JP2004188577A - Cutting tool of surface-coated cermet with hard coating layer having excellent thermal shock resistance - Google Patents

Cutting tool of surface-coated cermet with hard coating layer having excellent thermal shock resistance Download PDF

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JP2004188577A
JP2004188577A JP2003097528A JP2003097528A JP2004188577A JP 2004188577 A JP2004188577 A JP 2004188577A JP 2003097528 A JP2003097528 A JP 2003097528A JP 2003097528 A JP2003097528 A JP 2003097528A JP 2004188577 A JP2004188577 A JP 2004188577A
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layer
type
hard coating
heat
crystal structure
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Toshiaki Ueda
稔晃 植田
Takatoshi Oshika
高歳 大鹿
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Mitsubishi Materials Corp
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Mitsubishi Materials Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a cutting tool of surface-coated cermet with a hard coating layer having excellent thermal shock performance. <P>SOLUTION: This cutting tool of surface-coated cermet is manufactured by forming the hard coating layer on the surface of a tool base body composed of WC-based cemented carbide or TiCN-based cermet. The hard coating layer is composed of (a) a primer layer composed of a Ti compound layer comprising one layer or two or more layers among a TiC layer, a TiN layer, a TiCN layer, a TiCO layer, and a TiCNO layer, all formed by chemical vapor deposition, and having total average layer thickness of 3-20μm, (b) an upper layer composed of heat-transformed α-type Al<SB>2</SB>O<SB>3</SB>layer having texture in which Al<SB>2</SB>O<SB>3</SB>having a κ-type or θ-type crystal structure as formed by chemical vapor deposition is heat-treated to transform the crystal structure into α-type crystal structure, and in which heat-transformation cracks are dispersed and distributed, and having average layer thickness of 1-15μm, and (c) a surface layer composed of a deposited κ-type Al<SB>2</SB>O<SB>3</SB>layer having a κ-type crystal structure as formed by chemical vapor deposition, and having average layer thickness of 0.1-2μm. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【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)いずれも化学蒸着形成された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層以上からなり、かつ3〜20μmの合計平均層厚を有するTi化合物層で構成された下部層、
(b)化学蒸着形成した状態でα型の結晶構造を有し、かつ1〜17μmの平均層厚を有する蒸着α型酸化アルミニウム(以下、Alで示す)層で構成された上部層、
以上(a)の下部層と(b)の上部層からなる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Al 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、例えばCHCN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蒸着α型Al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Al層の耐熱衝撃性向上をはかるべく研究を行った結果、
工具基体の表面に、通常の化学蒸着装置で、下部層として、通常の条件で、上記Ti化合物層を形成した後、同じく通常の条件で、まず結晶構造がκ型またはθ型のAl層を形成し、この状態で水素雰囲気中、温度:1000〜1100℃、保持時間:2〜10時間の条件で加熱処理を施すと、前記Al層のκ型またはθ型の結晶構造が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Al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Al層を表面層として蒸着形成すると、この蒸着κ型Al層は前記加熱変態α型Al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Al層および蒸着κ型Al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Al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)いずれも化学蒸着形成されたTiC層、TiN層、TiCN層、TiCO層、およびTiCNO層のうちの1層または2層以上からなり、かつ3〜20μmの合計平均層厚を有するTi化合物層で構成された下部層、
(b)化学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Al層に加熱変態処理を施して結晶構造をα型結晶構造としてなると共に、加熱変態生成クラックが分散分布した組織および1〜15μmの平均層厚を有する加熱変態α型Al層で構成された上部層、
(c)化学蒸着形成した状態でκ型の結晶構造を有し、かつ0.1〜2μmの平均層厚を有する蒸着κ型Al層で構成された表面層、
以上(a)〜(c)からなる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Al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、その合計平均層厚が3μm未満では、前記作用を十分に発揮させることができず、一方その合計平均層厚が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、その合計平均層厚を3〜20μmと定めた。
【0009】
(b)上部層(加熱変態α型Al層)
加熱変態α型Al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1μm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1〜15μmと定めた。
【0010】
(c)表面層(蒸着κ型Al層)
蒸着κ型Al層には、上記の通り加熱変態α型Al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Al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0.1μm未満では、前記加熱変態α型Al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0.1〜2μm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、Cr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、MoC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Al層を蒸着形成し、これに水素雰囲気中、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Al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Al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1〜13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、上記の本発明被覆サーメット工具1〜13のそれぞれの硬質被覆層を構成する上部層および表面層に代って、同じく表5に示される平均層厚の蒸着α型Al層を形成する以外は同一の条件で従来被覆サーメット工具1〜13をそれぞれ製造した。
【0014】
この結果得られた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Al層と蒸着α型Al層の相違を観察する目的でX線回折を測定した。
まず、X線回折測定用試料として、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、8、および12の硬質被覆層を構成する上部層である目標層厚が15μm、10μm、および5μmの加熱変態α型Al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Al層を直接形成して本発明被覆試料A〜Cとし、また上記従来被覆サーメット工具1〜13の硬質被覆層の上部層を構成する蒸着α型Al層の形成条件と同一の条件で、前記本発明被覆サーメット工具3、8、および12に対応して、それぞれ目標層厚を15μm、10μm、および5μmとした蒸着α型Al層を直接形成して従来被覆試料a〜cとすることにより調製した。
【0015】
ついで、これら被覆試料の前記加熱変態α型Al層および蒸着α型Al層のX線回折測定を、通常のX線回折装置を用い、X線管中に設置されたCu陽極(ターゲット)に対して、電圧:40kV、電流:350mAの条件で金属Wフィラメントから発生させた熱電子を加速照射することにより、前記Cu陽極表面から0.154nmの波長を有する特性X線であるCu−Kα線を発生させ、前記特性X線を前記被覆試料表面に照射し、前記被覆試料から散乱したX線のうち、被覆試料表面に対するX線入射角度θと等しい角度で回折したX線の強度をX線検出器にて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Al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Al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Al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Al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。
【0016】
さらに、上記の本発明被覆サーメット工具1〜13および従来被覆サーメット工具1〜13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Al層、および蒸着κ型Al層からなり、後者では、いずれもTi化合物と蒸着α型Al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。
【0017】
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1〜7および従来被覆サーメット工具1〜7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。
【0018】
さらに、本発明被覆サーメット工具8〜13および従来被覆サーメット工具8〜13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。
【0019】
【表1】

Figure 2004188577
【0020】
【表2】
Figure 2004188577
【0021】
【表3】
Figure 2004188577
【0022】
【表4】
Figure 2004188577
【0023】
【表5】
Figure 2004188577
【0024】
【表6】
Figure 2004188577
【0025】
【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1〜13は、硬質被覆層の上部層を構成する加熱変態α型Al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Al層からなる従来被覆サーメット工具1〜13においては、高速断続切削では前記蒸着α型Al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の硬質被覆層の上部層に相当する目標層厚が15μmの加熱変態α型Al層の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8の硬質被覆層の上部層に相当する目標層厚が10μmの加熱変態α型Al層の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12の硬質被覆層の上部層に相当する目標層厚が5μmの加熱変態α型Al層の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の硬質被覆層の上部層を構成する蒸着α型Al層について、本発明被覆サーメット工具3に対応して目標層厚を15μmとした蒸着α型Al層の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の硬質被覆層の上部層を構成する蒸着α型Al層について、本発明被覆サーメット工具8に対応して目標層厚を10μmとした蒸着α型Al層の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の硬質被覆層の上部層を構成する蒸着α型Al層について、本発明被覆サーメット工具12に対応して目標層厚を5μmとした蒸着α型Al層の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) All of them are Ti carbide (hereinafter, referred to as TiC) layer, nitride (hereinafter, also referred to as TiN) layer, carbonitride (hereinafter, referred to as TiCN) layer, carbon oxide (hereinafter, referred to as TiCN) formed by chemical vapor deposition. , TiCO) layer, and one or more of carbon oxynitride (hereinafter, TiCNO) layers, and a Ti compound layer having a total average layer thickness of 3 to 20 μm. Lower layer,
(B) Upper layer composed of a vapor-deposited α-type aluminum oxide (hereinafter, referred to as Al 2 O 3 ) layer having an α-type crystal structure in a state formed by chemical vapor deposition and having an average layer thickness of 1 to 17 μm. ,
There is known 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). The coated cermet tool can be used for continuous cutting of, for example, various kinds of steel and cast iron. Also, it is known that it is used for interrupted 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. For the purpose, using a mixed gas containing an organic carbonitride, for example, CH 3 CN as a reaction gas, and performing chemical vapor deposition at a medium temperature range of 700 to 950 ° C. using a normal chemical vapor deposition apparatus, It is also known to have a growing crystal structure (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, and on the other hand, there is a strong demand for labor saving, energy saving, and further cost reduction for cutting work.Accordingly, cutting work tends to be even faster, 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 in high-speed interrupted cutting in which thermal shock is repeatedly applied at a very short pitch to the surface, the deposited α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer is hard and has excellent heat resistance, Because of its brittleness, 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.
After forming the Ti compound layer as a lower layer under ordinary conditions on the surface of the tool base using an ordinary chemical vapor deposition apparatus, first, under the same ordinary conditions, Al 2 O having a κ-type or θ-type crystal structure. When three layers are formed and subjected to a heat treatment in this state in a hydrogen atmosphere at a temperature of 1000 to 1100 ° C. and a holding time of 2 to 10 hours, a κ-type or θ-type crystal of the Al 2 O 3 layer is obtained. The structure is transformed into an α-type crystal structure, and cracks generated by heat transformation are distributed and distributed in the layer. The heat-transformed α-type Al 2 O 3 layer is used as an upper layer, and the surface of the upper layer is formed. Under the same conditions, when a relatively thin κ-type Al 2 O 3 layer is formed by vapor deposition as a surface layer, this vapor-deposited κ-type Al 2 O 3 layer is formed with the heat-transformed α-type Al 2 O 3 layer. Before penetrating sufficiently into cracks generated by heat transformation at the interface, Since so to retain the heat transformation product cracks remarkably stabilized state, the lower layer of the hard coating layer is composed of the Ti compound layer, the upper layer and the surface layer is above the heating transformation α-type Al 2 O 3 In a coated cermet tool composed of a layer and a vapor-deposited κ-type Al 2 O 3 layer, a heat-transformation generation crack dispersed and distributed in the heat-transformed α-type Al 2 O 3 layer constituting the upper layer is particularly high-speed intermittent cutting. A study result was obtained in which the intense thermal shock at the time was absorbed and alleviated, whereby the occurrence of chipping in the hard coating layer was significantly suppressed.
[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) a Ti compound comprising at least one of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer, and a TiCNO layer formed by chemical vapor deposition and having a total average layer thickness of 3 to 20 μm; Lower layer composed of layers,
(B) The Al 2 O 3 layer having a κ-type or θ-type crystal structure in a state formed by chemical vapor deposition is subjected to a heat transformation treatment to change the crystal structure to an α-type crystal structure, and cracks generated by heat transformation are dispersed and distributed. An upper layer composed of a texture and a heat-transformed α-type Al 2 O 3 layer having an average layer thickness of 1 to 15 μm;
(C) a surface layer composed of a vapor-deposited κ-type Al 2 O 3 layer having a κ-type crystal structure in a state formed by chemical vapor deposition and having an average layer thickness of 0.1 to 2 μm;
The present invention is characterized by a coated cermet tool in which the hard coating layer formed of the above (a) to (c) has excellent thermal shock resistance.
[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 total average layer thickness is less than 3 μm, the above effect cannot be sufficiently exerted. If the thickness exceeds 20 μm, it becomes easy to cause thermoplastic deformation, especially in high-speed interrupted cutting accompanied by high heat generation, and this causes uneven wear. Therefore, the total 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 1 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 1 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 0.1 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 0.1 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, an ordinary chemical vapor deposition apparatus was used, and Table 3 (l-TiCN in Table 3 is a vertically long one 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 is 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 is formed by vapor deposition under the same conditions as shown in Table 3, and the layer is formed in a hydrogen 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 coated cermet tools 1 to 13 of the present invention were respectively manufactured.
Also, for comparison purposes, as shown in Table 5, instead of the upper layer and the surface layer constituting each hard coating layer of the coated cermet tools 1 to 13 of the present invention, the average shown in Table 5 was used. Conventional coated cermet tools 1 to 13 were manufactured under the same conditions except that a vapor-deposited α-type Al 2 O 3 layer having a layer thickness was formed.
[0014]
For the purpose of observing 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 obtained as described above, X was used. Line diffraction was measured.
First, as a sample for X-ray diffraction measurement, a single crystal WC having a diffraction peak only on the (001) plane and the (002) plane on the X-ray diffraction chart was used as a substrate sample. cermet tools 3,8 and 12 the upper layer in which the target layer thickness is 15μm which constitutes the hard coating layer, 10 [mu] m, and 5μm under the same conditions as the conditions for forming the heat transformed α-type the Al 2 O 3 layer of each target Heat-transformed α-type Al 2 O 3 layers having a layer thickness of 15 μm, 10 μm, and 5 μm are directly formed to obtain coating samples A to C of the present invention, and the upper layer of the hard coating layer of the conventional coated cermet tools 1 to 13 is formed. under the same conditions as the conditions for forming the deposited α-type the Al 2 O 3 layer constituting the present invention coated cermet tool 3, 8, and 12 in response to, 15 [mu] m target layer thickness, respectively, 10 [mu] m, and 5μm It was prepared by a conventional coated samples a~c to form the deposited α-type the Al 2 O 3 layer directly.
[0015]
Next, the X-ray diffraction measurement of the above-mentioned heat-transformed α-type Al 2 O 3 layer and the vapor-deposited α-type Al 2 O 3 layer of these coated samples was carried out by using a usual X-ray diffractometer, and Cu was placed in an X-ray tube. By irradiating the anode (target) with thermoelectrons generated from the metal W filament under the conditions of voltage: 40 kV and current: 350 mA, characteristic X-rays having a wavelength of 0.154 nm from the Cu anode surface are obtained. X-rays that generate a certain Cu-Kα ray, irradiate the characteristic X-ray to the surface of the coated sample, and diffract at an angle equal to the X-ray incident angle θ with respect to the coated sample surface among the X-rays scattered from the coated sample Was measured with an X-ray detector. The measurement results are shown in FIGS.
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.
[0016]
Further, regarding the coated cermet tools 1 to 13 of the present invention and the conventional coated cermet tools 1 to 13, the constituent layers of the hard coating layer were observed using a scanning electron microscope (observing the longitudinal section of the layers). The former consists of a Ti compound layer, a heat-transformed α-type Al 2 O 3 layer in which cracks generated by heat transformation are dispersed and distributed in the layer, and a vapor-deposited κ-type Al 2 O 3 layer. It was confirmed that it was composed of an α-type Al 2 O 3 layer. In addition, when the thicknesses of the constituent layers of the hard coating layer of these coated cermet tools were measured using a scanning electron microscope (also in the longitudinal section), the average layer thickness was substantially the same as the target layer thickness. (Average value of five-point measurements).
[0017]
Next, the above coated cermet tools 1 to 7 according to the present invention and the conventional coated cermet tools 1 to 7 in a state where all of the above various coated cermet tools were screwed to the tip of a tool steel tool with a fixing jig. ,
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.
[0018]
Further, for the coated cermet tools 8 to 13 of the present invention and the conventional coated cermet tools 8 to 13,
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.
[0019]
[Table 1]
Figure 2004188577
[0020]
[Table 2]
Figure 2004188577
[0021]
[Table 3]
Figure 2004188577
[0022]
[Table 4]
Figure 2004188577
[0023]
[Table 5]
Figure 2004188577
[0024]
[Table 6]
Figure 2004188577
[0025]
【The invention's effect】
From the results shown in Tables 4 to 6, the coated cermet tools 1 to 13 of the present invention showed that the heating transformation generated cracks dispersed and distributed in the heating transformation α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer. Even in high-speed interrupted cutting of steel with extremely high thermal shock and high heat generation, chipping of the cutting edge portion is remarkably generated due to the action of the above-mentioned heat transformation generation crack existing in a state embedded in the hard coating layer. The conventional coated cermet tools 1 to 13 in which the upper layer of the hard coating layer is formed of a vapor-deposited α-type Al 2 O 3 layer, while exhibiting excellent wear resistance are suppressed, and the vapor-deposited α It is evident that the mold Al 2 O 3 layer cannot withstand severe thermal shock, chipping occurs at the cutting edge, and reaches a service life in a relatively short time.
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 diagram showing an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer having a target layer thickness of 15 μm corresponding to the upper layer of the hard coating layer of the coated cermet tool 3 of the present invention.
FIG. 2 is an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer having a target layer thickness of 10 μm corresponding to the upper layer of the hard coating layer of the coated cermet tool 8 of the present invention.
FIG. 3 is a diagram showing an X-ray diffraction chart of a heat-transformed α-type Al 2 O 3 layer having a target layer thickness of 5 μm corresponding to the upper layer of the hard coating layer of the coated cermet tool 12 of the present invention.
[4] Conventional coating the cermet tools hard layer deposition α type the Al 2 O 3 layer constituting the upper layer of the present invention coated cermet tool 3 deposited α-type to the target layer thickness and 15μm in correspondence with Al 2 X-ray diffraction chart of the O 3 layer is a diagram showing a.
[5] Conventional coated cermet for hard coating layer deposited α-type the Al 2 O 3 layer constituting the upper layer of the tool, the present invention coated cermet tool 8 corresponds deposited α-type target layer thickness was 10 [mu] m Al 2 X-ray diffraction chart of the O 3 layer is a diagram showing a.
[6] Conventional coated cermet for hard coating layer deposited α-type the Al 2 O 3 layer constituting the upper layer of the tool, the present invention coated cermet tool 12 in response to the deposition α-type target layer thickness was 5 [mu] m Al 2 X-ray diffraction chart of the O 3 layer is a diagram showing a.

Claims (1)

炭化タングステン基超硬合金または炭窒化チタン基サーメットで構成された工具基体の表面に、
(a)いずれも化学蒸着形成された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層以上からなり、かつ3〜20μmの合計平均層厚を有するTi化合物層で構成された下部層、
(b)化学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処理を施して結晶構造をα型結晶構造に変態してなると共に、加熱変態生成クラックが分散分布した組織および1〜15μmの平均層厚を有する加熱変態α型酸化アルミニウム層で構成された上部層、
(c)化学蒸着形成した状態でκ型の結晶構造を有し、かつ0.1〜2μmの平均層厚を有する蒸着κ型酸化アルミニウム層で構成された表面層、
以上(a)〜(c)からなる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) Each of them consists of one or more of a carbide layer, a nitride layer, a carbonitride layer, a carbonate layer and a carbonitride layer of Ti formed by chemical vapor deposition, and has a thickness of 3 to 20 μm. A lower layer composed of a Ti compound layer having a total average layer thickness of
(B) A structure in which aluminum oxide having a κ-type or θ-type crystal structure is subjected to heat treatment in a state formed by chemical vapor deposition to transform the crystal structure into an α-type crystal structure, and cracks generated by heat transformation are dispersed and distributed. And an upper layer composed of a heat-transformed α-type aluminum oxide layer having an average layer thickness of 1 to 15 μm,
(C) a surface layer comprising a deposited κ-type aluminum oxide layer having a κ-type crystal structure in a state formed by chemical vapor deposition and having an average layer thickness of 0.1 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 comprising (a) to (c).
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JP2006123031A (en) * 2004-10-27 2006-05-18 Mitsubishi Materials Corp Surface coated cemented carbide cutting tool with hard coating layer exhibiting excellent chipping resistance in high-speed heavy cutting
JP4529638B2 (en) * 2004-10-27 2010-08-25 三菱マテリアル株式会社 Cutting tool made of surface-coated cemented carbide that provides excellent chipping resistance with a hard coating layer in high-speed heavy cutting
CN103741117A (en) * 2013-12-24 2014-04-23 成都工具研究所有限公司 Cutting tool coating for low-speed and heavy-duty turning steel and stainless steel

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