JP2004188502A - Cutting tool of surface-coated cermet with hard coating layer having excellent thermal shock resistance - Google Patents
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【０００１】
【発明の属する技術分野】
この発明は、特に鋼や鋳鉄などの高速断続切削時に切刃部にきわめて短いピッチで繰り返し付加される熱衝撃に対して硬質被覆層がすぐれた耐チッピング性を発揮する、すなわち硬質被覆層がすぐれた耐熱衝撃性を有する表面被覆サーメット製切削工具（以下、被覆サーメット工具という）に関するものである。
【０００２】
【従来の技術】
従来、一般に、炭化タングステン（以下、ＷＣで示す）基超硬合金または炭窒化チタン（以下、ＴｉＣＮで示す）基サーメットで構成された基体（以下、これらを総称して工具基体という）の表面に、
（ａ）化学蒸着形成および／または物理蒸着形成（以下、単に蒸着形成という）されたＴｉの炭化物（以下、ＴｉＣで示す）層、窒化物（以下、同じくＴｉＮで示す）層、炭窒化物（以下、ＴｉＣＮで示す）層、炭酸化物（以下、ＴｉＣＯで示す）層、および炭窒酸化物（以下、ＴｉＣＮＯで示す）層のうちの１層または２層以上の積層からなるＴｉ化合物層で構成され、かつ３〜２０μｍの平均層厚を有する下部層、
（ｂ）蒸着形成した状態でα型および／またはκ型の結晶構造を有する酸化アルミニウム（以下、Ａｌ２Ｏ３で示す）層で構成され、かつ３〜２０μｍの平均層厚を有する上部層、
以上（ａ）の下部層と（ｂ）の上部層で構成された硬質被覆層を蒸着形成してなる被覆サーメット工具が知られており、この被覆サーメット工具が、例えば各種の鋼や鋳鉄などの連続切削や断続切削に用いられていることも知られている（例えば、特許文献１参照）。
【０００３】
また、一般に、上記の被覆サーメット工具の硬質被覆層を構成するＴｉ化合物層やＡｌ２ Ｏ３ 層が粒状結晶組織を有し、さらに前記Ｔｉ化合物層を構成するＴｉＣＮ層を、層自身の強度向上を目的として、通常の化学蒸着装置にて、反応ガスとして有機炭窒化物を含む混合ガスを使用し、７００〜９５０℃の中温温度域で化学蒸着することにより形成して縦長成長結晶組織をもつようにすることも知られている（例えば、特許文献２参照）。
【０００４】
【特許文献１】
特開平６−３１５０３号公報
【特許文献２】
特開平６−８０１０号公報
【０００５】
【発明が解決しようとする課題】
近年の切削装置の高性能化はめざましく、一方で切削加工に対する省力化および省エネ化、さらに低コスト化の要求は強く、これに伴い、切削加工は一段と高速化の傾向にあるが、上記の従来被覆サーメット工具においては、これを鋼や鋳鉄などの通常の条件での連続切削や断続切削に用いた場合には問題はないが、特にこれを切削条件の最も厳しい高速断続切削、すなわち切刃部にきわめて短いピッチで繰り返し熱衝撃が付加される高速断続切削に用いた場合、硬質被覆層の上部層を構成するＡｌ２Ｏ３層は、硬質で耐熱性にすぐれるものの、熱衝撃に脆いために、硬質被覆層にはチッピング（微小欠け）が発生し易くなり、この結果比較的短時間で使用寿命に至るのが現状である。
【０００６】
【課題を解決するための手段】
そこで、本発明者等は、上述のような観点から、上記の被覆サーメット工具の硬質被覆層の上部層を構成するＡｌ２Ｏ３層の耐熱衝撃性向上をはかるべく研究を行った結果、
まず、通常の条件で、結晶構造がκ型またはθ型のＡｌ２Ｏ３層を蒸着形成し、これに加熱処理、望ましくはＡｒ雰囲気中、温度：１０００℃以上で所定時間保持の条件で加熱処理を施すと、前記κ型またはθ型の結晶構造はα型結晶構造に変態し、かつ加熱変態生成クラックが層中に分散分布した組織を有するようになるが、この加熱変態α型Ａｌ２Ｏ３層を上部層とし、この上部層の表面に、同じく通常の条件で、相対的に薄膜のκ型Ａｌ２Ｏ３層を表面層として蒸着形成すると、この蒸着κ型Ａｌ２Ｏ３層は前記加熱変態α型Ａｌ２Ｏ３層との界面でこれの加熱変態生成クラック中に十分に入り込んで前記加熱変態生成クラックを著しく安定化した状態に保持するようになるので、硬質被覆層の下部層が上記Ｔｉ化合物層で構成され、同上部層および表面層が上記の加熱変態α型Ａｌ２Ｏ３層および蒸着κ型Ａｌ２Ｏ３層で構成された被覆サーメット工具においては、前記上部層を構成する加熱変態α型Ａｌ２Ｏ３層中に分散分布する加熱変態生成クラックが、特に高速断続切削時の激しい熱衝撃を吸収して、これを緩和することから硬質被覆層におけるチッピング発生が著しく抑制されるようになるという研究結果を得たのである。
【０００７】
この発明は、上記の研究結果に基づいてなされたものであって、ＷＣ基超硬合金またはＴｉＣＮ基サーメットで構成された工具基体の表面に、
（ａ）いずれも蒸着形成されたＴｉＣ層、ＴｉＮ層、ＴｉＣＮ層、ＴｉＣＯ層、およびＴｉＣＮＯ層のうちの１層または２層以上の積層からなるＴｉ化合物層で構成され、かつ３〜２０μｍの平均層厚を有する下部層、
（ｂ）蒸着形成した状態でκ型またはθ型の結晶構造を有するＡｌ２Ｏ３層に加熱変態処理を施して結晶構造をα型結晶構造とし、かつ加熱変態生成クラックが分散分布した組織を有する加熱変態α型Ａｌ２Ｏ３層で構成され、かつ３〜１５μｍの平均層厚を有する上部層、
（ｃ）蒸着形成した状態でκ型の結晶構造を有する蒸着κ型Ａｌ２Ｏ３層で構成され、かつ０．５〜２μｍの平均層厚を有する表面層、
以上（ａ）〜（ｃ）で構成された硬質被覆層を形成してなる、硬質被覆層がすぐれた耐熱衝撃性を有する被覆サーメット工具に特徴を有するものである。
【０００８】
なお、この発明の被覆サーメット工具の硬質被覆層の構成層の平均層厚を上記の通りに限定したのは以下に示す理由によるものである。
（ａ）下部層（Ｔｉ化合物層）
Ｔｉ化合物層は、自体が強度を有し、これの存在によって硬質被覆層が強度を具備するようになるほか、工具基体と上部層である加熱変態α型Ａｌ２Ｏ３層のいずれにも強固に密着し、よって硬質被覆層の工具基体に対する密着性向上に寄与する作用をもつが、その平均層厚が３μｍ未満では、前記作用を十分に発揮させることができず、一方その平均層厚が２０μｍを越えると、特に高熱発生を伴なう高速断続切削で熱塑性変形を起し易くなり、これが偏摩耗の原因となることから、その平均層厚を３〜２０μｍと定めた。
【０００９】
（ｂ）上部層（加熱変態α型Ａｌ２Ｏ３層）
加熱変態α型Ａｌ２Ｏ３層には、上記の通り層中に分散分布する加熱変態生成クラックの作用で熱衝撃を吸収して、硬質被覆層にチッピングが発生するのを防止する作用があるが、その平均層厚が３μｍ未満では、前記作用を十分に発揮させることができず、一方その平均層厚が１５μｍを越えて厚くなりすぎると、前記加熱変態生成クラックがチッピング発生の原因となることから、その平均層厚を３〜１５μｍと定めた。
【００１０】
（ｃ）表面層（蒸着κ型Ａｌ２Ｏ３層）
蒸着κ型Ａｌ２Ｏ３層には、上記の通り加熱変態α型Ａｌ２Ｏ３層との界面でこれの加熱変態生成クラック中に十分に入り込んで前記加熱変態生成クラックを著しく安定化した状態に保持し、もって前記加熱変態α型Ａｌ２Ｏ３層によってもたらされる耐熱衝撃性の向上を十分に発揮させるようにする作用があるが、その平均層厚が０．５μｍ未満では、前記加熱変態α型Ａｌ２Ｏ３層中の加熱変態生成クラックの安定化が不十分であるため、前記加熱変態生成クラックが原因のチッピングが発生し易くなり、一方その平均層厚が２μｍを越えて厚くなりすぎても、前記加熱変態生成クラックが表面層中に伝播し易くなり、これ自体にチッピングが発生し易くなることから、その平均層厚を０．５〜２μｍと定めた。
【００１１】
【発明の実施の形態】
つぎに、この発明の被覆サーメット工具を実施例により具体的に説明する。
原料粉末として、いずれも０．５〜４μｍの範囲内の所定の平均粒径を有するＷＣ粉末、（Ｔｉ，Ｗ）Ｃ（質量比で、以下同じ、ＴｉＣ／ＷＣ＝３０／７０）粉末、（Ｔｉ，Ｗ）ＣＮ（ＴｉＣ／ＴｉＮ／ＷＣ＝２４／２０／５６）粉末、（Ｔａ，Ｎｂ）Ｃ（ＴａＣ／ＮｂＣ＝９０／１０）粉末、Ｃｒ３Ｃ２粉末、およびＣｏ粉末を用意し、これら原料粉末を表１に示される配合組成に配合し、ボールミルで７２時間湿式混合し、乾燥した後、９８ＭＰａの圧力で所定形状の圧粉体にプレス成形し、この圧粉体を５Ｐａの真空中、１４１０℃に１時間保持の条件で真空焼結し、焼結後、切刃部にＲ：０．０７ｍｍのホーニング加工を施すことによりＩＳＯ・ＣＮＭＧ１２０４０８に規定するスローアウエイチップ形状をもったＷＣ基超硬合金製の工具基体Ａ〜Ｆをそれぞれ製造した。
【００１２】
また、原料粉末として、いずれも０．５〜２μｍの平均粒径を有するＴｉＣＮ（質量比でＴｉＣ／ＴｉＮ＝５０／５０）粉末、Ｍｏ２ Ｃ粉末、ＺｒＣ粉末、ＮｂＣ粉末、ＴａＣ粉末、ＷＣ粉末、Ｃｏ粉末、およびＮｉ粉末を用意し、これら原料粉末を、表２に示される配合組成に配合し、ボールミルで２４時間湿式混合し、乾燥した後、９８ＭＰａの圧力で圧粉体にプレス成形し、この圧粉体を１．３ｋＰａの窒素雰囲気中、温度：１５４０℃に１時間保持の条件で焼結し、焼結後、切刃部分にＲ：０．０７ｍｍのホーニング加工を施すことによりＩＳＯ規格・ＣＮＭＧ１２０４１２のチップ形状をもったＴｉＣＮ基サーメット製の工具基体ａ〜ｆを形成した。
【００１３】
ついで、これらの工具基体Ａ〜Ｆおよび工具基体ａ〜ｆの表面に、通常の化学蒸着装置を用い、表３（表３中のｌ−ＴｉＣＮは特開平６−８０１０号公報に記載される縦長成長結晶組織をもつＴｉＣＮ層の形成条件を示すものであり、これ以外は通常の粒状結晶組織の形成条件を示すものである）に示される条件にて、表４に示される目標層厚のＴｉ化合物層を硬質被覆層の下部層として蒸着形成し、ついで同じく表３に示される条件で結晶構造がκ型またはθ型のＡｌ２Ｏ３層を蒸着形成し、これにＡｒ雰囲気中、温度：１０５０℃に２〜１０時間の範囲内の所定時間保持の条件で加熱変態処理を施して、前記κ型またはθ型の結晶構造をα型に変態させ、加熱変態生成クラックが層中に分散分布した加熱変態α型Ａｌ２Ｏ３層を同じく表４に示される目標層厚で硬質被覆層の上部層として形成し、さらに同じく表３に示される条件で、かつ表４に示される目標層厚の蒸着κ型Ａｌ２Ｏ３層を同表面層として形成することにより本発明被覆サーメット工具１〜１２をそれぞれ製造した。
また、比較の目的で、表５に示される通り、硬質被覆層の上部層を同じく表５に示される平均層厚の蒸着α型Ａｌ２Ｏ３層とし、かつ表面層の形成を行なわない以外は同一の条件で従来被覆サーメット工具１〜１２をそれぞれ製造した。
【００１４】
さらに、上記の本発明被覆サーメット工具と従来被覆サーメット工具の硬質被覆層を構成する加熱変態α型Ａｌ２Ｏ３層と蒸着α型Ａｌ２Ｏ３層の相違を観察する目的でＸ線回折を測定した。
これらのＸ線回折の測定は、Ｘ線回折チャート上で（００１）面および（００２）面にのみ回折ピークが現れる単結晶ＷＣを基体試料として用い、この基体試料の表面に、本発明被覆サーメット工具３、７、および１１の目標層厚が１５μｍ、１０μｍ、および５μｍの加熱変態α型Ａｌ２Ｏ３層、並びに従来被覆サーメット工具１、２、および４の同じく目標層厚が１５μｍ、１０μｍ、および５μｍの蒸着α型Ａｌ２Ｏ３層の形成条件と同一の条件で、それぞれ目標層厚が１５μｍ、１０μｍ、および５μｍの加熱変態α型Ａｌ２Ｏ３層および蒸着α型Ａｌ２Ｏ３層を直接形成して本発明被覆試料Ａ〜Ｃおよび従来被覆試料ａ〜ｃを製造し、これら被覆試料の前記加熱変態α型Ａｌ２Ｏ３層および蒸着α型Ａｌ２Ｏ３層のＸ線回折を測定することにより行なった。この測定結果を図１〜６に示した。
本発明被覆試料Ａ〜Ｃの加熱変態α型Ａｌ２Ｏ３層のＸ線回折チャートを示す図１〜３と、従来被覆試料ａ〜ｃの蒸着α型Ａｌ２Ｏ３層のＸ線回折チャートを示す図４〜６の比較から、前記加熱変態α型Ａｌ２Ｏ３層では（００６）面および（０１８）面に明確な回折ピークが現れているのに対して、前記蒸着α型Ａｌ２Ｏ３層ではこれら（００６）面および（０１８）面に回折ピークは存在しないことが明かである。
さらに、上記の単結晶ＷＣで構成された基体試料の表面に、それぞれ目標層厚が１５μｍ、１０μｍ、および５μｍの加熱変態α型Ａｌ２Ｏ３層および蒸着α型Ａｌ２Ｏ３層を直接形成してなる本発明被覆試料Ａ〜Ｃおよび従来被覆試料ａ〜ｃの前記加熱変態α型Ａｌ２Ｏ３層および蒸着α型Ａｌ２Ｏ３層のそれぞれについて、基体試料表面と平行な研磨表面における結晶面の電子線後方散乱回折（ＥＢＳＤ）を、熱電界放射型走査電子顕微鏡（日本電子（株）製）および方位回折装置（テクセム・ラボラトリース（株）製）を用いて行なったところ、前記加熱変態α型Ａｌ２Ｏ３層では、いずれも結晶方位マップが濃い赤色の色調を示し、これはＡｌ２Ｏ３の結晶構造である六方晶の（０００１）面（六角形の平行面）が前記Ａｌ２Ｏ３層表面（基体試料表面）に対して平行にきわめて強く配向していることを示し、一方前記蒸着α型Ａｌ２Ｏ３層では、いずれも結晶方位マップに緑色や青色、さらに黄色およびピンク色など様々な色調が現れ、これは六方晶を構成する結晶面に特定の配向性が存在しないことを示すものである。
【００１５】
また、この結果得られた本発明被覆サーメット工具１〜１２および従来被覆サーメット工具１〜１２について、これの硬質被覆層の構成層を走査型電子顕微鏡を用いて観察（層の縦断面を観察）したところ、前者ではいずれもＴｉ化合物層、加熱変態生成クラックが層中に分散分布した加熱変態α型Ａｌ２Ｏ３層、および蒸着κ型Ａｌ２Ｏ３層からなり、後者では、いずれもＴｉ化合物と蒸着α型Ａｌ２Ｏ３層からなることが確認された。また、これらの被覆サーメット工具の硬質被覆層の構成層の厚さを、走査型電子顕微鏡を用いて測定（同じく縦断面測定）したところ、いずれも目標層厚と実質的に同じ平均層厚（５点測定の平均値）を示した。
【００１６】
つぎに、上記の各種の被覆サーメット工具をいずれも工具鋼製バイトの先端部に固定治具にてネジ止めした状態で、本発明被覆サーメット工具１〜６および従来被覆サーメット工具１〜６については、
被削材：ＪＩＳ・ＳＣＭ４４０の長さ方向等間隔４本縦溝入り丸棒、
切削速度：３５０ｍ／ｍｉｎ、
切り込み：１．５ｍｍ、
送り：０．２５ｍｍ／ｒｅｖ、
切削時間：３分、
の条件での合金鋼の乾式高速断続切削試験、
被削材：ＪＩＳ・ＳＵＳ３０４の長さ方向等間隔４本縦溝入り丸棒、
切削速度：３５０ｍ／ｍｉｎ、
切り込み：２．０ｍｍ、
送り：０．１５ｍｍ／ｒｅｖ、
切削時間：３分、
の条件でのステンレス鋼の乾式高速断続切削試験を行った。
【００１７】
さらに、本発明被覆サーメット工具７〜１２および従来被覆サーメット工具７〜１２については、
被削材：ＪＩＳ・ＳＣＭ４４０の長さ方向等間隔４本縦溝入り丸棒、
切削速度：３５０ｍ／ｍｉｎ、
切り込み：１．０ｍｍ、
送り：０．２５ｍｍ／ｒｅｖ、
切削時間：３分、
の条件での合金鋼の乾式高速断続切削試験、
被削材：ＪＩＳ・ＳＵＳ３０４の長さ方向等間隔４本縦溝入り丸棒、
切削速度：３５０ｍ／ｍｉｎ、
切り込み：１．５ｍｍ、
送り：０．１ｍｍ／ｒｅｖ、
切削時間：３分、
の条件でのステンレス鋼の乾式高速断続切削試験を行い、いずれの切削試験でも切刃の逃げ面摩耗幅を測定した。この測定結果を表６に示した。
【００１８】
【表１】
【表２】
【表３】
【表４】
【表５】
【表６】
【発明の効果】
表４〜６に示される結果から、本発明被覆サーメット工具１〜１２は、硬質被覆層の上部層を構成する加熱変態α型Ａｌ２Ｏ３層中に分散分布する加熱変態生成クラックの作用で、熱衝撃がきわめて高く、かつ高い発熱を伴なう鋼の高速断続切削でも、硬質被覆層中に内蔵された状態で存在する前記加熱変態生成クラックの作用で、切刃部のチッピング発生が著しく抑制され、すぐれた耐摩耗性を発揮するのに対して、硬質被覆層の上部層が蒸着α型Ａｌ２Ｏ３層からなる従来被覆サーメット工具１〜１２においては、高速断続切削では前記蒸着α型Ａｌ２Ｏ３層が激しい熱衝撃に耐えられず、切刃部にチッピングが発生し、比較的短時間で使用寿命に至ることが明らかである。
上述のように、この発明の被覆サーメット工具は、各種鋼や鋳鉄などの通常の条件での連続切削や断続切削は勿論のこと、特に熱衝撃がきわめて高く、かつ高い発熱を伴なう切削条件の最も厳しい高速断続切削でもすぐれた耐チッピング性を示し、長期に亘ってすぐれた切削性能を発揮するものであるから、切削装置の高性能化並びに切削加工の省力化および省エネ化、さらに低コスト化に十分満足に対応できるものである。
【図面の簡単な説明】
【図１】本発明被覆サーメット工具３の硬質被覆層を構成する加熱変態α型Ａｌ２Ｏ３層（目標層厚：１５μｍ）のＸ線回折チャートを示す図である。
【図２】本発明被覆サーメット工具７の硬質被覆層を構成する加熱変態α型Ａｌ２Ｏ３層（目標層厚：１０μｍ）のＸ線回折チャートを示す図である。
【図３】本発明被覆サーメット工具１１の硬質被覆層を構成する加熱変態α型Ａｌ２Ｏ３層（目標層厚：５μｍ）のＸ線回折チャートを示す図である。
【図４】従来被覆サーメット工具１の硬質被覆層を構成する蒸着α型Ａｌ２Ｏ３層（目標層厚：１５μｍ）のＸ線回折チャートを示す図である。
【図５】従来被覆サーメット工具２の硬質被覆層を構成する蒸着α型Ａｌ２Ｏ３層（目標層厚：１０μｍ）のＸ線回折チャートを示す図である。
【図６】従来被覆サーメット工具４の硬質被覆層を構成する蒸着α型Ａｌ２Ｏ３層（目標層厚：５μｍ）のＸ線回折チャートを示す図である。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention provides a hard coating layer that exhibits excellent chipping resistance against thermal shock repeatedly applied at a very short pitch to a cutting edge, particularly during high-speed intermittent cutting of steel or cast iron, that is, the hard coating layer is excellent. The present invention relates to a surface-coated cermet cutting tool having thermal shock resistance (hereinafter referred to as a coated cermet tool).
[0002]
[Prior art]
2. Description of the Related Art Conventionally, generally, a substrate (hereinafter, these are collectively referred to as a tool substrate) formed of a tungsten carbide (hereinafter, referred to as WC) -based cemented carbide or a titanium cermet (hereinafter, referred to as TiCN) -based cermet is generally provided on a surface of the substrate. ,
(A) Ti carbide (hereinafter referred to as TiC) layer, nitride (hereinafter also referred to as TiN) layer, carbonitride (hereinafter referred to as TiN) layer formed by chemical vapor deposition and / or physical vapor deposition (hereinafter simply referred to as vapor deposition) A Ti compound layer comprising one or two or more of a TiCN layer, a carbon oxide layer (hereinafter referred to as TiCO) layer, and a carbon oxynitride layer (hereinafter referred to as TiCNO) layer And a lower layer having an average layer thickness of 3 to 20 μm,
(B) an upper layer composed of an aluminum oxide (hereinafter, referred to as Al 2 O 3 ) layer having an α-type and / or κ-type crystal structure in an as-deposited state, and having an average layer thickness of 3 to 20 μm;
A coated cermet tool formed by vapor-depositing a hard coating layer composed of the lower layer of (a) and the upper layer of (b) is known, and this coated cermet tool is made of, for example, various kinds of steel or cast iron. It is also known to be used for continuous cutting and intermittent cutting (for example, see Patent Document 1).
[0003]
In general, the Ti compound layer and the Al 2 O 3 layer constituting the hard coating layer of the above-mentioned coated cermet tool have a granular crystal structure, and the TiCN layer constituting the Ti compound layer is further improved in strength by itself. With the use of a mixed gas containing an organic carbonitride as a reaction gas in a normal chemical vapor deposition apparatus, a chemical vapor deposition is performed at a medium temperature range of 700 to 950 ° C. to form a vertically elongated crystal structure. It is also known to do so (for example, see Patent Document 2).
[0004]
[Patent Document 1]
JP-A-6-31503 [Patent Document 2]
JP-A-6-8010 [0005]
[Problems to be solved by the invention]
In recent years, the performance of cutting equipment has been remarkably improved, but on the other hand, there has been a strong demand for labor saving, energy saving, and further cost reduction for cutting work.Accordingly, cutting work has tended to be further accelerated. In the case of coated cermet tools, there is no problem if this is used for continuous cutting or interrupted cutting under ordinary conditions such as steel or cast iron. When used for high-speed interrupted cutting, in which thermal shock is repeatedly applied at a very short pitch to the surface, the Al 2 O 3 layer constituting the upper layer of the hard coating layer is hard and excellent in heat resistance, but is brittle to thermal shock. In addition, chipping (small chipping) easily occurs in the hard coating layer, and as a result, the service life of the hard coating layer is relatively short in the present situation.
[0006]
[Means for Solving the Problems]
In view of the above, the present inventors have conducted research to improve the thermal shock resistance of the Al 2 O 3 layer constituting the upper layer of the hard coating layer of the coated cermet tool from the above-described viewpoint.
First, under normal conditions, an Al 2 O 3 layer having a κ-type or θ-type crystal structure is formed by vapor deposition, and a heat treatment is performed on the Al 2 O 3 layer, preferably in an Ar atmosphere at a temperature of 1000 ° C. or more for a predetermined time. When subjected to the process, the crystal structure of the κ-type or θ-type transformed into α-type crystal structure, and the heating transformation product cracks are to have a variance distribution organization in the layer, the heating transformation α-type Al 2 O 3 layer as an upper layer, the surface of the upper layer, also under normal conditions, when deposited form a κ type the Al 2 O 3 layer having a relatively thin film as a surface layer, the deposited κ type the Al 2 O 3 layer At the interface with the heat-transformed α-type Al 2 O 3 layer, penetrates sufficiently into the heat-transformed cracks and keeps the heat-transformed cracks in a remarkably stabilized state. The lower layer is composed of the Ti compound layer. In coated cermet tool the upper layer and the surface layer is constituted by the heat transformation α type the Al 2 O 3 layer and deposition κ-type Al 2 O 3 layer is heated transformed α-type Al 2 constituting the upper layer A study that cracks generated by heat transformation dispersed and distributed in the O 3 layer absorb severe thermal shock especially during high-speed interrupted cutting, and alleviate this, so that the occurrence of chipping in the hard coating layer is significantly suppressed. The result was obtained.
[0007]
The present invention has been made on the basis of the above research results, and has a tool base formed of a WC-based cemented carbide or a TiCN-based cermet,
(A) Each of them is composed of a Ti compound layer composed of one or two or more of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer, and a TiCNO layer formed by vapor deposition, and has an average of 3 to 20 μm. A lower layer having a layer thickness,
(B) The Al 2 O 3 layer having a κ-type or θ-type crystal structure in a state formed by vapor deposition is subjected to a heat transformation treatment to change the crystal structure to an α-type crystal structure, and a structure in which heat transformation-generated cracks are dispersed and distributed. An upper layer composed of a heat-transformed α-type Al 2 O 3 layer and having an average layer thickness of 3 to 15 μm;
(C) a surface layer composed of an evaporated κ-type Al 2 O 3 layer having a κ-type crystal structure in an as-deposited state and having an average layer thickness of 0.5 to 2 μm;
The present invention is characterized by a coated cermet tool having a hard coating layer having excellent thermal shock resistance, formed by forming a hard coating layer composed of (a) to (c) above.
[0008]
The reason why the average layer thickness of the constituent layers of the hard coating layer of the coated cermet tool of the present invention is limited as described above is as follows.
(A) Lower layer (Ti compound layer)
The Ti compound layer itself has strength, and the presence of the Ti compound layer allows the hard coating layer to have strength. In addition, the Ti compound layer is firmly attached to both the tool base and the heating-transformed α-type Al 2 O 3 layer as the upper layer. Has a function of contributing to the improvement of the adhesion of the hard coating layer to the tool base, but if the average layer thickness is less than 3 μm, the above effect cannot be sufficiently exerted. If it exceeds 20 μm, it becomes easy to cause thermoplastic deformation especially in high-speed interrupted cutting accompanied by high heat generation, which causes uneven wear. Therefore, the average layer thickness is set to 3 to 20 μm.
[0009]
(B) Upper layer (heat-transformed α-type Al 2 O 3 layer)
The heat-transformed α-type Al 2 O 3 layer has a function of absorbing thermal shock by the action of the heat-transformed cracks dispersed and distributed in the layer as described above, thereby preventing chipping from occurring in the hard coating layer. However, if the average layer thickness is less than 3 μm, the above effect cannot be sufficiently exerted. On the other hand, if the average layer thickness exceeds 15 μm and becomes too thick, the heat transformation generation cracks cause chipping. Therefore, the average layer thickness was determined to be 3 to 15 μm.
[0010]
(C) Surface layer (evaporated κ-type Al 2 O 3 layer)
As described above, the deposited κ-type Al 2 O 3 layer sufficiently penetrates into the heat-transformed cracks at the interface with the heat-transformed α-type Al 2 O 3 layer, and the heat-transformed cracks are significantly stabilized. To improve the thermal shock resistance provided by the heat-transformed α-type Al 2 O 3 layer, but if the average layer thickness is less than 0.5 μm, the heat transformed Since the stabilization of the heat transformation cracks in the α-type Al 2 O 3 layer is insufficient, chipping due to the heat transformation cracks is likely to occur, while the average layer thickness becomes larger than 2 μm. Even if it is too long, the cracks generated by the heat transformation easily propagate into the surface layer and chipping easily occurs on the cracks. Therefore, the average layer thickness is set to 0.5 to 2 μm.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, the coated cermet tool of the present invention will be specifically described with reference to examples.
As raw material powders, WC powders each having a predetermined average particle size in the range of 0.5 to 4 μm, (Ti, W) C (the same hereinafter, TiC / WC = 30/70 by mass ratio) powder, Ti, W) CN (TiC / TiN / WC = 24/20/56) powder, (Ta, Nb) C (TaC / NbC = 90/10) powder, Cr 3 C 2 powder, and Co powder, These raw material powders were blended in the composition shown in Table 1, wet-mixed in a ball mill for 72 hours, dried, and then pressed into a green compact of a predetermined shape at a pressure of 98 MPa. Medium, vacuum sintering at 1410 ° C. for 1 hour, and after sintering, a WC having a throw-away tip shape specified in ISO · CNMG120408 by subjecting the cutting edge to honing processing of R: 0.07 mm. Base cemented carbide The tool substrate A~F were produced, respectively.
[0012]
Further, as raw material powders, TiCN (TiC / TiN = 50/50 by mass ratio) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder each having an average particle diameter of 0.5 to 2 μm , Co powder, and Ni powder are prepared, and these raw material powders are blended in the blending composition shown in Table 2, wet-mixed in a ball mill for 24 hours, dried, and pressed into a green compact at a pressure of 98 MPa. The green compact was sintered in a nitrogen atmosphere of 1.3 kPa at a temperature of 1540 ° C. for 1 hour, and after sintering, the cutting edge was subjected to a honing process of R: 0.07 mm to obtain an ISO. Tool bases a to f made of TiCN-based cermet having a tip shape of standard CNMG120412 were formed.
[0013]
Then, on the surfaces of the tool bases A to F and the tool bases a to f, a conventional chemical vapor deposition apparatus was used, and Table 3 (l-TiCN in Table 3 is a vertically long sheet described in JP-A-6-8010). It shows the conditions for forming a TiCN layer having a growth crystal structure, and the other conditions show the conditions for forming a normal granular crystal structure.) A compound layer was formed by vapor deposition as a lower layer of the hard coating layer, and then a κ-type or θ-type Al 2 O 3 layer was formed by vapor deposition under the same conditions as shown in Table 3, and the layer was formed in an Ar atmosphere at a temperature of: A heat transformation treatment is performed at a temperature of 1050 ° C. for a predetermined time within a range of 2 to 10 hours to transform the κ-type or θ-type crystal structure into α-type. similarly Table heated transformation α-type Al 2 O 3 layer and Formed as an upper layer of the hard coating layer at the target layer thickness shown in further similarly under the conditions shown in Table 3, and as the surface layer the target layer thickness deposited κ type the Al 2 O 3 layer as indicated in Table 4 By forming, the
For the purpose of comparison, as shown in Table 5, except that the upper layer of the hard coating layer was a vapor-deposited α-type Al 2 O 3 layer having an average layer thickness also shown in Table 5, and the surface layer was not formed. Manufactured the conventional coated
[0014]
Further, X-ray diffraction was performed to observe the difference between the heat-transformed α-type Al 2 O 3 layer and the vapor-deposited α-type Al 2 O 3 layer constituting the hard coating layer of the coated cermet tool of the present invention and the conventional coated cermet tool. It was measured.
In the measurement of these X-ray diffractions, a single crystal WC having diffraction peaks only on the (001) plane and the (002) plane on the X-ray diffraction chart was used as a substrate sample, and the surface of the substrate sample was coated with the coated cermet of the present invention. The target layer thickness of the
FIGS. 1 to 3 show X-ray diffraction charts of the heat-transformed α-type Al 2 O 3 layers of coating samples A to C of the present invention, and X-ray diffraction charts of vapor-deposited α-type Al 2 O 3 layers of conventional coating samples a to c. 4 to 6, the heating-transformed α-type Al 2 O 3 layer shows clear diffraction peaks on the (006) plane and the (018) plane, whereas the vapor-deposited α-type Al 2 the O 3 layer is clear that these (006) plane and (018) diffraction peak at a surface are not present.
Further, a heat-transformed α-type Al 2 O 3 layer and a vapor-deposited α-type Al 2 O 3 layer having target layer thicknesses of 15 μm, 10 μm, and 5 μm, respectively, are directly formed on the surface of the base sample composed of the single crystal WC. Each of the heat-transformed α-type Al 2 O 3 layer and the vapor-deposited α-type Al 2 O 3 layer of the coated samples A to C of the present invention and the conventionally coated samples a to c, Electron backscatter diffraction (EBSD) of the crystal plane was performed using a thermal field emission scanning electron microscope (manufactured by JEOL Ltd.) and an azimuthal diffractometer (manufactured by Texem Laboratories, Inc.). In each of the heat-transformed α-type Al 2 O 3 layers, the crystal orientation map shows a dark red color tone, which is due to the hexagonal (0001) plane (hexagonal parallel plane), which is the crystal structure of Al 2 O 3. said Al Indicates that the relative O 3 layer surface (the substrate surface of the sample) are oriented parallel to very strong, whereas the in the deposition α type the Al 2 O 3 layer, either green or blue crystal orientation map, further yellow and pink Various color tones, such as colors, appear, indicating that the crystal planes constituting the hexagonal crystal have no specific orientation.
[0015]
Further, with respect to the
[0016]
Next, the above coated
Work material: JIS SCM440 4 rods with longitudinal grooves at regular intervals in the longitudinal direction,
Cutting speed: 350m / min,
Cut: 1.5 mm,
Feed: 0.25 mm / rev,
Cutting time: 3 minutes,
Dry high-speed interrupted cutting test of alloy steel under the conditions of
Work material: Round bar with four vertical grooves at equal intervals in the length direction of JIS / SUS304,
Cutting speed: 350m / min,
Notch: 2.0 mm,
Feed: 0.15 mm / rev,
Cutting time: 3 minutes,
A dry high-speed interrupted cutting test of stainless steel was performed under the following conditions.
[0017]
Further, for the coated cermet tools 7 to 12 of the present invention and the conventional coated cermet tools 7 to 12,
Work material: JIS SCM440 4 rods with longitudinal grooves at regular intervals in the longitudinal direction,
Cutting speed: 350m / min,
Cut: 1.0 mm,
Feed: 0.25 mm / rev,
Cutting time: 3 minutes,
Dry high-speed interrupted cutting test of alloy steel under the conditions of
Work material: Round bar with four vertical grooves at equal intervals in the length direction of JIS / SUS304,
Cutting speed: 350m / min,
Cut: 1.5 mm,
Feed: 0.1 mm / rev,
Cutting time: 3 minutes,
A dry high-speed intermittent cutting test of stainless steel was performed under the following conditions, and the flank wear width of the cutting edge was measured in each cutting test. Table 6 shows the measurement results.
[0018]
[Table 1]
[Table 2]
[Table 3]
[Table 4]
[Table 5]
[Table 6]
【The invention's effect】
From the results shown in Tables 4 to 6, the
As described above, the coated cermet tool of the present invention can be used not only for continuous cutting or interrupted cutting under ordinary conditions such as various types of steel and cast iron, but also for cutting conditions involving extremely high thermal shock and high heat generation. It shows excellent chipping resistance even in the most severe high-speed interrupted cutting, and exhibits excellent cutting performance over a long period of time. It can respond satisfactorily to the conversion.
[Brief description of the drawings]
FIG. 1 is a view showing an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer (target layer thickness: 15 μm) constituting a hard coating layer of the
FIG. 2 is a view showing an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer (target layer thickness: 10 μm) constituting a hard coating layer of the coated cermet tool 7 of the present invention.
FIG. 3 is an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer (target layer thickness: 5 μm) constituting a hard coating layer of the coated cermet tool 11 of the present invention.
FIG. 4 is a diagram showing an X-ray diffraction chart of a vapor-deposited α-type Al 2 O 3 layer (target layer thickness: 15 μm) constituting a hard coating layer of the conventional coated
FIG. 5 is an X-ray diffraction chart of a vapor-deposited α-type Al 2 O 3 layer (target layer thickness: 10 μm) constituting a hard coating layer of the conventional coated cermet tool 2.
FIG. 6 is a diagram showing an X-ray diffraction chart of a vapor-deposited α-type Al 2 O 3 layer (target layer thickness: 5 μm) constituting a hard coating layer of the conventional coated cermet tool 4.
Claims (1)
（ａ）いずれも蒸着形成されたＴｉの炭化物層、窒化物層、炭窒化物層、炭酸化物層、および炭窒酸化物層のうちの１層または２層以上の積層からなるＴｉ化合物層で構成され、かつ３〜２０μｍの平均層厚を有する下部層、
（ｂ）蒸着形成した状態でκ型またはθ型の結晶構造を有する酸化アルミニウムに加熱変態処理を施して結晶構造をα型結晶構造とし、加熱変態生成クラックが分散分布した組織を有する加熱変態α型酸化アルミニウム層で構成され、かつ３〜１５μｍの平均層厚を有する上部層、
（ｃ）蒸着形成した状態でκ型の結晶構造を有する蒸着κ型酸化アルミニウム層で構成され、かつ０．５〜２μｍの平均層厚を有する表面層、
以上（ａ）〜（ｃ）で構成された硬質被覆層を形成してなる、硬質被覆層がすぐれた耐熱衝撃性を有する表面被覆サーメット製切削工具。On the surface of a tool substrate composed of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet,
(A) A Ti compound layer composed of one or two or more of Ti carbide layers, nitride layers, carbonitride layers, carbonate layers, and carbonitride layers formed by vapor deposition. A lower layer, which is constituted and has an average layer thickness of 3-20 μm,
(B) Heat-transformed α in which aluminum oxide having a κ-type or θ-type crystal structure is subjected to a heat transformation treatment to form an α-type crystal structure in which the heat-transformed cracks are dispersed and distributed. An upper layer composed of a type aluminum oxide layer and having an average layer thickness of 3 to 15 μm;
(C) a surface layer composed of a deposited κ-type aluminum oxide layer having a κ-type crystal structure in an as-deposited state and having an average layer thickness of 0.5 to 2 μm;
A cutting tool made of a surface-coated cermet having a hard coating layer having excellent thermal shock resistance, wherein the cutting tool is formed by forming the hard coating layer constituted by (a) to (c) above.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2007111293A1 (en) | 2006-03-28 | 2007-10-04 | Sumitomo Metal Industries, Ltd. | Cutting tool and process for manufacturing the same |
| JP2011005567A (en) * | 2009-06-24 | 2011-01-13 | Mitsubishi Materials Corp | Surface coated cutting tool excellent in chipping resistance and peeling resistance of hard coating layer |
| JP6047268B1 (en) * | 2015-10-09 | 2016-12-21 | 住友電工ハードメタル株式会社 | Surface coated cutting tool |
| WO2017061144A1 (en) * | 2015-10-09 | 2017-04-13 | 住友電工ハードメタル株式会社 | Surface-coated cutting tool |
-
2002
- 2002-12-02 JP JP2002349651A patent/JP2004188502A/en active Pending
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2007111293A1 (en) | 2006-03-28 | 2007-10-04 | Sumitomo Metal Industries, Ltd. | Cutting tool and process for manufacturing the same |
| US7704593B2 (en) | 2006-03-28 | 2010-04-27 | Sumitomo Metal Industries, Ltd. | Cutting tool and method of producing the same |
| JP2011005567A (en) * | 2009-06-24 | 2011-01-13 | Mitsubishi Materials Corp | Surface coated cutting tool excellent in chipping resistance and peeling resistance of hard coating layer |
| JP6047268B1 (en) * | 2015-10-09 | 2016-12-21 | 住友電工ハードメタル株式会社 | Surface coated cutting tool |
| WO2017061144A1 (en) * | 2015-10-09 | 2017-04-13 | 住友電工ハードメタル株式会社 | Surface-coated cutting tool |
| US9863064B2 (en) | 2015-10-09 | 2018-01-09 | Sumitomo Electric Hardmetal Corp. | Surface-coated cutting tool |
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