CN1978192A - 用于铣削钢的刀片 - Google Patents

用于铣削钢的刀片 Download PDF

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CN1978192A
CN1978192A CNA2006101531342A CN200610153134A CN1978192A CN 1978192 A CN1978192 A CN 1978192A CN A2006101531342 A CNA2006101531342 A CN A2006101531342A CN 200610153134 A CN200610153134 A CN 200610153134A CN 1978192 A CN1978192 A CN 1978192A
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coating
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tooth
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谢尔·努德勒夫
玛丽亚·阿斯特兰德
托里尔·米尔特韦特
安德斯·伦德奎斯特
马茨·阿尔格伦
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Sandvik Intellectual Property AB
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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
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0617—AIII BV compounds, where A is Al, Ga, In or Tl and B is N, P, As, Sb or Bi
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
    • C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C—CHEMISTRY; METALLURGY
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0641—Nitrides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
    • C23C14/325—Electric arc evaporation
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34—Sputtering
    • C23C14/3464—Sputtering using more than one target
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    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
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    • Y10T407/00—Cutters, for shaping
    • Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
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    • Y10T428/24967—Absolute thicknesses specified
    • Y10T428/24975—No layer or component greater than 5 mils thick
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    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
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    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明涉及一种切削工具，如硬质合金刀片、整体硬质合金钻头或者铣刀或者硬质合金刀头，特别用于铣削钢、不锈钢、HRSA、钛或者该组中任何的合金材料，包括硬质合金基底和非周期多层涂层，硬质合金基底具有10％Co， 0.39％Cr和余量碳化钨，涂层本质上是由A+B+A+B+...层组成的非周期多层涂层，其中子层A和B分别由AlxTi1－xN和 TiyAl1－yN组成。每个A+B序列的一般平均厚度为30－300nm，涂层的总厚度为0.5－20nm。在整个涂层上平均的总化学成分由TizAl1－zN组成，其中z的范围为0.40－0.70。

Description

用于铣削钢的刀片
技术领域
本发明涉及一种用于加工钢或不锈钢的涂层硬质合金刀片，具有所要求的高耐磨性和高的边缘韧性。
背景技术
在一般的铣削加工中，刀片上的热负荷将随着时间而发生变化，这经常会诱发热应力并且随后可在涂层中产生热致裂缝。在热变化比干式加工更明显的冷/湿式加工中，这尤其是个值得关注的问题。
铣削中常见的磨损机理是裂化，然后碎屑或切削刃的碎片从基底剩余部分松散开。因此，提高边缘韧性对延长刀具的使用期限是非常重要的。一种可能降低热裂以及其它原因导致的裂化的方法是使用多层涂层。希望多层涂层作为开裂抑制剂，当沿着涂层向下出现初始裂隙时，可在任何子层界面处将其重新定向。当在硬耐磨层之间插入较软的子层时，希望可以显现出多层涂层的另一个优点。较软层可以吸收冲击，因此可抑止裂隙贯穿全部涂层。
WO98/48072涉及一种切削工具，其含有烧结硬质合金、陶瓷或高速钢的本体，在本体上，至少在本体表面起作用的部分上涂覆一层薄的、粘附的、硬耐磨层。该涂层包括层状多晶难熔化合物的多层结构，非重复地形成MX+NX+MX+NX...，其中交替层MX和NX由金属氮化物或金属碳化物组成。单层厚度的排序在整个多层机构中基本上是非周期的。
发明内容
本发明的一个目的是提供一种切削工具刀片，其能够承受间歇加工(如，铣削钢)中常见的磨损机理。
已经发现，具有高含量铝的(Ti，Al)N耐磨层与具有高含量钛的较软(Ti，Al)N薄层交错形成的薄多层结构赋予涂层在间歇操作中更高的耐裂性。
附图说明
图1显示的是具有所有单个多层的涂层的扫描电子显微镜(SEM)照片。图2显示的是涂层详细情况的SEM照片，其中测试了各单个涂层并且层状结构基本非周期的性质是明显的。
具体实施方式
根据本发明，提供了一种硬质合金本体的涂敷切削工具刀片，其成分为8-11wt％的Co，优选地9.5-10.5wt％的Co，最优选地9.9-10.1wt％的Co，0.1-0.5wt％的Cr，优选地0.38-0.40wt％的Cr和余量的WC。该硬质合金本体还可含有较少量的其它元素，其含量与工艺杂质(technical impurity)含量相当。矫顽力为18-22KA/m，优选地19-21KA/m，最优选地19.8-20.2KA/m。将钴粘结相与一定量的W和Cr熔成合金，赋予本发明硬质合金切削刀片要求的性能。粘结相中的W和Cr影响了钴的磁性，因此与CW比有关，将其定义为
CW比＝磁性％Co/wt％Co
其中磁性％Co是本体中磁性材料的测定重量百分数，wt％Co是本体中Co的重量百分数。
CW比在1和约0.75之间变化，这取决于粘结相的合金化程度。较低的CW比对应于较高的W和Cr含量，CW比＝1相当于在粘结相中实际上没有W和Cr。
根据本发明现在已经发现，如果硬质合金本体的CW比为0.78-0.90，优选地为0.80-0.89，和最优选地为0.83-0.87，就会获得提高的切割性能。该硬质合金还可含有少量，＜1体积％的η相(M6C)，而不会带来任何不利影响。根据本发明，从指定的CW比(＜1)，还要求硬质合金本体中不能有任何游离石墨。
根据本发明的刀片，具有由二元A+B+A+B+...结构组成的多层非周期TiAIN，薄的交替子层A和B在整个涂层中反复。将A+B子层的一个序列在这里表示为薄片。由于涂层的非周期性质，每组薄片的厚度不同，但薄片的平均厚度在30-300nm之内，优选地在60-120nm。子层A包括AlxTi1-xN，其中x为0.40-0.7，优选地0.5-0.67。层B包括TiyAl1-yN，其中y为0.6-1，优选地0.75-1。对于全部涂层的化学计量，通过例如微探针或EDS测量，在TizAl1-zN范围内，z：0.40-0.7，优选地0.45-0.6。多层涂层的总厚度在斜面(rake side)上为0.5μm-15μm，优选地1μm-10μm，更优选地1-5μm，在侧面(flank side)上为2-8μm。在一个优选的实施方案中，具有外部TibAl1-bN层，b＝0.8-0.9，优选地0.82-0.85，其具有足够的厚度以提供一种可见的、同质的古铜色外观，优选厚度为0.1-1μm。
本发明还涉及一种含有硬质合金基底和涂层的切削刀片的制备方法。根据该方法，含有WC，8-11wt％的Co，优选9.5-10.5wt％的Co和0.1-0.5wt％Cr的基底，矫顽力为18-22kA/m，优选19-21kA/m，最优选19.8-20.2kA/m，CW比在0.78-0.90，优选地在0.80-0.89，和最优选地在0.83-0.87范围内。在该基底上沉淀的涂层含有A+B+A+B+...的层状多层结构，其中层A和B分别由多晶AlxTi1-xN和TiyAl1-yN以非重复形式构成，x＝0.40-0.70，优选地0.50-0.67，和y＝0.60-1.00，优选地0.75-1.00，一个A+B子层的平均厚度在30-300nm范围之内，优选地60-120nm，基本上可任意变化。多层涂层在斜面上的总厚度为0.5μm-15μm，优选地1μm-10μm，更优选地1-5μm，在侧面上的厚度2-8μm。在N2或N2+Ar混合气体气氛中，用两对或三对由纯净Ti和/或TiAl合金组成的弧光源，使用阴极电弧蒸发法沉积涂层。在优选的实施方案中，沉积外部TibAl1-bN层，b＝0.8-0.9，优选地0.82-0.85，其厚度足够提供一种可见的、同质的古铜色外观，厚度优选为0.1-1μm。
本发明还涉及上述切削工具刀片在铣削合金钢和不锈钢中的应用，优选在干燥条件下进行，切削速度和进料速度如下表：
铣削进入角为90度：
→Vc：25-350m/min，优选50-250m/min和fz：0.04-0.4mm/齿
铣面(45-75度进入角)：
→Vc：25-350m/min，优选50-250m/min和fz：0.05-0.7mm/齿
高速进料铣削方案：
→Vc：25-350m/min，和fz：0.30-3.0mm/齿，优选0.3-1.8mm/齿。
实施例1
通过阴极电弧蒸发法在硬质合金铣削刀片上用10wt％Co，0.4wt％Cr和余量WC的组合物沉积非周期的多层，用Foerster仪器公司的FRSTER KOERZIMAT CS 1.096测量的矫顽力为20.2kA/m，CW比为0.85。将一对Ti84Al16靶和两对Ti33Al67靶与刀片安装在三折(fold)旋转基底工作台上，沉积多层获得非周期结构。在N2气氛中进行电弧蒸发。涂层的总厚度为2-9μm，因不同的批次、刀片而有所差异，并且在整个刀片表面上不同。涂层由二元的A+B+A+B+...非周期多层组成，即由具有非重复厚度的层组成，但层A+B平均厚度为60-120nm。最外层用Ti84Al16N涂覆刀片，使其呈现出青铜色。
在图1和2中可以看到涂层横截面的SEM照片。非周期的性质可以从图2中看出。子层中的弯曲至少在一定程度上是由基底的粗糙度造成的。
涂层具有在两个子层A和B成分之间的平均成分TizAl1-zN。在侧面的中心用微探针测得这种平均组成。获得的成分相当于Ti0.5Al0.5N。
对实施例2-7的说明：
以下是在金属切削中常用的符号/术语，并在下表中解释：
Vc(m/min)：切削速度，米/分钟
fz(mm/tooth)：进料速度，毫米/齿
z：(number)：刀具的齿数
ae(mm)：径向切割深度，毫米
ap(mm)：轴向切割深度，毫米
D(mm)：刀具直径，毫米
实施例2
测试实施例1的刀片并与参照例A相比较，参照例A含有同样的基底，具有相同厚度的同质Ti33Al67N层。两个刀片的几何形状都是R390-11T0308M-PM。在低合金钢中以Vc＝150m/min，fz＝0.15mm/齿，ae＝25mm，ap＝3mm，z＝3，D＝25mm的条件下对它们测试。冷却剂为乳剂。实施例1的刀片在使用中维持了56分钟，而参考例A仅维持了29分钟。在磨损类型中增加工具寿命决定性的差异在于在边缘线中含有较少的碎屑。
实施例3
测试实施例1的刀片并与参考例A(同质Ti33Al67N层)以及参考例B(TiN多层与TiCN形成夹层，和顶部为较厚的TiCN层)相比较。各种情况下的几何形状都是N331A-145008 H-WL。加工材料是非合金钢。干燥条件。切削条件是Vc＝466m/min，fz＝0.22mm/齿。参照例B持续了2.3分钟，参照例A持续了9分钟。9分钟后，实施例1的多层刀片依然可以使用，只有很少的磨损迹象，而其它两个刀片由于遭到严重破坏已经完全不能使用。在磨损类型中增加工具寿命决定性的差异在于在边缘线中含有较少的碎屑。
实施例4
对具有R300-1648M-PH几何形状，与实施例1具有相同基底成分和相同涂层的刀片进行测试，并与在刀片上与同批基底沉积相同厚度的同质Ti33Al67N层的参考例A比较。本例中采用的加工材料是硬度为48HRC的工具钢。切削数据是：Vc＝35m/min，fz＝0.5mm/齿，z＝6，ap＝1.5mm，D＝63mm，ae＝30-64mm。冷却剂：空气吹冷。在本测试中，工具的寿命是17分钟，与参考例A的仅仅12分钟相比增加了42％。在增加工具寿命的磨损类型中的决定性差异在于具有较高的槽口耐磨性。
实施例5
测试实施例1中的刀片并与参考例A以及参考例B比较。全部情形下的几何形状都是R390-11 T0308M-PM。加工材料是硬度为220HB的合金钢。切削条件是Vc＝94m/min，fz＝0.055mm/齿。干燥条件。参考例B可以加工16个零件，参考例A可以加工24个，而实施例1中的刀片可以加工40个零件。在磨损类型中增加工具寿命决定性的差异在于在边缘线中含有较少的碎屑。
实施例6
测试实施例1中的刀片并与参考例A以及参考例B比较。全部情形下的几何形状都是CM245-12T3 E-PL。加工材料是奥氏体不锈钢。切削数据：Vc＝250m/min，fz＝0.09mm/齿，ap＝2mm，ae＝50mm，z＝1。干燥条件。在这个测试中，实施例1中的刀片维持了6米，参考例A维持了3.5米，参考例B维持了3米。实施例1中的多层刀片的工作性能明显优于其它变形体。增加工具寿命的磨损类型中的决定性差异在于较高的边缘线韧性(无裂缝，无边缘断裂)。
实施例7
按照专利申请WO01/16389实施例1中的方法测试实施例1中的刀片并与参考例C比较。在各种情形下的几何形状是R210-140512M-PM。本例中采用的加工材料是硬度为45HRC的工具钢。切削数据：Vc＝90m/min，fz＝0.58mm/齿，ap＝1mm，ae＝38.6mm，z＝1，D＝66mm。干燥条件。在这个测试中，实施例1的刀片维持34分钟，而参考例C最高达到14分钟。增加工具寿命的磨损类型中的决定性差异在于具有较高的槽口耐磨性。
总之，本发明的刀片能够优于其它测试刀片承受各种磨损环境，这表明在不稳定的条件下，其边缘线行为具有更高可预见性和更高的可靠性。允许改善切削数据。

Claims (6)

1.一种切削刀片，包括硬质合金基底和涂层，其特征在于，
基底含有WC，8-11 wt％Co，更优选地9.5-10.5wt％Co，最优选地9.9-10.1wt％Co和0.1-0.5wt％Cr，更优选地0.38-0.40wt％Cr，矫顽力范围在18-22kA/m，更优选地19-21kA/m，最优选地19.8-20.2kA/m，CW比为0.78-0.90，优选地0.80-0.89，和最优选地0.83-0.87，和
涂层含有片状的A+B+A+B+...多层结构，其中A和B层分别由多晶AlxTi1-xN和TiyAl1-yN以非重复的形式组成，x为0.4-0.7，优选地0.5-0.67，y为0.6-1，优选地0.75-1，并且x＜y，一个A+B子层的平均厚度在30-300nm范围内，优选地60-120nm，其实际上可以任意变化，多层涂层在斜面上的总厚度为0.5μm-15μm，优选地1μm到10μm，更优选地1μm到5μm，侧面上的总厚度为2-8μm。
2.如权利要求1所述的切削工具，其特征在于外部TibAl1-bN层，b＝0.8-0.9，优选地0.82-0.85，具有足够的厚度以显示出可见的、同质的古铜色外观，厚度优选为0.1-1μm。
3.如权利要求1或2所述的切削工具，其特征在于，在全部涂层上平均的总化学成分表达式为TizAl1-zN，z＝0.4-0.7。
4.一种含有硬质合金基底和涂层的切削刀片的制备方法，其特征在于，提供含有WC，8-11wt％Cr，优选地9.5-10.5wt％Co和0.1-0.5wt％Cr，矫顽力18-22kA/m和CW比为0.78-0.90的基底，和在N2或N2+Ar混合气体气氛中，使用两或三对由纯Ti和/或TiAl合金组成的电弧光源，利用阴极电弧蒸发沉积含有A+B+A+B+...的薄片状多层结构的涂层，其中A和B层分别由多晶AlxTi1-xN和TiyAl1-yN以非重复的形式组成，x为0.4-0.7，优选地0.5-0.67，y为0.6-1，优选地0.75-1，A+B子层的平均厚度在30-300nm范围内，优选地60-120nm，其实际上可以任意变化，多层涂层在斜面上的总厚度为0.5μm-15μm，优选地1μm到10μm，更优选地1μm到5μm，侧面上的总厚度为2-8μm。
5.如权利要求4所述的方法，其特征在于，沉积外部TibAl1-bN层，b＝0.8-0.9，优选地0.82-0.85，具有足够的厚度以提供可见的同质古铜色外观，厚度优选0.1-1μm。
6.如权利要求1-3的切削工具在合金钢和不锈钢的金属铣削中的应用，优选干燥条件，并且切削速度和进料速度如下：
Vc＝25-350m/min，优选地50-250m/min和fz：0.04-0.4mm/齿的条件下以90°角铣削，或者，
Vc：25-350m/min，优选地50-250m/min和fz：0.05-0.7mm/齿的条件下铣面在45°～75°进入角，或者，
Vc：25-350 m/min和fz：0.30-3.0mm/齿，优选地0.3-1.8mm/齿的条件下，应用高速进料铣削。
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