101516802 A CN A2006101516802A CN 200610151680 A CN200610151680 A CN 200610151680A CN 1927513 A CN1927513 A CN 1927513A
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法伊特·席尔
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Abstract

本发明描述了一种切削工具，该切削工具针对金属加工具有改进的性能，该切削工具具有硬质合金基底和位于该基底的表面上的硬且耐磨的涂层。涂层是通过物理气相沉积(PVD)而沉积的。涂层由金属氮化物与氧化铝(Al2O3)结合组成。涂层由分层的多层结构组成。刀片被进一步处理成分别在前刀面和侧面上具有不同的外层。

Description

PVD涂覆切削工具
技术领域
本发明涉及一种切削工具，该切削工具针对金属加工具有改进的性能，该切削工具具有硬质合金基底和位于该基底的表面上的硬且耐磨的涂层。涂层是通过物理气相沉积(PVD)而沉积的。涂层由金属氮化物与氧化铝(Al2O3)结合组成。涂层由分层的多层结构组成。为了优化性能，刀片被进一步处理成分别在前刀面和侧面上具有不同的外层。
背景技术
用于金属的切屑形成(chip forming)加工的现代高产率工具需要具有优良磨损性能的可靠工具。从20世纪60年代末期开始，就已知可以通过向工具表面涂覆适当的涂层来显著地提高工具的寿命。用于磨损应用的最早涂层通过化学气相沉积(CVD)形成，并且该涂层技术仍然广泛用于切削工具应用。物理气相沉积(PVD)在20世纪80年代中期提出，并且从那时起从单层稳定金属化合物如TiN或Ti(C，N)进一步发展成包括多组分和多层涂层，它们还包括亚稳定化合物像(Ti，Al)N或非金属化合物像Al2O3。
在Shinzato等人的Thin Sol.Films，97(1982)333-337一文中描述了使用高至900℃的沉积温度在硬质合金切削工具上射频溅射氧化铝。在Knotek等人的Surf.Coat.Techn.(表面涂覆技术)，59(1993)14-20一文中描述了使用氧化铝的PVD涂层用于磨损保护，其中氧化铝被沉积为耐磨碳氮化物层上的最外层。氧化铝层据说可以将粘附磨损减小到最低，并且可以充当化学侵蚀的屏障。美国专利号5,879,823中公开了一种工具材料，该工具材料涂覆有PVD氧化铝作为层叠当中的一层或两层，非氧化层例如包含TiAl。该工具可以具有TiN的外层。Al2O3可以为α、κ、θ、γ型或无定形的。在美国专利号6,210,726中公开了氧化铝涂覆的工具，其中氧化物多晶型物为γ型，具有400或440晶体结构。美国专利号5,310,607公开了PVD沉积氧化铝，含有大于5％的Cr。对于Cr含量超过20％的氧化铝，可以发现具有大于20GPa的硬度和α相的晶体结构。如果没有Cr添加物，就会给出具有5GPa硬度的无定形氧化铝。
现今的大多数涂覆工具都具有金色的TiN以易于通过肉眼区别出使用过的和未使用的切削刃。TiN并不总是优选的顶层，尤其是在其中切屑可能粘附至TiN层的应用中不是优选的。在EP-A-1193328中公开了涂层的部分喷砂，其目的是在保持底层涂层的有益性能的同时能够磨损检测。前刀面上的磨损在本质上主要是化学上的并且需要化学性能稳定的化合物，而在侧面上的磨损在本质上主要是机械上的并且需要更硬的并且耐磨的化合物。
发明内容
本发明的一个目的是提供一种具有多层涂层的改进的切削工具组成。
本发明的另一个目的是分别在前刀面和侧面上使用不同外层的概念来进一步提高PVD涂覆切削工具的性能。
优选通过PVD工艺形成的涂层包括紧邻基底的(Ti，Al)N化合物、在(Ti，Al)N层上面的氧化铝层和至少两个另外(Ti，Al)N和氧化铝的交替层以及最外层的ZrN。ZrN层在后处理中被从前刀面上除去，且优选通过喷砂或刷除而被除去。通常需要几次重复的刷除或喷砂来完全除去前刀面上的ZrN涂层。不完全的除去通常会导致ZrN残留物局部焊接到切屑上，这会降低工具寿命。为了减小顶部ZrN层的粘附，在氧化铝层上、ZrN层下方沉积亚化学计量的ZrN1-x的中间层。亚化学计量ZrN1-x具有减小的强度并且便于顶部ZrN层的除去。
依照本发明，现在提供了一种切削工具刀片，它具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交的间隙面以界定切削刃，其包括硬质合金基底和硬层系统。硬质合金具有如下组成：重量百分比为86-90％的WC、重量百分比为0.2-0.8％的Cr3C2和重量百分比为10-14％的Co，且优选为重量百分比为86-87％的WC、重量百分比为0.4-0.6％的Cr3C2和重量百分比为11-13％的Co，且具有小于1.5微米且优选小于1.1微米的粒度。硬层系统具有3-30微米的总厚度，并且包括：
-(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
-氧化铝层，优选为γ-氧化铝，具有1-4微米且优选1-2微米的厚度，
-((Ti，Al)N+氧化铝)*N的多层，其中N≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，
-优选亚化学计量ZrN1-x，优选x＝0.01-0.1，且优选厚度小于0.1微米的薄层，以及
-ZrN层，具有小于1微米且优选为0.1-0.6微米的厚度，在前刀面和刀口上没有ZrN层，
其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成。
本发明还涉及一种用于制造涂覆切削工具刀片的方法，该刀片具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，该方法包括下列步骤：
-提供一种硬质合金基底，该基底具有如下组成：重量百分比为86-90％的WC、重量百分比为0.2-0.8％的Cr3C2和重量百分比为10-14％的Co，且优选为重量百分比为86-87％的WC、重量百分比为0.4-0.6％的Cr3C2和重量百分比为11-13％的Co，且具有小于1.5微米且优选小于1.1微米的粒度，
-使用PVD方法，在硬质合金基底上沉积一个硬层系统，其具有3-30微米的总厚度，并且该硬层系统包括：
-(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
-氧化铝层，优选为γ-氧化铝，具有1-4微米且优选为1-2微米的厚度，
-((Ti，Al)N+氧化铝)*N的多层，其中N≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，
-优选亚化学计量ZrN1-x，优选x＝0.01-0.1，且优选小于0.1微米的薄层，以及
-最外侧的ZrN层，其具有小于1微米且优选0.1-0.6微米的厚度，其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成，并且
-通过后处理且优选通过刷除或喷砂，除去前刀面和刀口上的所述ZrN层。
实例1
硬质合金刀片ADMT 160608R，其具有如下组成：重量百分比为87.5％的WC、重量百分比为0.5％的Cr3C2和重量百分比为12％的Co，使用PVD技术依照下列次序在一个工序中涂覆：
方案A：层叠(Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3)，
方案B；层叠(Ti0.33Al0.67N-Al2O3)
方案C；Ti0.33Al0.67N层。
刀片在干燥的台肩铣削应用中进行测试。
工件材料：马氏体不锈钢X90CrMoV18(1.4112)。
切削速度：140米/分钟
工具寿命标准：所生产的零件的数目
表1工具寿命中铣边之后所生产的零件
  涂层   Ti0.33Al0.67N   Ti0.33Al0.67N-Al2O3   3x(Ti0.33Al0.67N-Al2O3)
  工具寿命中所生产的零件   3   4   7
结果显示出提高的层厚度在铣边中对工具寿命的影响。
实例2
硬质合金刀片P600x-D19R，其具有如下组成：重量百分比为90％的WC、重量百分比为10％的Co，使用PVD技术依照下列次序在一个工序中涂覆：
方案A：层叠Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3-ZrN(ZrN在涂覆之后喷砂清理掉)
方案B；Ti0.33Al0.67N层
在有冷却剂的情况下，在钻孔操作中测试刀片。
工件材料：GG25，灰口铸铁，直径：19毫米，
切削速度：100米/分钟，
转速：1675转/分钟，
进给：每齿0.16毫米，
进给速度：536毫米/分钟，
切削深度：90毫米
工具使用寿命：
方案A：95分钟
方案B：42分钟
结果显示出多层(Ti，Al)N-氧化铝与纯(Ti，Al)N对比的效果。

Claims (4)

1.一种PVD涂覆硬质合金刀片，其具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，其特征在于：
－硬质合金基底具有如下组成：重量百分比为86-90％的WC、重量百分比为0.2-0.8％的Cr3C2和重量百分比为10-14％的Co，且优选的是重量百分比为86-87％的WC、重量百分比为0.4-0.6％的Cr3C2和重量百分比为11-13％的Co，且具有小于1.5微米且优选地小于1.1微米的粒度，并且涂覆有
－硬层系统，其具有3-30微米的总厚度，包括
－(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
－氧化铝层，优选为γ-氧化铝层，具有1-4微米且优选1-2微米的厚度，
－((Ti，Al)N+氧化铝)*N的多层，其中N≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，以及
－ZrN层，具有小于1微米且优选0.1-0.6微米的厚度，在前刀面和刀口上没有ZrN层，
其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成。
2.如权利要求1所述的切削工具刀片，其特征在于，在ZrN顶层下面具有亚化学计量ZrN1-x，优选x＝0.01-0.1，且厚度优选小于0.1微米的薄层。
3.一种用于制造涂覆切削工具刀片的方法，该刀片具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，其特征在于，该方法包括下列步骤：
－提供一种硬质合金基底，该基底具有如下组成：重量百分比为86-90％的WC、重量百分比为0.2-0.8％的Cr3C2和重量百分比为10-14％的Co，且优选为重量百分比为86-87％的WC、重量百分比为0.4-0.6％的Cr3C2和重量百分比为11-13％的Co，且具有小于1.5微米且优选小于1.1微米的粒度，
－使用PVD方法，在该硬质合金基底上沉积一硬层系统，该硬层系统具有3-30微米的总厚度，并且包括：
－(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
－氧化铝层，优选为γ-氧化铝，具有1-4微米且优选为1-2微米的厚度，
－((Ti，Al)N+氧化铝)*N的多层，其中N≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，以及
－最外侧的ZrN层，具有小于1微米且优选0.1-0.6微米的厚度，其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成；以及
－通过后处理且优选通过刷除或喷砂，除去前刀面和刀口上的所述ZrN层。
4.如权利要求3所述的方法，其特征在于，在((Ti，Al)N+氧化铝)*N的多层上面沉积亚化学计量ZrN1-x，优选x＝0.01-0.1，且厚度优选小于0.1微米的薄层。
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