CN1982052A - 涂覆切削刀片 - Google Patents

涂覆切削刀片 Download PDF

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CN1982052A
CN1982052A CNA2006101700618A CN200610170061A CN1982052A CN 1982052 A CN1982052 A CN 1982052A CN A2006101700618 A CNA2006101700618 A CN A2006101700618A CN 200610170061 A CN200610170061 A CN 200610170061A CN 1982052 A CN1982052 A CN 1982052A
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composition
blade
cutting
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CN1982052B (zh
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里卡德·森德斯特龙
苏珊娜·诺格伦
玛丽·彼得松
莱夫·阿克松
比约恩·永贝里
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Sandvik Intellectual Property AB
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B27/00Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14Cutting tools of which the bits or tips or cutting inserts are of special material
    • CCHEMISTRY; METALLURGY
    • C23COATING 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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    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B27/00Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
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    • C23COATING 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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    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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    • C23C16/34Nitrides
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    • C23COATING 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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    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40Oxides
    • C23C16/403Oxides of aluminium, magnesium or beryllium
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    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/042Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
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    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/044Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
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    • C23C30/00Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00Cutters, for shaping
    • Y10T407/27Cutters, for shaping comprising tool of specific chemical composition
    • YGENERAL 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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    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495Thickness [relative or absolute]
    • Y10T428/24967Absolute thicknesses specified
    • Y10T428/24975No layer or component greater than 5 mils thick
    • YGENERAL 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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    • YGENERAL 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

本发明公开了一种涂覆硬质合金刀片,尤其用于带有或不带有未加工表面,例如铸造表皮、锻造表皮、热轧或冷轧表皮、或预加工表面的低、中合金钢和不锈钢在恶劣条件,例如振动、长悬臂和切屑再切削下的有韧性需求的湿、干加工,优选为铣削。所述刀片的特征在于具有W和Cr合金Co-粘结相的WC-Co硬质合金,和包括至少三个TiCxNyOz层和至少位于光滑α-Al2O3的前刀面上的顶层的涂层。

Description

涂覆切削刀片
技术领域
本发明涉及一种涂覆硬质合金切削刀片,其尤其用于具有未加工表面,例如铸造表皮、锻造表皮、热轧或冷轧表皮、或预加工表面的低和中合金钢、不锈钢在不稳定条件下的有韧性需求的湿和干加工,优选地铣削。
背景技术
当利用硬质合金刀具加工低和中合金钢和不锈钢时,切削刃发生根据不同机理的磨损,例如化学磨损,磨料磨损,粘附磨损,以及根据由沿切削刃形成的裂纹,即所谓的梳状裂纹所引起的刃切屑。在恶劣切削条件下,常发生基体和刃边破裂。
不同的工件材料和不同的切削条件需要不同的刀片性能。例如,当切削带有未加工表面区域的钢部件或者在其他不同条件下切削时,涂覆硬质合金刀片必须基于坚硬的硬质合金基底并且具有良好粘性的涂层。当加工低合金钢和不锈钢时,粘附磨损通常是主要的磨损类型。这里通常必须使用1-3μm的薄CVD或PVD涂层。
可以采取措施改进或优化针对于特定磨损类型的切削性能。然而,通常,这种措施将对其他磨损特性具有负面影响。
一些可能措施的影响给出如下:
1)通过减少粘结相含量能够减少梳状裂纹形成。然而,低粘合剂含量将降低刀片的韧性,该刀片远不是人们所希望的。
2)改进的磨料磨损可以通过增加涂层厚度而获得。然而,厚涂层增大了片状剥落的风险,并且还将降低抗粘附磨损能力。
3)以高切削速度和在导致高切削刃温度的其他条件下加工需要具有较多数量的立方碳化物(WC-TiC-TaC-NbC的固溶体)的硬质合金,但是这些碳化物将促进梳状裂纹形成。
4)改进的韧性可以通过提高钴粘合剂含量而获得。然而,高钴含量降低了抗塑性变形能力。
到目前为止,同时改进所有的刀具性能是极为困难的。商用硬质合金等级因此相对于上述磨损类型中的一个或几个和特定的切削应用领域进行了优化。
US6,062,776公开了一种涂覆切削刀片,特别用于在湿或干条件下对带有或不带有未加工表面区域的低和中合金钢进行铣削。该刀片的特征在于,具有低含量立方碳化物和高W-合金粘结相的WC-Co硬质合金,包括具有柱状晶粒的TiCxNyOz最内层和κ-Al2O3层以及TiN顶层的涂层。
US6,406,224公开了一种涂覆切削刀片,还特别用于高速铣削带有或不带有磨损面区域的合金钢。该涂覆刀片包括硬质合金主体,其具有7.1-7.9wt%Co,0.2-1.8wt%金属Ta、Nb和Ti的立方碳化物,和余量的WC组成。该刀片涂覆有具有柱状晶粒的TiCxNyOz最内层和κ-Al2O3层以及TiN顶层。
EP-A-736615公开了一种涂覆切削刀片,特别用于灰口铸铁的干铣削。该刀片的特征在于,具有直的WC-Co硬质合金基底和由具有柱状晶粒的TiCxNyOz层和细粒结构的α-Al2O3顶层组成的涂层。
US2006/0204757A公开了一种涂覆切削刀片,适合于通过车削、铣削、钻削或通过类似的切屑形成加工手段进行金属加工。该刀片尤其用于间断的韧性需要的切削操作。
US6,200,271公开了一种涂覆车削刀片,尤其用于不锈钢的车削。该刀片的特征在于,具有高W合金的Co粘结相的WC-Co基的硬质合金基底和包括具有柱状晶粒的TiCxNyOz最内层、TiN顶层和细粒的κ-Al2O3内层的涂层。
发明内容
发明人在对市售刀片进行大量实验和多次测试之后发现,通过组合多个特定特征,可以获得尤其适于铣削的改进的切削刀片。所述组合特征是:特定的硬质合金组成,特定WC晶粒尺寸,合金粘结相,由多个限定层组成的内涂层和光滑的α-Al2O3顶部前刀面层。
该刀片对带有或不带有未加工表面区域的低和中合金钢,尤其是在例如振动、长悬臂梁、切屑锻造(chip-hammering)或切屑再切削的不稳定条件下或者在湿和干两种条件下通常有韧性需要的操作中具有改进的切削性能。还令人惊讶的是,本发明的刀片还对不锈钢实现良好加工。根据本发明的刀具与现有技术中的刀片相比,相对于上述许多磨损类型具有改进的切削特性。特别地,梳状裂纹韧性特性得以提高。
附图说明
图1和2以6000X显示了氧化铝层的SEM图像,图1为喷砂处理之前的顶视图,图2是喷砂处理之后的顶视图。
具体实施方式
根据本发明的切削刀片包括硬质合金主体和涂层,所述硬质合金主体具有W和Cr合金Co粘结相,良好平衡的化学组成和适当选定的WC晶粒尺寸,所述涂层包括柱状TiCxNyOz内层,随后是光滑α-Al2O3顶层。优选地,TiN层是位于刀片间隙面(clearance face)处的顶层。
根据本发明,提供了一种涂覆切削刀片,其包括具有12.0-15.0wt%Co,优选地12.5-14.5wt%Co,最优选13-14wt%Co,0.52-0.64wt%Cr,优选地0.54-0.62wt%Cr,最优选地0.55-0.61wt%Cr和余量WC的组成的硬质合金主体。该硬质合金主体还可以包括较少量的其他元素,不过是在相当于工艺杂质的水平上。根据IEC标准60404-7测量的极化矫顽力(polarization coercivity)HcJ间接地测量WC晶粒尺寸并且应当具有12.5-14.5kA/m,优选地12.7-14.0kA/m范围内的值。钴粘结相与赋予本发明刀片希望特性的特定数量的W和Cr形成合金。粘结相中的W和Cr影响钴的磁性并且因此可以与值CW相关,CW定义为:
CW=磁性%Co/wt%Co
其中,磁性%Co是磁性材料的重量百分比,wt%是硬质合金中Co的重量百分比。
CW值可以在1和约0.6之间变化,取决于合金度。较低的CW值对应粘结相中较高的W和Cr含量,并且CW=1实际上相当于粘结相中没有W和Cr。
根据本发明已经发现,如果硬质合金主体具有0.76-0.84,优选地0.78-0.82,最优选地0.79-0.81范围之内的CW比的话,可以获得改进的切削性能。该硬质合金还可以包括少量(<1体积%)的η相(M6C),而没有任何有害的影响。由于特定的CW值(<1),还遵循,不允许在根据本发明的硬质合金中具有游离石墨。
该硬质合金刀片至少部分地涂覆有4.1-6.9μm厚的涂层,包括至少三层TiCxNyOz。该三层形成内涂层,带有α-Al2O3层作为至少位于前刀面(rake face)上的外层。这些TiCxNyOz层具有1.9-3.6μm的总厚度并且包括:
紧邻所述硬质合金的第一TiCxNyOz层,0.1-1μm,具有x+y=1,x>=0,优选地x<0.2,z=0的组成。
第二TiCxNyOz层,1-3.4μm,具有x>0.4,y>0.4并且0=<z<0.1,优选地z=0的组成。
紧邻α-Al2O3层的第三TiCxNyOz层,0.1-1μm,具有x+y+z>=1,并且z>0,优选地z>0.2,x+y+z=1并且y<0.2的组成。
所述α-Al2O3外层具有1.8-3.6μm的厚度,具有位于经受了喷砂处理的表面上磨扁的晶粒。
在优选实施例中,该刀片具有位于前刀面处的薄0.1-1μm着色顶层,优选地为TiN,TiCN,TiC,ZrN或HfN,最优选地通过CVD工艺沉积。
本发明还涉及制造涂覆切削刀片的方法,通过粉末冶金工艺、湿磨形成硬质成分和粘结相的粉末,将已磨好的混合物压制到希望形状和尺寸的主体并烧结,所述主体为具有12.0-15.0wt%Co,优选地12.5-14.5wt%Co,最优选地13-14wt%Co,0.52-0.64wt%Cr,优选地0.54-0.62wt%Cr,最优选地0.55-0.61wt%Cr和余量WC的硬质合金主体。所述硬质合金主体还可以包括较少数量的其他元素,但是在相当于工艺杂质的水平上。选择研磨和烧结条件以获得一烧结结构,具有12.5-14.5kA/m,优选地12.7-14.0kA/m的极化矫顽力HcJ,并具有0.76-0.84,优选地0.78-0.82,最优选地0.79-0.81的CW比。
所述硬质合金刀片主体至少部分地涂覆有4.1-6.9μm厚的涂层,包括至少三层TiCxNyOz,该三层形成内涂层,带有喷砂处理过的α-Al2O3层作为至少位于前刀面上的外层。这些TiCxNyOz层具有1.9-3.6μm的总厚度,包括:
紧邻所述硬质合金的第一TiCxNyOz层,0.1-1μm,具有x+y=1,x>=0,优选地x<0.2,并且z=0的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD方法制成。
第二TiCxNyOz层,1-3.4μm,具有x>0.4,y>0.4并且0=<z<0.1,优选地z=0的组成,该层通过已知的MTCVD工艺,温度885-850℃,并且CH3CN作为碳/氮源而制成。
紧邻α-Al2O3层的第三TiCxNyOz层,0.1-1μm,具有x+y+z>=1,并且z>0,优选地z>0.2,x+y+z=1并且y<0.2的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD工艺制成,
α-Al2O3层厚度为1.8-3.6μm,具有位于经受了喷砂处理的表面上磨扁的晶粒,该层通过使用已知的CVD工艺沉积。
紧邻α-Al2O3层的第三TiCxNyOz层,具有x+y+z>=1,并且z>0,优选地z>0.2,x+y+z=1并且y<0.2的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD工艺制成,
所述α-Al2O3层具有1.8-3.6μm的厚度,通过已知CVD工艺沉积,并且
使刀片至少在前刀面上经受喷砂处理。
在一个实施例中,附加的0.1-1μm的着色层优选地通过CVD工艺在喷砂处理之前沉积在α-Al2O3层的顶面上,所述层优选地为TiN,TiCN,TiC,ZrN或HfN。
在另一个实施例中,在喷砂处理之后,附加的0.1-1μm的着色顶层利用CVD或PVD工艺,优选地利用CVD工艺,沉积在至少后刀面(flank face)上,所述层优选地为TiN,TiCN,TiC,ZrN或HfN。
本发明还涉及根据上文所述的刀具的应用,用于对带有未加工表面,例如铸造表皮,锻造表皮,热轧或冷轧表皮,或预加工表皮的低和中合金钢和不锈钢进行有韧性要求的湿和干加工,优选地铣削,所述加工在下表所列的切削速度和进给速度下进行:
以90°切入角铣削:
切削速度:25-350米/分钟,优选地100-250米/分钟,进给速度:0.04-0.4毫米/齿
端面铣削:(45-75°切入角):
切削速度:25-350米/分钟,优选地100-250米/分钟,进给速度:0.05-0.7毫米/齿
高速进给铣削概念:
切削速度:25-350米/分钟,进给速度:0.30-3.0毫米/齿,优选地0.3-1.8毫米/齿
还结合以下实例来说明本发明,这些实例应该认为是示例性的。应该理解,本发明不限于这些实例的特定细节。
实例1(发明)
制造下列类型的硬质合金铣削刀片,R390-11T308M-PM,R390-170408M-PM,R245-12T3M-PM,R300-1648M-PH和R300-1240M-PH,其具有13.5wt%Co,0.58wt%Cr,和余量WC的组成,并且HcJ值为13kA/m,CW值为0.80,如以Foerster Instruments Inc.的FORSTER KOERZIMAT CS 1.096测量的那样。该刀片随后如下涂覆:
0.5μm的TiCxNyOz第一层,具有大约x=0.05,y=0.95,并且z=0的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD方法制成,
1.7μm的柱状TiCxNyOz第二层,具有大约x=0.55,y=0.45并且z=0的组成,该层通过已知MTCVD工艺,温度885-850℃,并且CH3CN作为碳/氮源制成,和
0.5μm的TiCxNyOz第三粘接层。该第三层的晶粒为针形,并且组成为大约x=0.5,y=0和z=0.5
由2.5μm的α-Al2O3组成的第四层,最后,通过使用已知CVD工艺沉积大约0.3μm的TiN顶层。XRD测量确认所述Al2O3层为100%α相。
在涂覆周期之后,该刀片的顶侧(前刀面)利用Al2O3粗砂和水的浆液经受猛烈的湿喷砂处理。该喷砂处理去除前刀面上的顶部TiN层,露出光滑的α-Al2O3,其中大部分晶粒如图1和2所示被磨扁,图1和2以6000X显示了氧化铝层的SEM图像,图1为喷砂处理之前的顶视图,图2是喷砂处理之后的顶视图。
实例2(现有技术)
制造下列类型的硬质合金铣削刀片,R390-11T308M-PM,R390-170408M-PM,R245-12T3M-PM,R300-1648M-PH和R300-1240M-PH,其具有11.5wt%Co,1.25wt%TaC,0.30wt%NbC和余量WC的组成,并且HcJ值为10.4kA/m,CW值为0.94,如以FoersterInstruments Inc.的KOERZIMAT CS 1.096测量的那样。该刀片随后如下涂覆:
0.5μm的由等轴晶粒组成的TiCxNy第一层(具有相当于估计的x=0.95,y=0.05的高氮含量),其后为
4μm厚的TiCN层,其具有柱状晶粒,通过使用MTCVD工艺在885-850℃的温度下以CH3CN作为碳/氮源获得。在后续步骤中,在同一涂覆周期中,如EP-A-523 021中所公开的,在970℃的温度下,利用0.4%浓度的H2S掺杂剂沉积1.0μm厚的Al2O3层。0.3μm的TiN薄层按照已知的CVD工艺沉积在顶部。XRD测量显示出,Al2O3层由100%的κ相组成。所述硬质合金主体具有平均尺寸为1.7μm的WC晶粒。用带有包含硬质SiC晶粒的刷毛(straw)的尼龙刷子刷该涂覆刀片。在光学显微镜下观察被刷过的刀片显示出,TiN顶层已经沿切削刃刷落,留下光滑的Al2O3表面。对横向剖开的被刷样品进行涂层厚度测量显示出,沿刃边的Al2O3层的层厚度已经减少大约50%。
实例3
实例1和2中不同类型的刀片在切削实验中进行比较。
操作1:    肩部铣削-粗加工,R390-32毫米
工件:     实验件
材料:            42CrMo4,300HB,中合金钢
切削速度:        150米/分钟
进给速度/齿:     0.17毫米/齿
切削深度:        3毫米
刀片类型:        R390-11T308M-PM
注意:1刀片,干,由于铣刀出口处的大切屑负载产生极高的韧性要求。
刀具寿命标准是刃边切成碎屑和破裂。
结果:           刀具寿命,持续时间(passes):
发明A:          47
现有技术B:      20
操作2:          肩部铣削,R390-32毫米
工件:           厚钢板
材料:           SS2134,低合金钢
切削速度:       181米/分钟
进给速度/齿:    0.17毫米/齿
切削深度:       10毫米
刀片类型:       R390-170408M-PM
注意:刀具上有3个刀片,干,由于部件和程序采用逆铣。
刀具寿命标准是侧面磨损和刃边切成碎屑。
结果:           刀具寿命,制成部件:
发明A:          15
现有技术B:      5
操作3:          端铣-粗加工,R245-63毫米
工件:            连杆
材料:            49MnVS3
切削速度:        198米/分钟
进给速度/齿:     0.20毫米/齿
切削深度:        4毫米
刀片类型:        R245-12T3M-PM
注意:干,6刀片,锻造表皮,由于部件复杂性引起的不良出口角。
刀具寿命标准是导致工件上毛刺的刃切屑。
结果:          刀具寿命,分钟:
发明A:         404
现有技术B:     110
操作4:         端铣-粗加工,R300-100毫米
工件:          连杆机构
材料:          铸件,SS2225-23
切削速度:      157米/分钟
进给速度/齿:   0.24毫米/齿
切削深度:      3-5毫米
刀片类型:      R300-1648M-PH
注意:干,8齿,由于铸造表皮造成难于加工。
刀具寿命标准是由于梳状裂纹导致的刃边切屑。好的结果导致在无人操纵加工期间更好的可靠性。
结果:         刀具寿命,分钟:
发明A:        76
现有技术B:    47
操作5:          端面铣削和仿形铣削,R300-80毫米
工件:           注模
材料:           Impax Supreme 30HRc,工具钢
切削速度:       150米/分钟
进给速度/齿:    0.6毫米/齿
切削深度:       1毫米
刀片类型:       R300-1240M-PH
注意:干,6刀片,轮廓仿形铣削,高工作台进给。
刀具寿命标准是由于梳状裂纹导致的切削。
结果:           刀具寿命,分钟:
发明A:          93
现有技术B:      47
从切削试验的结果可以清楚地看出,实例1的刀片优于根据实例2的现有技术的刀片。
尽管本发明已经结合优选实施例进行了描述,但是本领域的技术人员应该认识到,在不脱离由所附权利要求限定的本发明的精神和范围的情况下,可以进行未具体描述的增加、减少、变形和替换。

Claims (8)

1.一种用于在湿或干条件下加工带有或不带有未加工表面的低和中合金钢、不锈钢的切削工具铣削刀片,其包括硬质合金主体和涂层,其特征在于:所述硬质合金主体具有12.0-15.0wt%Co,优选地12.5-14.5wt%Co,最优选地13-14wt%Co,0.52-0.64wt%Cr,优选地0.54-0.62wt%Cr,最优选地0.55-0.61wt%Cr和余量WC的组成,并且CW比为0.76-0.84,优选地0.78-0.82,最优选地0.79-0.81,HcJ值为12.5-14.5kA/m,优选地12.7-14.0kA/m,并且
所述刀片至少部分地涂覆有4.1-6.9μm厚的涂层,该涂层包括总厚度为1.9-3.6μm的至少三层TiCxNyOz,其中一层紧邻硬质合金,并且喷砂处理的α-Al2O3层为至少位于前刀面上的外层,具有1.9-3.6μm的总厚度的TiCxNyOz层包括:
紧邻所述硬质合金的第一TiCxNyOz层,具有x+y=1,x>=0,优选地x<0.2并且z=0的组成;
第二TiCxNyOz层,具有x>0.4,y>0.4并且0=<z<0.1,优选地z=0的组成;
紧邻所述α-Al2O3层的第三TiCxNyOz层,具有x+y+z>=1,并且z>0,优选地z>0.2,最优选地z>0.2,x+y+z=1并且y<0.2的组成;
所述α-Al2O3层具有1.8-3.6μm的厚度,具有位于经受了喷砂处理的表面上的磨扁晶粒。
2.如权利要求1所述的刀片,其特征在于:所述硬质合金具有13.3-13.7wt%Co和0.56-0.60wt%Cr的组成。
3.如权利要求1所述的刀片,其特征在于:在后刀面上具有0.1-1μm的着色顶层。
4.如权利要求3所述的刀片,其特征在于:所述着色顶层由通过CVD或PVD工艺,优选地CVD工艺沉积的TiN,TiCN,TiC,ZrN和/或HfN构成。
5.制造切削刀片的方法,所述刀片用于在湿或干条件下加工带有或不带有未加工表面的低和中合金钢、不锈钢,所述刀片包括硬质合金主体和涂层,该涂层通过粉末冶金工艺,湿磨形成硬质成分和粘结相的粉末,将已磨好的混合物压制到希望形状和尺寸的主体上并烧结而成,其特征在于,所述硬质合金主体具有12.0-15.0wt%Co,优选地12.5-14.5wt%Co,最优选地13-14wt%Co,0.52-0.64wt%Cr,优选地0.54-0.62wt%Cr,最优选地0.55-0.61wt%Cr和余量WC的组成,并且极化矫顽力HcJ值为12.5-14.5kA/m,优选地12.7-14.0kA/m,CW比为0.76-0.84,优选地0.78-0.82,最优选地0.79-0.81,并且所述主体至少部分地涂覆有4.1-6.9μm厚的涂层,该涂层包括至少三层TiCxNyOz形成内涂层,α-Al2O3层作为至少位于前刀面上的外层,所述TiCxNyOz层具有1.9-3.6μm的总厚度并且包括:
紧邻所述硬质合金的第一TiCxNyOz层,具有x+y=1,x>=0,优选地x<0.2,并且z=0的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD方法制成,
第二TiCxNyOz层,具有x>0.4,y>0.4并且0=<z<0.1,优选地z=0的组成,该层通过已知MTCVD工艺,温度885-850℃,并且CH3CN作为碳/氮源而制成,
紧邻α-Al2O3层的第三TiCxNyOz层,具有x+y+z>=1,并且z>0,优选地z>0.2,x+y+z=1并且y<0.2的组成,该层利用由TiCl4,H2和N2组成的反应混合物通过已知CVD工艺制成,
所述α-Al2O3层厚度为1.8-3.6μm,由已知的CVD工艺沉积而成,并且
至少在前刀面上使所述刀片经受喷砂处理。
6.如权利要求5所述的方法,其特征在于:在喷砂处理之前优选地使用CVD工艺在α-Al2O3层的顶部沉积优选地为TiN,TiCN,TiC,ZrN或HfN的附加的0.1-1μm的着色层。
7.如权利要求6所述的方法,其特征在于:在喷砂处理之后,最优选地使用CVD工艺在后刀面上沉积优选地为TiN,TiCN,TiC,ZrN或HfN的附加的0.1-1μm的着色顶层。
8.如权利要求1-4所述的刀片的应用,用于对带有未加工表面,例如铸造表皮,锻造表皮,热轧或冷轧表皮,或预加工表面的低和中合金钢和不锈钢在不稳定条件下进行有韧性要求的湿和干铣削,其中切削速度和进给速度如下:
以90°切入角铣削,切削速度为25-350米/分钟,优选地100-250米/分钟,并且进给速度为0.04-0.4毫米/齿,或
以45-75°切入角端面铣削,切削速度为25-350米/分钟,优选地100-250米/分钟,并且进给速度为0.05-0.7毫米/齿,或
高速进给铣削应用,切削速度为25-350米/分钟,进给速度为0.30-3.0毫米/齿,优选地0.3-1.8毫米/齿。
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