JP2004190118A

JP2004190118A - Cemented carbide, its production method, and cutting tool using the same

Info

Publication number: JP2004190118A
Application number: JP2002362577A
Authority: JP
Inventors: Hiroshi Ohata; 浩志大畑
Original assignee: Kyocera Corp
Current assignee: Kyocera Corp
Priority date: 2002-12-13
Filing date: 2002-12-13
Publication date: 2004-07-08
Anticipated expiration: 2022-12-13
Also published as: JP4313567B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cemented carbide which exhibits high cutting performance even to severe cutting conditions, and has excellent oxidation resistance and impact resistance. <P>SOLUTION: The cemented carbide is obtained by bonding the spaces in a hard phase 4 consisting of 60 to 85 vol% WC particles 2 with a mean particle diameter of 0.2 to 0.8 μm and βphase particles 3 with a mean particle diameter of 1.2 to 3 μm consisting of the carbide, nitride or carbonitride of at least one kind selected from the group 4a, 5a and 6a metals in the Periodic Table by a 5 to 20 vol.% bonding phase 5 essentially consisting of at least one kind selected from iron group metals. The ratio between the density Db of a bulk body measured by a gas replacement method and the density Dp of the powder after pulverization of the bulk body to a size permitting passage through #200 meshes, Db/Dp is ≥0.95. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、切削工具等に使用される高強度かつ高靭性を有し、難削材の切削や高送り切削などの衝撃の大きい条件下での切削に優れた性能を発揮する超硬合金とその製造方法、並びにそれを用いた切削工具に関する。
【０００２】
【従来の技術】
従来より、超硬合金は切削工具や耐摩工具等に用いられており、近年では特に靭性を重視したＫ種超硬合金として、ＷＣ粒子の粒径が１μｍより小さい、いわゆる超微粒超硬合金が開発されている。
【０００３】
かかる超微粒超硬合金は、微粒のＷＣ原料粉末とコバルト原料粉末に対して、微量の炭化クロムや炭化バナジウム粉末を粒成長抑制剤として添加し焼成したものであるが、現状、このＫ種超微粒超硬合金はもっぱら仕上げ加工用等の衝撃の少ない切削条件で切削工具やプリント基板穴あけ加工用のマイクロドリル材料などの非鉄材料の加工に利用されていた（特許文献１参照）。
【０００４】
一方、超硬合金の用途としては、上記仕上げ加工等の切削以外にも、ステンレス等の難削材の切削や高送り切削などの衝撃の大きい条件で、局部的に高温になり、かつ断続的に強い衝撃がかかるような加工に対しては、超硬合金組織中にＴｉやＴａの炭化物等のいわゆるβ相粒子を分散含有させて耐酸化性や耐熱衝撃性などの特性向上を図った、いわゆるＭ種またはＰ種超硬合金が知られている。
【０００５】
上記β相粒子を分散させた超硬合金として、例えば、特許文献２では、平均粒径０．６μｍ以下で最大粒径が３．０μｍ以下のＷＣ粒子が分散している超硬合金素地中に、Ｖ，Ｃｒ，Ｔａ，ＮｂおよびＴｉのβ相粒子を最大粒径３．０μｍ以下とＷＣ粒子と同程度に微細に制御し、かつ５体積％以下と少ない比率で分散させることで硬さおよび靭性を改善した超硬合金が記載されている。
【０００６】
また、最近ではステンレス鋼といった難削材の加工や、切削の更なる効率化を求めて高速切削・高送り切削への利用も進められており、かかる加工に対して、従来のβ相粒子を分散したＭ種またはＰ種超硬合金よりもさらに高温特性、熱衝撃性および耐衝撃性の高い超硬合金が要求されている。
【０００７】
【特許文献１】
特開昭６１−１２８４７号公報
【特許文献２】
特開平６−８１０７２号公報
【０００８】
【発明が解決しようとする課題】
このような要求に対して、上記特許文献１の超硬合金では、高温特性、熱衝撃性および耐衝撃性に対して十分な特性を有しておらず、また、上記特許文献２に記載されるような、微粒なＷＣ粒子およびＷＣ粒子と同程度に微粒なβ相粒子を５体積％以下と少ない含有比率で分散した超硬合金を用いて過酷な条件で切削を行うと、耐酸化性や耐熱衝撃性および耐衝撃性が低くて欠損が発生しやすいという問題があった。
【０００９】
これに対して、耐酸化性や耐熱衝撃性を改善する上では、β相粒子の含有比率を増加せしめることが考えられるが、このβ相粒子の含有比率を増加せしめただけでは、結合相量を減じつつＷＣ粒子やβ相粒子の粒成長抑制を制御することができなくなったり、焼結性が低下して合金を高緻密化させることができなくなり、硬さ、抗折力ともに低下してしまうために、過酷な条件で切削を行うとやはり耐衝撃性が低くて欠損が発生しやすいという問題があった。
【００１０】
したがって、本発明の目的は、過酷な切削条件に対しても高い切削性能を発揮する耐酸化性、耐熱衝撃性および過酷な条件においても耐衝撃性、耐欠損性に優れた超硬合金とこれを用いた切削工具を提供することにある。
【００１１】
【課題を解決するための手段】
本発明者は、耐酸化性および耐衝撃性に優れた超硬合金の構成について検討した結果、β相粒子の含有比率を５〜３０体積％と増した状態でＷＣ粒子と結合相の含有比率を適正化するとともに、ＷＣ粒子の平均粒径よりもβ相粒子の平均粒径を積極的に大きくした範囲に制御することによって、ＷＣ粒子の粒径を制御できるとともに超硬合金を高緻密化することができ、かつ超硬合金の耐酸化性を高めることができる結果、耐酸化性および耐衝撃性を改善できることを見出した。
【００１２】
すなわち、本発明の超硬合金は、平均粒径０．２〜０．８μｍのＷＣ粒子を６０〜８５体積％と、平均粒径１．２〜３μｍの周期律表第４ａ，５ａ，６ａ族金属の少なくとも１種の炭化物、窒化物または炭窒化物からなるβ相粒子を５〜３０体積％と、からなる硬質相と、前記硬質相の間を鉄族金属の少なくとも１種を主体とする結合相５〜２０体積％にて結合してなり、ガス置換法で測定したバルク体の密度Ｄｂと、＃２００メッシュを通過するサイズに微粉砕した後の粉末の密度Ｄｐの比率Ｄｂ／Ｄｐが０．９５以上であることを特徴とする。
【００１３】
なお、かかる超硬合金においては、前記β相粒子中におけるＴｉ、Ｚｒ、ＮｂおよびＴａの少なくとも１種の総量が、β相粒子中におけるＷ以外の周期律表第４ａ，５ａ，６ａ族金属の総量に対して金属換算で７０質量％以上であること、さらには、前記β相粒子中におけるＷの含有量が、β相粒子中における周期律表第４ａ，５ａ，６ａ族金属の全量に対して金属換算で３０質量％以上であることによって、合金の耐熱衝撃性および耐衝撃性を高めることができる。
【００１４】
また、前記結合相が凝集した結合相プールの最大粒径が１μｍ以下であることによって、超硬合金の強度を高め、耐欠損性を高めることができる。
【００１５】
さらに、前記ＷＣ粒子が、粒径０．５μｍ未満の粒子の面積比率が４０〜８０％、粒径０．５〜１．２μｍの粒子の面積比率が１５〜４０％、粒径１．２μｍを超える粒子の面積比率が５〜２０％の割合の粒度分布からなることによって、耐衝撃性を高めて過酷な切削条件においても耐欠損性を高めることができる。
【００１６】
また、本発明の超硬合金の製造方法は、平均粒径０．１〜０．８μｍのＷＣ原料粉末と、平均粒径１〜１．３μｍの周期律表第４ａ，５ａ，６ａ族金属の少なくとも１種の炭化物、窒化物または炭窒化物原料粉末と、平均粒径０．１〜１μｍの少なくとも１種の鉄族金属原料粉末とを混合粉砕した後、これを成形し、１４００〜１４５０℃にて１〜２時間真空焼成した後、さらに前記焼成温度より２０〜５０℃低い温度にて０．５〜１時間、５０〜１００ＭＰａの圧力で熱間静水圧処理することを特徴とするものである。
【００１７】
なお、上記の混合粉砕時間は１２〜３６時間であることによって、合金中の硬質相の粒径を所定範囲に制御することができる。
【００１８】
また、本発明は、前記超硬合金を切削工具として用いることで、難削材の切削や高送り切削などの衝撃の大きい条件下でも優れた切削性能を有する切削工具を得ることができる。
【００１９】
【発明の実施の形態】
本発明の超硬合金について、その一例についてのＳＥＭ写真である図１を基にその組織を説明する。
本発明の超硬合金は、図１に示すように、ＷＣ粒子２と、周期律表第４ａ，５ａ，６ａ族金属の少なくとも１種の炭化物、窒化物または炭窒化物粒子（以下、β相粒子と称す。ただし、ＷＣ粒子は除く。）３とからなる硬質相４と、少なくとも１種の鉄族金属を主成分として、特にＣｏおよび／またはＮｉを８０質量％以上含有する結合相５とから構成されている。また、部分的に結合相５がプール化した結合相プール６が形成される場合もある。
【００２０】
本発明によれば、硬質相４として、平均粒径０．２〜０．８μｍのＷＣ粒子２を６０〜８５体積％、平均粒径１．２〜３μｍのβ相粒子３を５〜３０体積％の割合でそれぞれ分散含有するとともに、ＷＣ粒子２、β相粒子３の粒子間を５〜２０体積％の結合相５にて結合してなることが重要である。
【００２１】
つまり、ＷＣ粒子２の平均粒径よりもβ相粒子３の平均粒径を積極的に大きくすることによって、ＷＣ粒子２の粒径を前記所定範囲に制御できるとともに合金を高緻密化することができ、かつ合金の耐酸化性を高めることができる結果、合金の耐酸化性および耐衝撃性を高めることができることから、過酷な切削条件によって刃先が高温に晒されるような場合においても良好に使用可能な超硬合金となり、上記範囲を逸脱すると合金の耐酸化性、耐熱衝撃性または耐衝撃性が低下してしまう。
【００２２】
すなわち、ＷＣ粒子２の平均粒径が０．２μｍより小さいと、ＷＣ粒子２同士の凝集が生じて結合相５が凝集しやすくなり、粗大な結合相プールを生成するために合金の強度低下をもたらす。逆に、ＷＣ粒子２の平均粒径が０．８μｍを超えると、従来のＭ種またはＰ種超硬合金に比較して強度を向上させることができず、耐欠損性や耐摩耗性を向上させることができない。また、ＷＣ粒子２の含有量が６０体積％より少ないと合金の硬度が低下し、逆に８５体積％を超えると耐酸化性または合金の緻密化が損なわれて、いずれも合金の強度が低下する。
【００２３】
さらに、β相粒子３の平均粒径が１．２μｍより小さいと焼結性が極端に低下して緻密な合金が得られなくなり、β相粒子３の平均粒径が３μｍを超えるとＷＣ粒子の平均粒径に対し大きくなり、応力集中により破壊源として働くために合金の強度が低下する。また、β相粒子３の含有量が５体積％より少ないと合金の耐酸化性、耐欠損性が低下してしまい、逆に２５体積％より多いと合金を緻密化が不十分となり合金の強度が低下する。
【００２４】
さらにまた、結合相５の含有量が５体積％より少ないと合金を高緻密化することができず合金の強度が低下し、逆に結合相５の含有量が２０体積％を超えると合金の硬度が低下するとともに結合相５が凝集した粗大な金属プールが生じやすく合金の強度が低下する。
【００２５】
なお、本発明の超硬合金は、ガス置換法で測定したバルク体の密度Ｄｂと、該バルク体を＃２００メッシュを通過するサイズに微粉砕した後の粉末の密度Ｄｐの比率Ｄｂ／Ｄｐが０．９５以上、特に０．９７５以上、さらには０．９８以上であることも重要である。この比率Ｄｂ／Ｄｐが大きいということは、つまり合金中の開気孔が少なく、合金が高緻密化した状態であることを意味するものである。
【００２６】
従って、本発明において、このＤｂ／Ｄｐが０．９５よりも小さいと、合金内部にボイドが残存するために、高硬度化、高強度化を達成することができず、耐酸化性、耐熱衝撃性および耐衝撃性を向上させることはできない。なお、本発明によれば、ＷＣ粒子−β相粒子−結合相間で金属の固溶が一切ないと仮定したときの理論密度に対し、アルキメデス法による超硬合金の相対密度が９８％〜１０２％となることが望ましい。
【００２７】
ここで、本発明によれば、β相粒子３におけるＴｉ、Ｚｒ、ＮｂおよびＴａの少なくとも１種の総量が、β相粒子３中におけるＷ以外の周期律表第４ａ，５ａ，６ａ族金属の総量に対して金属換算で７０質量％以上、特に８０質量％以上、さらに９０質量％以上の割合で含有することによって、合金の耐酸化性および耐衝撃性を高めることができる。
【００２８】
また、合金の耐熱衝撃性を高める点で、β相粒子３中に、Ｗを周期律表第４ａ，５ａ，６ａ族金属の総量に対して金属換算で３０質量％以上、特に４０〜６０質量％の割合で含有することが望ましい。
【００２９】
さらに、本発明によれば、合金の組織を上記のように制御することによって、結合相５が凝集した金属プール６の最大粒径を１μｍ以下、特に０．７μｍ以下に制御することができ、これにより、合金を安定して高強度化することができる。
【００３０】
また、ＷＣ粒子２の粒度分布が、粒径０．５μｍ未満の粒子の面積比率が４０〜８０％、粒径０．５〜１．２μｍの粒子の面積比率が１５〜４０％、粒径１．２μｍを超える粒子の面積比率が５〜２０％の割合で存在することによって合金の耐衝撃性を高めることができる。
【００３１】
なお、上記本発明の超硬合金は、それ単独で切削工具を形成することができるが、この超硬合金の表面に、周期律表第４ａ、５ａ、６ａ族金属の炭化物、窒化物、炭窒化物、ＴｉＡｌＮ、ＴｉＺｒＮ、ＴｉＣｒＮ、ダイヤモンド、ダイヤモンドライクカーボンおよびＡｌ₂Ｏ₃の群から選ばれる少なくとも１種の被覆層を単層または複数層形成することによって、さらに耐酸化性、耐摩耗性に優れた切削工具等の高硬度材とすることができるが、この場合でも、本発明の超硬合金（母材）が耐酸化性、耐熱衝撃性、耐衝撃性に優れることから、例え上記被覆層が摩滅または剥離した場合であっても欠損や摩耗が急激に進行することなく、長時間にわたって良好な切削加工が可能な切削工具となるのである。
【００３２】
次に、上述した超硬合金を製造する方法について説明すると、まず、平均粒径０．１〜０．８μｍのＷＣ粉末を７０〜８５質量％、平均粒径１〜１．３μｍの周期律表４ａ、５ａ、６ａ族金属、特に、Ｔｉ、Ｚｒ、Ｖ、Ｃｒ、Ｍｏ、Ｔａ、Ｎｂ、Ｗの群から選ばれる少なくとも１種の金属の炭化物、窒化物および炭窒化物粉末もしくは前記金属２種以上の固溶体粉末を総量で５〜１５質量％、平均粒径０．１〜１μｍの鉄族金属粉末を５〜１５質量％、さらには所望により、金属Ｗ（Ｗ）粉末、あるいはカーボンブラック（Ｃ）を調合して、混合、粉砕する。
【００３３】
ここで、本発明によれば、上記原料の粒径および後述する下記焼成条件を制御することによって、上述した組織の超硬合金を作製することができる。
【００３４】
本発明によれば、上記混合、粉砕は、焼結体である合金中の各成分の粒径を制御する点でアトライタミルを用いること、また、混合、粉砕時間は１２〜３６時間、特に１５〜２４時間とすることが望ましい。これは、従来のボールミルでは、ボールの摩擦とボールの落下の衝撃により粉砕・混合を進める方法であるのに対して、アトライタミルは、回転する攪拌羽根により粉砕用ボールが大きく動くため、粉砕効率が高く、所望の粒度に制御することが容易であるという長所を有するためであり、粉砕時間が１２時間よりも短いと、粉砕粒度及び混合度に偏りが生じることになり、３６時間よりも長くしても粉砕粒度はそれ以上微細化しないためである。
【００３５】
上記混合、粉砕粉末を金型プレス等の成形方法によって所定の切削工具形状にプレス成形した後に焼成する。
【００３６】
焼成にあたっては、まず、この成形体を、１４００〜１４５０℃にて１〜２時間真空焼成する。この真空焼成によって、相対密度９８％以上にち密化する。そして、この後、前記焼成温度より２０〜５０℃低い温度にて０．５〜１時間、５０〜１００ＭＰａの圧力で熱間静水圧処理を施す。なお、真空焼成時の真空度は、０．１〜１００Ｐａであることが適当である。
【００３７】
ここで、上記焼成条件において、焼成温度が１４００℃より低いと合金を緻密化が難しく、前記Ｄｂ／Ｄｐが前記範囲よりも小さくなり、また１４５０℃を超えると硬質相４が異常粒成長を引き起こすため、ＷＣ粒子２、β相粒子３を前記所定の粒径に制御することができない。
【００３８】
また、焼成時間が１時間より短いと後述する熱間静水圧処理にて合金を十分に緻密化させることができず、逆に２時間を越えると、ＷＣ粒子２やβ相粒子２などの硬質相４が粒成長して前述した所定の粒径に制御することができない。
【００３９】
また、熱間静水圧処理の温度が上記範囲よりも高い、または圧力が１００ＭＰａよりも高いと、ＷＣ粒子２とβ相粒子３が粒成長し各粒子の粒径を上述した範囲に制御することができず、合金の耐酸化性および耐衝撃性が低下する。逆に、熱間静水圧処理の温度が前記処理温度よりも低い、または圧力が５０ＭＰａよりも低いと、合金を高緻密化させることができず、特に、合金の耐熱衝撃性、耐衝撃性が低下する。さらに、熱間静水圧処理時間が０．５時間より短いと合金を高緻密化させることができず、前記Ｄｂ／Ｄｐが前記範囲よりも小さくなり、１時間を越えると硬質相４が粒成長してＷＣ相２やβ相粒子３を前記所定の粒径に制御することができず、かつ結合相プール６が粗大化する。
【００４０】
なお、上記の超硬合金に、前述したような被覆層を形成するには、所望により、上記超硬合金の表面を研削、研磨、洗浄した後、従来公知のＰＶＤ法やＣＶＤ法等の薄膜形成法によって形成することができる。また、被覆層の厚みは、耐衝撃性、耐摩耗性の点で１〜２０μｍであることが望ましい。
【００４１】
【実施例】
表１に示す平均粒径のＷＣ粉末、Ｃｏ粉末および他炭化物粉末を表１に示す比率で添加し、アトライタミルあるいはボールミルにて表１に示す時間混合、粉砕し、乾燥した後、プレス成形により切削工具形状（ＳＤＫＮ１２０３）に成形し、表１に示す条件で焼成し、さらに必要に応じ、表１の条件で熱間静水圧処理して超硬合金を作製した。
【００４２】
【表１】

【００４３】
得られた超硬合金の任意断面５箇所について、走査型電子顕微鏡により反射電子像を観察し、２０μｍ×２０μｍの任意領域について、画像解析法によってＷＣ粒子、β相粒子の含有量および粒径（平均および分布）、結合相の含有量、結合相プールの最大径を算出した。なお、含有量は上記画像解析に基づく面積比率を体積比率とした。
【００４４】
また、同写真中のβ相粒子（任意５個）についてＥＰＭＡ分析を行い、金属含有量（β相粒子中におけるＷの含有量／β相粒子中における周期律表第４ａ，５ａ，６ａ族金属の全量：表中Ａ（％）と記載、β相粒子中におけるＴｉ、Ｚｒ、ＮｂおよびＴａの少なくとも１種の総量／β相粒子中におけるＷ以外の周期律表第４ａ，５ａ，６ａ族金属の総量：表中Ｂ（％）と記載）を算出した。
【００４５】
さらに、焼結性の目安となるバルク体の密度Ｄｂと、バルク体を超硬合金製の乳鉢によって＃２００メッシュを通過するサイズに、微粉砕した粉末の密度Ｄｐをヘリウムを使用してガス置換法で測定し、比率Ｄｂ／Ｄｐ値を表２に示した。なお、表中、試料Ｎｏ．１〜５についてはいずれも相対密度が９８〜１０２％であった。
【００４６】
また、得られた各超硬合金の表面に、ＰＶＤ法により膜厚２μｍのＴｉＡｌＮ膜を成膜して切削工具を作製した。
【００４７】
そして、この切削工具を用いて下記の条件により靭性試験として溝付合金鋼の高送りを行い欠損を生じた時の送り速度を測定した。これら結果は表２に示した。
（耐衝撃性試験）
被削材：溝付合金鋼（ＳＣＭ４４０Ｈ）
工具形状：ＳＤＫＮ１２０３
切削速度：８０ｍ／分
送り速度：可変０．２〜０．８ｍｍ／刃
切り込み：２ｍｍ
その他：乾式切削
【００４８】
【表２】

【００４９】
表１、２の結果より、本発明の製造方法に対して、原料粒径、調合比率、混合条件、焼成条件のいずれかが逸脱する試料Ｎｏ．６〜１２については、合金の開気孔率または組織が本発明の範囲から逸脱して耐酸化性、耐衝撃性を両立させることができず、いずれも欠損に至る時間が短いものであった。
【００５０】
これに対して、本発明の範囲内の組織からなり、且つガス置換法で測定した前記超硬合金のバルク体の密度Ｄｂとガス置換法で測定した前記超硬合金の微粉砕した粉末の密度Ｄｐの比率Ｄｂ／Ｄｐが０．９５以上で、かつ超硬合金である試料Ｎｏ．１〜５については、いずれも靭性試験において欠損を生じる送りも実用上十分な０．５ｍｍ／刃以上と優れた耐衝撃性を有するものであった。
【００５１】
【発明の効果】
以上詳述したとおり、本発明の超硬合金によれば、β相粒子の含有量を５〜３０体積％と増した状態でＷＣ粒子と結合相の含有量を適正化するとともに、ＷＣ粒子の平均粒径よりもβ相粒子の平均粒径を積極的に大きくした範囲にて制御することによって、ＷＣ粒子の粒径を制御できるとともに合金を高緻密化することができ、かつ合金の耐酸化性を高めることができる結果、耐酸化性、耐熱衝撃性および耐衝撃性に優れ、切削工具に適した超硬合金を得ることができる。
【図面の簡単な説明】
【図１】本発明の超硬合金の一例を示す代用ＳＥＭ写真である。
【符号の説明】
１超硬合金
２ＷＣ粒子
３ β相粒子
４硬質相
５結合相
６結合相プール[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a cemented carbide that has high strength and high toughness used for cutting tools and the like, and exhibits excellent performance in cutting under conditions of high impact such as cutting of difficult-to-cut materials or high feed cutting. The present invention relates to a manufacturing method thereof and a cutting tool using the same.
[0002]
[Prior art]
Conventionally, cemented carbides have been used for cutting tools and wear-resistant tools. In recent years, so-called ultrafine-grained cemented carbides having a WC particle size of less than 1 μm have been used as K-type cemented carbides, with particular emphasis on toughness. Is being developed.
[0003]
Such ultrafine-grained cemented carbide is obtained by adding a small amount of chromium carbide or vanadium carbide powder as a grain growth inhibitor to fine WC raw material powder and cobalt raw material powder and calcining them. Fine-grain cemented carbide has been mainly used for processing non-ferrous materials such as cutting tools and microdrill materials for drilling printed circuit boards under cutting conditions with low impact, such as for finishing (see Patent Document 1).
[0004]
On the other hand, as applications of cemented carbide, in addition to cutting such as the above finishing, under high impact conditions such as cutting of difficult-to-cut materials such as stainless steel or high feed cutting, the temperature becomes locally high and intermittent. For such processing as to apply a strong impact, so-called β-phase particles such as carbides of Ti and Ta are dispersed and contained in the cemented carbide structure to improve properties such as oxidation resistance and thermal shock resistance. So-called M-type or P-type cemented carbides are known.
[0005]
As a cemented carbide in which the β phase particles are dispersed, for example, in Patent Document 2, in a cemented carbide base material in which WC particles having an average particle diameter of 0.6 μm or less and a maximum particle diameter of 3.0 μm or less are dispersed. , V, Cr, Ta, Nb, and Ti are controlled so as to have a maximum particle size of 3.0 μm or less, as fine as WC particles, and disperse at a small ratio of 5% by volume or less, thereby improving hardness and hardness. A cemented carbide with improved toughness is described.
[0006]
Recently, the use of difficult-to-cut materials such as stainless steel and the use of high-speed cutting and high-feed cutting in pursuit of more efficient cutting have been promoted. There is a demand for a cemented carbide having higher high-temperature properties, thermal shock resistance and impact resistance than dispersed M-class or P-class cemented carbide.
[0007]
[Patent Document 1]
JP-A-61-12847 [Patent Document 2]
JP-A-6-81072
[Problems to be solved by the invention]
In response to such demands, the cemented carbide disclosed in Patent Document 1 does not have sufficient properties with respect to high-temperature characteristics, thermal shock resistance and impact resistance. When cutting is performed under severe conditions using hard WC particles in which fine WC particles and β phase particles as fine as WC particles are dispersed at a content ratio as low as 5% by volume or less, oxidation resistance is high. And the thermal shock resistance and the impact resistance are low, and there is a problem that defects are easily generated.
[0009]
On the other hand, in order to improve oxidation resistance and thermal shock resistance, it is conceivable to increase the content ratio of β-phase particles. It is not possible to control the grain growth suppression of WC particles and β phase particles while reducing the sintering property, and it is not possible to make the alloy highly dense due to reduced sinterability, and both the hardness and the bending strength are reduced. Therefore, when cutting is performed under severe conditions, there is also a problem that the impact resistance is low and the chip is likely to be generated.
[0010]
Accordingly, an object of the present invention is to provide a cemented carbide having excellent oxidation resistance, thermal shock resistance and excellent impact resistance and fracture resistance even under severe conditions, which exhibit high cutting performance even under severe conditions. And a cutting tool using the same.
[0011]
[Means for Solving the Problems]
The present inventor studied the configuration of a cemented carbide having excellent oxidation resistance and impact resistance. As a result, the content ratio of the WC particles and the binder phase was increased while the content ratio of the β-phase particles was increased to 5 to 30% by volume. By controlling the average particle diameter of the β-phase particles more than the average particle diameter of the WC particles, the particle diameter of the WC particles can be controlled and the cemented carbide can be made denser. It has been found that as a result, the oxidation resistance and impact resistance can be improved.
[0012]
That is, the cemented carbide according to the present invention comprises 60 to 85% by volume of WC particles having an average particle size of 0.2 to 0.8 μm and a group 4a, 5a, 6a of the periodic table having an average particle size of 1.2 to 3 μm. A hard phase composed of 5 to 30% by volume of β-phase particles made of at least one kind of carbide, nitride or carbonitride of a metal, and a space between the hard phases mainly composed of at least one kind of iron group metal The ratio Db / Dp of the density Db of the bulk body measured by the gas displacement method and the density Dp of the powder after finely pulverizing to a size passing through # 200 mesh is obtained by bonding at 5 to 20% by volume of the bonding phase. It is not less than 0.95.
[0013]
In the cemented carbide, the total amount of at least one of Ti, Zr, Nb, and Ta in the β-phase particles is less than that of the group 4a, 5a, or 6a metal of the periodic table other than W in the β-phase particles. It is 70% by mass or more in terms of metal with respect to the total amount. Further, the content of W in the β-phase particles is more than the total amount of Group 4a, 5a, and 6a metals in the β-phase particles. When the content is 30% by mass or more in terms of metal, the thermal shock resistance and the impact resistance of the alloy can be enhanced.
[0014]
Further, when the maximum particle size of the binder phase pool in which the binder phase is aggregated is 1 μm or less, the strength of the cemented carbide can be increased, and the fracture resistance can be enhanced.
[0015]
Further, the WC particles have an area ratio of particles having a particle size of less than 0.5 μm of 40 to 80%, an area ratio of particles of a particle size of 0.5 to 1.2 μm of 15 to 40%, and a particle size of 1.2 μm. When the area ratio of the particles exceeding the particle size distribution is 5 to 20%, the impact resistance can be enhanced, and the fracture resistance can be enhanced even under severe cutting conditions.
[0016]
Further, the method for producing a cemented carbide according to the present invention comprises the steps of forming a WC raw material powder having an average particle size of 0.1 to 0.8 μm and a group 4a, 5a, or 6a metal of the periodic table having an average particle size of 1 to 1.3 μm. After mixing and pulverizing at least one kind of carbide, nitride or carbonitride raw material powder and at least one kind of iron group metal raw material powder having an average particle size of 0.1 to 1 μm, the mixture is formed and molded to 1400 to 1450 ° C. After firing for 1 to 2 hours in a vacuum at a temperature 20 to 50 ° C. lower than the firing temperature for 0.5 to 1 hour, hot isostatic pressure treatment at a pressure of 50 to 100 MPa. is there.
[0017]
The particle size of the hard phase in the alloy can be controlled within a predetermined range by setting the mixing and grinding time to 12 to 36 hours.
[0018]
Further, according to the present invention, by using the cemented carbide as a cutting tool, it is possible to obtain a cutting tool having excellent cutting performance even under conditions of large impact such as cutting of difficult-to-cut materials or high-feed cutting.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
The structure of the cemented carbide of the present invention will be described with reference to FIG. 1 which is an SEM photograph of one example.
As shown in FIG. 1, the cemented carbide of the present invention comprises WC particles 2 and at least one type of carbide, nitride or carbonitride particles (hereinafter referred to as β phase) of metals belonging to groups 4a, 5a and 6a of the periodic table. And a binder phase 5 containing at least one iron group metal as a main component, and particularly containing 80% by mass or more of Co and / or Ni. It is composed of In some cases, a binder phase pool 6 in which the binder phase 5 is partially pooled is formed.
[0020]
According to the present invention, 60 to 85% by volume of WC particles 2 having an average particle size of 0.2 to 0.8 μm and 5 to 30 volumes of β phase particles 3 having an average particle size of 1.2 to 3 μm are used as the hard phase 4. It is important that the WC particles 2 and the β-phase particles 3 are bonded together by a binder phase 5 of 5 to 20% by volume, while being dispersed and contained at a ratio of 2%.
[0021]
That is, by positively increasing the average particle diameter of the β-phase particles 3 than the average particle diameter of the WC particles 2, it is possible to control the particle diameter of the WC particles 2 within the above-mentioned predetermined range and to increase the density of the alloy. Can be used and the oxidation resistance of the alloy can be increased.As a result, the oxidation resistance and impact resistance of the alloy can be increased, so that it can be used well even when the cutting edge is exposed to high temperatures under severe cutting conditions. If the alloy is out of the above range, the oxidation resistance, thermal shock resistance, or impact resistance of the alloy will decrease.
[0022]
That is, when the average particle size of the WC particles 2 is smaller than 0.2 μm, the WC particles 2 aggregate with each other and the binder phase 5 easily aggregates, and a coarse binder phase pool is generated. Bring. Conversely, if the average particle size of the WC particles 2 exceeds 0.8 μm, the strength cannot be improved as compared with the conventional M-type or P-type cemented carbide, and the fracture resistance and wear resistance are improved. I can't let it. When the content of the WC particles 2 is less than 60% by volume, the hardness of the alloy decreases. On the other hand, when the content exceeds 85% by volume, the oxidation resistance or the densification of the alloy is impaired, and the strength of the alloy decreases in all cases. I do.
[0023]
Further, when the average particle diameter of the β-phase particles 3 is smaller than 1.2 μm, the sinterability is extremely reduced and a dense alloy cannot be obtained. When the average particle diameter of the β-phase particles 3 exceeds 3 μm, It becomes larger than the average particle size and acts as a fracture source due to stress concentration, so that the strength of the alloy decreases. On the other hand, if the content of the β-phase particles 3 is less than 5% by volume, the oxidation resistance and fracture resistance of the alloy will be reduced. On the other hand, if the content is more than 25% by volume, the alloy will be insufficiently densified and the strength of the alloy will be insufficient. Decreases.
[0024]
Furthermore, if the content of the binder phase 5 is less than 5% by volume, the alloy cannot be densified and the strength of the alloy decreases. Conversely, if the content of the binder phase 5 exceeds 20% by volume, the As the hardness decreases, a coarse metal pool in which the binder phase 5 is aggregated easily occurs, and the strength of the alloy decreases.
[0025]
In the cemented carbide of the present invention, the ratio Db / Dp of the density Db of the bulk body measured by the gas replacement method and the density Dp of the powder after finely pulverizing the bulk body to a size passing through # 200 mesh is obtained. It is also important that it be 0.95 or more, especially 0.975 or more, and even 0.98 or more. The fact that the ratio Db / Dp is large means that there are few open pores in the alloy and the alloy is in a highly densified state.
[0026]
Therefore, in the present invention, if Db / Dp is smaller than 0.95, high hardness and high strength cannot be achieved because voids remain in the alloy, and oxidation resistance and thermal shock resistance are not achieved. The properties and impact resistance cannot be improved. According to the present invention, the relative density of the cemented carbide by the Archimedes method is 98% to 102% with respect to the theoretical density assuming that there is no solid solution of metal between the WC particles, the β phase particles, and the binding phase. It is desirable that
[0027]
Here, according to the present invention, the total amount of at least one of Ti, Zr, Nb, and Ta in the β-phase particles 3 is determined by the amount of the group 4a, 5a, or 6a metal of the periodic table other than W in the β-phase particles 3. Oxidation resistance and impact resistance of the alloy can be increased by containing 70% by mass or more, particularly 80% by mass or more, and more preferably 90% by mass or more in terms of metal relative to the total amount.
[0028]
In order to enhance the thermal shock resistance of the alloy, W is contained in the β-phase particles 3 in an amount of 30% by mass or more, particularly 40 to 60% by mass, in terms of metal, based on the total amount of metals of Groups 4a, 5a and 6a of the periodic table. % Is desirable.
[0029]
Further, according to the present invention, by controlling the structure of the alloy as described above, the maximum particle size of the metal pool 6 in which the binder phase 5 is aggregated can be controlled to 1 μm or less, particularly 0.7 μm or less, Thereby, the strength of the alloy can be stably increased.
[0030]
Further, the particle size distribution of the WC particles 2 is such that the area ratio of particles having a particle size of less than 0.5 μm is 40 to 80%, the area ratio of particles having a particle size of 0.5 to 1.2 μm is 15 to 40%, and the particle size is 1%. The impact resistance of the alloy can be enhanced by the fact that the area ratio of particles exceeding 0.2 μm is present at a ratio of 5 to 20%.
[0031]
The cemented carbide of the present invention can form a cutting tool by itself, but carbides, nitrides, and carbons of metals of Groups 4a, 5a, and 6a of the periodic table are formed on the surface of the cemented carbide. Oxidation resistance and wear resistance are further improved by forming at least one kind of coating layer selected from the group consisting of nitride, TiAlN, TiZrN, TiCrN, diamond, diamond-like carbon and Al ₂ O _3. Although it can be used as a high-hardness material such as an excellent cutting tool, even in this case, the cemented carbide (base material) of the present invention has excellent oxidation resistance, thermal shock resistance, and impact resistance. Even if the layer is worn out or peeled off, the cutting tool is capable of performing a good cutting operation for a long period of time without causing breakage or wear to progress rapidly.
[0032]
Next, a method for manufacturing the above-mentioned cemented carbide will be described. First, a WC powder having an average particle size of 0.1 to 0.8 μm is 70 to 85% by mass, and a periodic table having an average particle size of 1 to 1.3 μm. Group 4a, 5a, 6a metals, in particular, carbides, nitrides and carbonitride powders of at least one metal selected from the group consisting of Ti, Zr, V, Cr, Mo, Ta, Nb, W or two of the above metals The above solid solution powder is 5 to 15% by mass in total, 5 to 15% by mass of iron group metal powder having an average particle size of 0.1 to 1 μm, and if desired, metal W (W) powder or carbon black (C ), Mix and crush.
[0033]
Here, according to the present invention, a cemented carbide having the above-described structure can be produced by controlling the particle size of the raw material and the firing conditions described below.
[0034]
According to the present invention, the mixing and pulverization use an attritor mill in controlling the particle size of each component in the sintered alloy, and the mixing and pulverization time is 12 to 36 hours, particularly 15 to 36 hours. Desirably 24 hours. This is a method in which grinding and mixing are advanced by the friction of the ball and the impact of the falling of the ball in the conventional ball mill, whereas the grinding efficiency of the attritor mill is large because the grinding ball moves greatly due to the rotating stirring blades. This is because it has the advantage of being high and it is easy to control to the desired particle size. If the grinding time is shorter than 12 hours, the crushed particle size and the degree of mixing are biased, and the grinding time is longer than 36 hours. This is because the pulverized particle size is not further reduced.
[0035]
The mixed and pulverized powder is press-molded into a predetermined cutting tool shape by a molding method such as a die press and then fired.
[0036]
In firing, first, the molded body is vacuum fired at 1400 to 1450 ° C. for 1 to 2 hours. By this vacuum firing, the density is increased to a relative density of 98% or more. Thereafter, hot isostatic pressure treatment is performed at a temperature 20 to 50 ° C. lower than the firing temperature for 0.5 to 1 hour at a pressure of 50 to 100 MPa. It is appropriate that the degree of vacuum during the vacuum firing is 0.1 to 100 Pa.
[0037]
Here, under the above firing conditions, if the firing temperature is lower than 1400 ° C., it is difficult to densify the alloy, and the Db / Dp becomes smaller than the above range, and if it exceeds 1450 ° C., the hard phase 4 causes abnormal grain growth. Therefore, the WC particles 2 and the β-phase particles 3 cannot be controlled to the predetermined particle sizes.
[0038]
On the other hand, if the sintering time is shorter than 1 hour, the alloy cannot be sufficiently densified by the hot isostatic pressure treatment described later. Conversely, if the sintering time is longer than 2 hours, the WC particles 2 and the β-phase particles 2 will be hardened. Phase 4 grows and cannot be controlled to the above-mentioned predetermined particle size.
[0039]
Further, when the temperature of the hot isostatic pressure treatment is higher than the above range or the pressure is higher than 100 MPa, the WC particles 2 and the β phase particles 3 grow, and the particle diameter of each particle is controlled to the above range. And the oxidation resistance and impact resistance of the alloy are reduced. Conversely, if the temperature of the hot isostatic pressure treatment is lower than the treatment temperature or the pressure is lower than 50 MPa, the alloy cannot be made denser, and particularly, the heat shock resistance and the impact resistance of the alloy are descend. Further, if the hot isostatic pressure treatment time is shorter than 0.5 hour, the alloy cannot be densified with high density, and the Db / Dp becomes smaller than the above range. As a result, the WC phase 2 and the β phase particles 3 cannot be controlled to the predetermined particle size, and the binder phase pool 6 becomes coarse.
[0040]
In order to form the above-mentioned coating layer on the cemented carbide, if necessary, the surface of the cemented carbide is ground, polished, and washed, and then a thin film such as a conventionally known PVD method or CVD method is used. It can be formed by a forming method. Further, the thickness of the coating layer is desirably 1 to 20 μm in terms of impact resistance and abrasion resistance.
[0041]
【Example】
WC powder, Co powder and other carbide powder having the average particle diameters shown in Table 1 were added at the ratio shown in Table 1, mixed with an attritor mill or a ball mill for the time shown in Table 1, pulverized, dried, and then cut by press molding. It was formed into a tool shape (SDKN1203), fired under the conditions shown in Table 1, and further subjected to hot isostatic pressure treatment under the conditions shown in Table 1 as needed to produce a cemented carbide.
[0042]
[Table 1]

[0043]
Reflection electron images were observed with a scanning electron microscope at five arbitrary cross sections of the obtained cemented carbide, and the content and particle size of WC particles and β phase particles were determined by image analysis for an arbitrary region of 20 μm × 20 μm. Mean and distribution), binder phase content, and maximum diameter of the binder phase pool. The content was defined as the volume ratio based on the area ratio based on the image analysis.
[0044]
EPMA analysis was performed on the β-phase particles (arbitrarily 5 particles) in the photograph to determine the metal content (content of W in the β-phase particles / metals of Groups 4a, 5a, and 6a in the periodic table in the β-phase particles). : A (%) in the table, the total amount of at least one of Ti, Zr, Nb, and Ta in the β-phase particles / Group 4a, 5a, and 6a metals other than W in the β-phase particles (B:% in the table) was calculated.
[0045]
Further, the density Dp of the bulk body, which is a measure of sinterability, and the density Dp of the finely pulverized powder to a size that allows the bulk body to pass through a # 200 mesh with a mortar made of cemented carbide, are replaced with gas using helium. The ratio Db / Dp value is shown in Table 2. In the table, sample No. Regarding 1 to 5, the relative density was 98 to 102%.
[0046]
Further, a 2 μm-thick TiAlN film was formed on the surface of each of the obtained cemented carbides by a PVD method to produce a cutting tool.
[0047]
Then, using this cutting tool, high feed of the grooved alloy steel was performed as a toughness test under the following conditions, and the feed speed when a fracture occurred was measured. These results are shown in Table 2.
(Impact resistance test)
Work material: grooved alloy steel (SCM440H)
Tool shape: SDKN1203
Cutting speed: 80m / min Feeding speed: Variable 0.2-0.8mm / Blade cut: 2mm
Others: dry cutting
[Table 2]

[0049]
From the results of Tables 1 and 2, the sample No. deviated from any one of the raw material particle size, the mixing ratio, the mixing conditions, and the firing conditions with respect to the production method of the present invention. With regard to Nos. 6 to 12, the open porosity or structure of the alloy deviated from the range of the present invention, so that it was impossible to achieve both oxidation resistance and impact resistance, and all of them had a short time to fracture.
[0050]
On the other hand, the density Db of the cemented carbide bulk body having a structure within the scope of the present invention and measured by the gas replacement method and the density of the pulverized powder of the cemented carbide measured by the gas replacement method In the case of Sample No. 1 in which the ratio Db / Dp of Dp is 0.95 or more and the cemented carbide is used. All of the samples Nos. 1 to 5 had an impact resistance of 0.5 mm / blade or more, which was sufficient for practical use, which caused fracture in the toughness test.
[0051]
【The invention's effect】
As described in detail above, according to the cemented carbide of the present invention, the contents of the WC particles and the binder phase are optimized while the content of the β phase particles is increased to 5 to 30% by volume, and By controlling the average particle diameter of the β-phase particles to be positively larger than the average particle diameter, the particle diameter of the WC particles can be controlled, the alloy can be made denser, and the oxidation resistance of the alloy can be improved. As a result, it is possible to obtain a cemented carbide having excellent oxidation resistance, thermal shock resistance and impact resistance and suitable for a cutting tool.
[Brief description of the drawings]
FIG. 1 is a substitute SEM photograph showing an example of a cemented carbide according to the present invention.
[Explanation of symbols]
1 cemented carbide 2 WC particles 3 β phase particles 4 hard phase 5 binder phase 6 binder phase pool

Claims

60 to 85% by volume of WC particles having an average particle diameter of 0.2 to 0.8 μm, and at least one kind of carbide or nitride of a metal of Groups 4a, 5a, and 6a of the periodic table having an average particle diameter of 1.2 to 3 μm Alternatively, a hard phase composed of 5 to 30% by volume of β-phase particles made of carbonitride is bonded to the hard phase with 5 to 20% by volume of a bonded phase mainly composed of at least one iron group metal. The ratio Db / Dp of the density Db of the bulk body measured by the gas replacement method to the density Dp of the powder after finely pulverizing the bulk body to a size passing through # 200 mesh is 0.95 or more. A cemented carbide characterized by the following.

The total amount of at least one of Ti, Zr, Nb, and Ta in the β-phase particles is 70 mass in terms of metal with respect to the total amount of metals in Groups 4a, 5a, and 6a other than W in the β-phase particles. % Or more.

The content of W in the β-phase particles is 30% by mass or more in terms of metal with respect to the total amount of metals in Groups 4a, 5a, and 6a of the periodic table in the β-phase particles. The cemented carbide described.

The cemented carbide according to any one of claims 1 to 3, wherein a maximum particle size of the binder phase pool in which the binder phase is aggregated is 1 µm or less.

The WC particles have an area ratio of particles having a particle size of less than 0.5 μm of 40 to 80%, an area ratio of particles having a particle size of 0.5 to 1.2 μm of 15 to 40%, and a particle having a particle size of more than 1.2 μm. The cemented carbide according to any one of claims 1 to 4, wherein the area ratio of the cemented carbide has a particle size distribution of 5 to 20%.

WC raw material powder having an average particle diameter of 0.1 to 0.8 μm, and at least one carbide, nitride or carbonitride raw material of a Group 4a, 5a, or 6a metal of the periodic table having an average particle diameter of 1 to 1.3 μm After mixing and pulverizing the powder and at least one type of iron group metal raw material powder having an average particle size of 0.1 to 1 μm, the mixture is molded, vacuum-baked at 1400 to 1450 ° C. for 1 to 2 hours, and then fired. A method for producing a cemented carbide, comprising performing hot isostatic pressure treatment at a pressure of 50 to 100 MPa at a temperature of 20 to 50 ° C. lower than the temperature for 0.5 to 1 hour.

The method for producing a cemented carbide according to claim 6, wherein the mixing and grinding time is 12 to 36 hours.

A cutting tool comprising the cemented carbide according to any one of claims 1 to 5.