JP2005205586A - Surface-coated cermet cutting tool exhibiting excellent chipping resistance in hard coated layer - Google Patents

Surface-coated cermet cutting tool exhibiting excellent chipping resistance in hard coated layer Download PDF

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JP2005205586A
JP2005205586A JP2004172511A JP2004172511A JP2005205586A JP 2005205586 A JP2005205586 A JP 2005205586A JP 2004172511 A JP2004172511 A JP 2004172511A JP 2004172511 A JP2004172511 A JP 2004172511A JP 2005205586 A JP2005205586 A JP 2005205586A
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JP4512989B2 (en
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Takatoshi Oshika
高歳 大鹿
Toshiaki Ueda
稔晃 植田
Takuya Hayatoi
拓也 早樋
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Mitsubishi Materials Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a surface-coated cermet cutting tool exhibiting excellent chipping resistance in a hard coated layer. <P>SOLUTION: A Ti compound layer consisting of one or two or more layers of chemical vapor-deposited TiC layer, TiN layer, TiCN layer, TiCO layer and TiCNO layer and having the total average layer thickness of 3-20 μm as a lower layer, and an Al<SB>2</SB>O<SB>3</SB>layer having α-type crystalline structure in a chemical vapor-deposited state, exhibiting a distribution graph of the frequency of the angle of inclination for totaling the frequency present in each section in which the maximum peak is present in the section of the angle of inclination in a range of 0-10°, and the total frequency present in the range of 0-10° occupies the ratio of ≥ 45% of the entire frequency in the distribution graph of the angle of inclination, and having the average layer thickness of 1-30 μm as an upper layer are deposited on a surface of a tool base body formed of WC-based cemented carbide or TiCN-based cermet. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

この発明は、特に各種の鋼や鋳鉄などの高速断続切削で、硬質被覆層がすぐれた耐チッピング性を発揮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。   The present invention relates to a surface-coated cermet cutting tool (hereinafter referred to as a coated cermet tool) that exhibits excellent chipping resistance with a hard coating layer, particularly in high-speed intermittent cutting of various types of steel and cast iron.

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)下部層として、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、酸化物(以下、TiO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の全体平均層厚を有するTi化合物層、
(b)上部層として、化学蒸着形成した状態でα型の結晶構造を有し、かつ1〜30μmの平均層厚を有する酸化アルミニウム層(以下、α型Al23層で示す)、
以上(a)および(b)で構成された硬質被覆層を化学蒸着形成(以下、単に蒸着形成という)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ることは良く知られている。
Conventionally, generally on the surface of a substrate (hereinafter collectively referred to as a tool substrate) composed of a tungsten carbide (hereinafter referred to as WC) -based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN) -based cermet. ,
(A) As a lower layer, a Ti carbide (hereinafter referred to as TiC) layer, nitride (hereinafter also referred to as TiN) layer, carbonitride (hereinafter referred to as TiCN) layer formed by chemical vapor deposition, It is composed of one or more of an oxide (hereinafter referred to as TiO) layer, a carbon oxide (hereinafter referred to as TiCO) layer, and a carbonitride oxide (hereinafter referred to as TiCNO) layer, and 3 to 3 A Ti compound layer having an overall average layer thickness of 20 μm,
(B) As an upper layer, an aluminum oxide layer (hereinafter, referred to as an α-type Al 2 O 3 layer) having an α-type crystal structure in a state of chemical vapor deposition and having an average layer thickness of 1 to 30 μm,
There is known a coated cermet tool formed by chemical vapor deposition (hereinafter simply referred to as vapor deposition) of the hard coating layer composed of (a) and (b) above. It is well known that it is used for continuous cutting and intermittent cutting of cast iron and the like.

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α型Al23 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。
特開平6−31503号公報 特開平6−8010号公報
In general, the Ti compound layer and the α-type Al 2 O 3 layer constituting the hard coating layer of the above-mentioned coated cermet tool have a granular crystal structure, and further, the TiCN layer constituting the Ti compound layer is the layer itself. For the purpose of improving the strength of the crystal, a vertically grown crystal formed by chemical vapor deposition at a medium temperature range of 700 to 950 ° C. using a mixed gas containing an organic carbonitride as a reaction gas in a normal chemical vapor deposition apparatus. It is also known to have an organization.
Japanese Unexamined Patent Publication No. 6-31503 Japanese Patent Laid-Open No. 6-8010

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ほか、高切り込みや高送りなどの重切削条件での切削加工を余儀なくされる状況にあるが、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、硬質被覆層を構成するα型Al23層は、硬質で耐熱性にすぐれるものの、十分な強度を具備するものでないために、これが原因で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。 In recent years, the performance of cutting equipment has been remarkable. On the other hand, there is a strong demand for labor saving and energy saving and further cost reduction for cutting work. When cutting with heavy cutting conditions such as high feed is inevitable, the above-mentioned conventional coated cermet tools are used for continuous cutting and interrupted cutting under normal conditions such as steel and cast iron. Although there is no problem with this, especially when this is used for high-speed intermittent cutting with the severest cutting conditions, that is, high-speed intermittent cutting in which repeated thermal shock is applied to the cutting edge portion at a very short pitch, α constituting the hard coating layer Although the type Al 2 O 3 layer is hard and has excellent heat resistance, it does not have sufficient strength, so that the hard coating layer is likely to cause chipping (micro chipping) due to this, As a result, the service life is reached in a relatively short time.

そこで、本発明者等は、上述のような観点から、上記のα型Al23層が硬質被覆層を構成する被覆サーメット工具に着目し、これの耐チッピング性向上を図るべく研究を行った結果、
(a)工具基体の表面に、硬質被覆層としてのα型Al23層を蒸着形成するに際して、例えばこれの蒸着形成に先だって、通常の化学蒸着装置にて、
反応ガス組成:容量%で、AlCl3:3〜10%、CO2:0.5〜3%、C24:0.01〜0.3%、H2:残り、
反応雰囲気温度:750〜900℃、
反応雰囲気圧力:3〜13kPa、
の低温条件で、下部層であるTi化合物層の表面にAl23核を形成し、この場合前記Al23核は20〜200nmの平均層厚を有するAl23核薄膜であるのが望ましく、引き続いて、反応雰囲気を圧力:3〜13kPaの水素雰囲気に変え、反応雰囲気温度を1100〜1200℃に昇温した条件で前記Al23核薄膜に加熱処理を施した状態で、硬質被覆層としてのα型Al23層を通常の条件で形成すると、この結果の前記加熱処理Al23核薄膜上に蒸着形成されたα型Al23層は、電界放出型走査電子顕微鏡を用い、図1(a),(b)に概略説明図で示される通り、表面研磨面の測定範囲内に存在する六方晶結晶格子を有するα型Al23結晶粒個々に電子線を照射して、前記表面研磨面の法線に対して、前記結晶粒の結晶面である(0001)面の法線がなす傾斜角を測定し、前記測定傾斜角のうち、0〜45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分すると共に、各区分内に存在する度数を集計してなる傾斜角度数分布グラフを作成した場合、前記従来のα−Al23層は、図3に例示される通り、(0001)面の測定傾斜角の分布が0〜45度の範囲内で不偏的な傾斜角度数分布グラフを示すのに対して、前記加熱処理Al23核薄膜上に蒸着形成されたα型Al23層は、図2に例示される通り、傾斜角区分の特定位置にシャープな最高ピークが現れ、このシャープな最高ピークは、前記Al23核薄膜の平均層厚を変化させることによりグラフ横軸の傾斜角区分に現れる位置が変わること。
In view of the above, the present inventors focused on the coated cermet tool in which the α-type Al 2 O 3 layer constitutes a hard coating layer, and conducted research to improve the chipping resistance. As a result,
(A) When the α-type Al 2 O 3 layer as the hard coating layer is vapor-deposited on the surface of the tool base, for example, prior to the vapor-deposition formation,
Reaction gas composition:% by volume, AlCl 3 : 3 to 10%, CO 2 : 0.5 to 3%, C 2 H 4 : 0.01 to 0.3%, H 2 : remaining,
Reaction atmosphere temperature: 750 to 900 ° C.
Reaction atmosphere pressure: 3 to 13 kPa,
Under these low temperature conditions, Al 2 O 3 nuclei are formed on the surface of the lower Ti compound layer. In this case, the Al 2 O 3 nuclei are Al 2 O 3 nuclei thin films having an average layer thickness of 20 to 200 nm. Subsequently, the reaction atmosphere is changed to a hydrogen atmosphere at a pressure of 3 to 13 kPa, and the reaction atmosphere temperature is raised to 1100 to 1200 ° C., and the Al 2 O 3 core thin film is heated. When the α-type Al 2 O 3 layer as a hard coating layer is formed under normal conditions, the α-type Al 2 O 3 layer deposited on the heat-treated Al 2 O 3 core thin film as a result is subjected to field emission. Using a scanning electron microscope, each α-type Al 2 O 3 crystal grain having a hexagonal crystal lattice existing within the measurement range of the surface polished surface as shown in the schematic explanatory diagrams of FIGS. 1 (a) and 1 (b) An electron beam is irradiated onto the surface polished surface normal to the surface polished surface. The inclination angle formed by the normal line of the (0001) plane, which is the crystal plane of the crystal grain, is measured, and the measurement inclination angle within the range of 0 to 45 degrees out of the measurement inclination angles is set for every 0.25 degree pitch. When the slope angle number distribution graph is created by dividing and counting the frequencies existing in each section, the conventional α-Al 2 O 3 layer has a (0001) plane as illustrated in FIG. In contrast, the measured inclination angle distribution shows an unbiased inclination angle number distribution graph in the range of 0 to 45 degrees, whereas the α-type Al 2 O deposited on the heat-treated Al 2 O 3 nuclear thin film is deposited. As shown in FIG. 2, the three layers have a sharp maximum peak at a specific position in the tilt angle section, and this sharp maximum peak is obtained by changing the average layer thickness of the Al 2 O 3 nuclear thin film. The position that appears in the tilt angle section of the horizontal axis changes.

(b)上記の加熱処理Al23核薄膜上に蒸着形成されたα型Al23層は上記従来α型Al23層に比して著しく高温強度の向上したものとなるので、これを硬質被覆層の上部層として蒸着形成した被覆サーメット工具は、同じく前記従来α型Al23層を蒸着形成した従来被覆サーメット工具に比して、一段とすぐれた耐チッピング性を発揮するようになること。 (B) The α-type Al 2 O 3 layer deposited on the heat-treated Al 2 O 3 core thin film has a significantly improved high-temperature strength as compared with the conventional α-type Al 2 O 3 layer. The coated cermet tool formed by vapor deposition using the same as the upper layer of the hard coating layer exhibits excellent chipping resistance as compared with the conventional coated cermet tool formed by vapor deposition of the conventional α-type Al 2 O 3 layer. To be like that.

(c)試験結果によれば、上記Al23核薄膜の平均層厚を20〜200nmとすると、上記シャープな最高ピークが傾斜角区分の0〜10度の範囲内に現れると共に、前記0〜10度の範囲内に存在する度数の合計が、傾斜角度数分布グラフにおける度数全体の45%以上の割合を占める傾斜角度数分布グラフを示すようになり、この結果の傾斜角度数分布グラフで0〜10度の範囲内に傾斜角区分の最高ピークが現れ、かつ前記0〜10度の範囲内に存在する度数割合が45%以上の割合を占めるα−Al23層を硬質被覆層の上部層として、下部層のTi化合物層と共存した状態で蒸着形成してなる被覆サーメット工具は、上記の従来被覆サーメット工具に比して、特に高速断続切削で切刃部にチッピングの発生なく、一段とすぐれた耐摩耗性を発揮するようになること。
以上(a)〜(c)に示される研究結果を得たのである。
(C) According to the test results, when the average layer thickness of the Al 2 O 3 nuclear thin film is 20 to 200 nm, the sharp maximum peak appears in the range of 0 to 10 degrees of the inclination angle section, and the 0 An inclination angle number distribution graph in which the sum of the frequencies existing in the range of -10 degrees occupies a ratio of 45% or more of the entire frequency in the inclination angle number distribution graph is shown. The α-Al 2 O 3 layer in which the highest peak of the tilt angle section appears in the range of 0 to 10 degrees and the frequency ratio existing in the range of 0 to 10 degrees occupies a ratio of 45% or more is a hard coating layer The coated cermet tool formed by vapor deposition in the state of coexisting with the lower Ti compound layer as the upper layer of the above-described conventional coated cermet tool has no chipping at the cutting edge portion particularly at high-speed intermittent cutting. , Much better It is like to exhibit wear resistance.
The research results shown in (a) to (c) above were obtained.

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)下部層として、いずれも化学蒸着形成されたTiC層、TiN層、TiCN層、TiO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の全体平均層厚を有するTi化合物層、
(b)上部層として、化学蒸着形成した状態でα型の結晶構造を有し、電界放出型走査電子顕微鏡を用い、表面研磨面の測定範囲内に存在する六方晶結晶格子を有する結晶粒個々に電子線を照射して、前記表面研磨面の法線に対して、前記結晶粒の結晶面である(0001)面の法線がなす傾斜角を測定し、前記測定傾斜角のうち、0〜45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分すると共に、各区分内に存在する度数を集計してなる傾斜角度数分布グラフにおいて、0〜10度の範囲内の傾斜角区分に最高ピークが存在すると共に、前記0〜10度の範囲内に存在する度数の合計が、傾斜角度数分布グラフにおける度数全体の45%以上の割合を占める傾斜角度数分布グラフを示し、かつ1〜30μmの平均層厚を有するAl23層、
以上(a)および(b)で構成された硬質被覆層を蒸着形成してなる、硬質被覆層がすぐれた耐チッピング性を発揮する被覆サーメット工具に特徴を有するものである。
The present invention has been made based on the above research results, and on the surface of a tool base composed of a WC-based cemented carbide or TiCN-based cermet,
(A) As a lower layer, each consists of one or more of a TiC layer, a TiN layer, a TiCN layer, a TiO layer, a TiCO layer, and a TiCNO layer formed by chemical vapor deposition, and a total of 3 to 20 μm A Ti compound layer having an average layer thickness;
(B) As an upper layer, each crystal grain having a hexagonal crystal lattice which has an α-type crystal structure in a state where chemical vapor deposition is formed, and which exists within the measurement range of the surface polished surface using a field emission scanning electron microscope Is irradiated with an electron beam to measure the inclination angle formed by the normal line of the (0001) plane, which is the crystal plane of the crystal grain, with respect to the normal line of the surface polished surface. In the inclination angle distribution graph formed by dividing the measured inclination angles within the range of ˜45 degrees into the pitches of 0.25 degrees and totaling the frequencies existing in the respective sections, within the range of 0 to 10 degrees. An inclination angle number distribution graph in which the highest peak exists in the inclination angle section and the sum of the frequencies existing in the range of 0 to 10 degrees occupies a ratio of 45% or more of the entire frequency in the inclination angle distribution graph. And having an average layer thickness of 1 to 30 μm Al 2 O 3 layer,
The hard coating layer formed by vapor deposition of the hard coating layer composed of the above (a) and (b) is characterized by a coated cermet tool that exhibits excellent chipping resistance.

また、この発明の被覆サーメット工具の硬質被覆層の構成層において、上記の通りに数値限定した理由を以下に説明する。
(a)Ti化合物層
Ti化合物層は、基本的にはα型Al23層の下部層として存在し、自身の具備するすぐれた高温強度によって硬質被覆層の高温強度向上に寄与するほか、工具基体とα型Al23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を向上させる作用を有するが、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。
In addition, the reason why the numerical values of the constituent layers of the hard coating layer of the coated cermet tool of the present invention are limited as described above will be described below.
(A) Ti compound layer The Ti compound layer basically exists as a lower layer of the α-type Al 2 O 3 layer, and contributes to improving the high temperature strength of the hard coating layer by its excellent high temperature strength. The tool base and the α-type Al 2 O 3 layer are firmly adhered to each other, thereby improving the adhesion of the hard coating layer to the tool base. However, if the average layer thickness is less than 3 μm, the above action is sufficient. On the other hand, if the average layer thickness exceeds 20 μm, it becomes easy to cause thermoplastic deformation especially at high-speed intermittent cutting with high heat generation, and this causes uneven wear. The layer thickness was determined to be 3-20 μm.

(b)α型Al23
上記の通り加熱処理Al23核薄膜上に形成されたα型Al23層には、Al23自体のもつすぐれた高温硬度と耐熱性によって硬質被覆層の耐摩耗性を向上させると共に、従来α型Al23層に比して、一段とすぐれた高温強度を有するので、硬質被覆層の耐チッピング性を一段と向上させる作用があるが、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30μmを越えて厚くなりすぎると、チッピングが発生し易くなることから、その平均層厚を1〜30μmと定めた。
(B) The α-type the Al 2 O 3 layer above α-type Al 2 O 3 layer formed as heat treatment Al 2 O 3 on the nuclear membrane of the high-temperature hardness and heat resistance superior with the Al 2 O 3 itself In addition to improving the wear resistance of the hard coating layer, it has a higher high-temperature strength than the conventional α-type Al 2 O 3 layer, so it has the effect of further improving the chipping resistance of the hard coating layer. When the average layer thickness is less than 1 μm, the above-mentioned effect cannot be sufficiently exhibited. On the other hand, when the average layer thickness exceeds 30 μm, the chipping tends to occur. It was defined as 1 to 30 μm.

(c)加熱処理Al23核薄膜
この発明の被覆サーメット工具の硬質被覆層を構成するα型Al23層に関して、傾斜角度数分布グラフで最高ピークを示す傾斜角区分と加熱処理Al23核薄膜の平均層厚との間には密接な関係があり、この場合試験結果によれば、前記加熱処理Al23核薄膜の平均層厚を20〜200nmの範囲で変化させると、最高ピークが0〜10度の範囲内の傾斜角区分に現れると共に、前記0〜10度の範囲内に存在する度数の合計が、傾斜角度数分布グラフにおける度数全体の45%以上の割合を占める傾斜角度数分布グラフを示すようになるものであり、したがって、前記加熱処理Al23核薄膜の平均層厚が、20nm未満では、これの上に蒸着形成されるα型Al23層の傾斜角度数分布グラフの0〜10度の範囲内に現れるピーク高さが不十分、すなわち、前記0〜10度の範囲内に存在する度数の合計割合が、傾斜角度数分布グラフにおける度数全体の45%未満となってしまい、この場合上記の通り、前記α型Al23層に所望のすぐれた高温強度を確保することができず、この結果耐チッピング性に所望の向上効果が得られず、一方その平均層厚が200nmを越えると、最高ピークの現れる傾斜角区分が0〜10度の範囲から外れてしまい、この場合も前記α型Al23層に所望のすぐれた高温強度を確保することができないことから、硬質被覆層を構成するTi化合物層上に形成される前記Al23核薄膜の平均層厚を20〜200nm、望ましくは同30〜150nmとしたのである。
(C) Heat-treated Al 2 O 3 core thin film Regarding the α-type Al 2 O 3 layer constituting the hard coating layer of the coated cermet tool of the present invention, the tilt angle segment showing the highest peak in the tilt angle number distribution graph and the heat-treated Al There is a close relationship between the average layer thickness of the 2 O 3 core thin film. In this case, according to the test results, the average layer thickness of the heat-treated Al 2 O 3 core thin film is changed in the range of 20 to 200 nm. And the highest peak appears in the inclination angle section within the range of 0 to 10 degrees, and the total of the frequencies existing within the range of 0 to 10 degrees is a ratio of 45% or more of the entire degrees in the inclination angle frequency distribution graph. Therefore, if the average layer thickness of the heat-treated Al 2 O 3 core thin film is less than 20 nm, the α-type Al 2 O formed on the thin film is deposited. 3-layer inclination angle frequency distribution graph of The peak height appearing in the range of 0 to 10 degrees is insufficient, that is, the total ratio of the frequencies existing in the range of 0 to 10 degrees is less than 45% of the entire frequencies in the inclination angle frequency distribution graph. In this case, as described above, the α-type Al 2 O 3 layer cannot secure a desired excellent high-temperature strength, and as a result, a desired improvement effect in chipping resistance cannot be obtained, while the average layer When the thickness exceeds 200 nm, the tilt angle section where the highest peak appears is out of the range of 0 to 10 degrees, and in this case as well, the desired excellent high-temperature strength cannot be secured in the α-type Al 2 O 3 layer. Therefore, the average layer thickness of the Al 2 O 3 core thin film formed on the Ti compound layer constituting the hard coating layer is 20 to 200 nm, preferably 30 to 150 nm.

なお、被覆サーメット工具の使用前後の識別を目的として、黄金色の色調を有するTiN層を、硬質被覆層の最表面層として必要に応じて蒸着形成してもよいが、この場合の平均層厚は0.1〜1μmでよく、これは0.1μm未満では、十分な識別効果が得られず、一方前記TiN層による前記識別効果は1μmまでの平均層厚で十分であるという理由からである。   For the purpose of identification before and after the use of the coated cermet tool, a TiN layer having a golden color tone may be vapor-deposited as the outermost surface layer of the hard coating layer, but the average layer thickness in this case 0.1-1 μm may be sufficient, because if the thickness is less than 0.1 μm, a sufficient discrimination effect cannot be obtained, while the discrimination effect by the TiN layer is sufficient with an average layer thickness of up to 1 μm. .

この発明の被覆サーメット工具は、機械的熱的衝撃がきわめて高く、かつ高い発熱を伴なう各種の鋼や鋳鉄の高速断続切削でも、硬質被覆層を構成するα型Al23層が、図2に例示される通り0〜10度の範囲内の傾斜角区分に最高ピークが現れる傾斜角度数分布グラフを示し、すぐれた耐チッピング性を発揮することから、すぐれた耐摩耗性を長期に亘ってすぐれた切削性能を示すものである。 The coated cermet tool of the present invention has an α-type Al 2 O 3 layer that constitutes a hard coating layer even in high-speed intermittent cutting of various steels and cast irons with extremely high mechanical and thermal shock and high heat generation. As shown in FIG. 2, the inclination angle number distribution graph in which the highest peak appears in the inclination angle section within the range of 0 to 10 degrees is shown, and since excellent chipping resistance is exhibited, excellent wear resistance is extended over a long period of time. It shows excellent cutting performance.

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。   Next, the coated cermet tool of the present invention will be specifically described with reference to examples.

原料粉末として、いずれも1〜3μmの平均粒径を有するWC粉末、TiC粉末、ZrC粉末、VC粉末、TaC粉末、NbC粉末、Cr3 2 粉末、TiN粉末、TaN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、さらにワックスを加えてアセトン中で24時間ボールミル混合し、減圧乾燥した後、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、1370〜1470℃の範囲内の所定の温度に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。 WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder, TaN powder, and Co powder all having an average particle diameter of 1 to 3 μm are prepared as raw material powders. These raw material powders were blended into the composition shown in Table 1, added with wax, ball milled in acetone for 24 hours, dried under reduced pressure, and pressed into a green compact with a predetermined shape at a pressure of 98 MPa. The green compact was vacuum sintered at a predetermined temperature in the range of 1370 to 1470 ° C. for 1 hour in a vacuum of 5 Pa. After sintering, the cutting edge portion was R: 0.07 mm honing By performing the processing, tool bases A to F made of a WC-base cemented carbide having a throwaway tip shape specified in ISO · CNMG120408 were manufactured.

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。 In addition, as raw material powders, TiCN (mass ratio TiC / TiN = 50/50) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder, all 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 by a ball mill for 24 hours, dried, and pressed into a 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 the sintering, the cutting edge portion was subjected to a honing process of R: 0.07 mm. Tool bases a to f made of TiCN-based cermet having a standard / CNMG12041 chip shape were formed.

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、まず、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、
反応ガス組成:容量%で、AlCl3:6.5%、CO2:1.6%、C24:0.13%、H2:残り、
反応雰囲気温度:820℃、
反応雰囲気圧力:8kPa、
時間:5〜80分、
の低温条件で表4に示される目標層厚のAl23核薄膜を形成した後(前記Al23核薄膜の層厚と処理時間の関係は上記Ti化合物層の場合と同様に実験により予め調査されている)、反応雰囲気を圧力:8kPaの水素雰囲気に変え、反応雰囲気温度を1135℃に昇温した条件で前記Al23核薄膜に加熱処理を施し、引続いて、同じく表3に示される条件で、同じく表4に示される目標層厚のα型Al23層を硬質被覆層の上部層として蒸着形成し、さらに必要に応じて前記α型Al23層の上に同じく表3に示される条件にて、表4に示される目標層厚のTiN層を硬質被覆層の最表面層として蒸着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。
Subsequently, a normal chemical vapor deposition apparatus was used on the surfaces of the tool bases A to F and the tool bases a to f. First, Table 3 (l-TiCN in Table 3 is described in JP-A-6-8010). The target layer thickness shown in Table 4 under the conditions shown in Table 4 is a condition for forming a TiCN layer having a vertically grown crystal structure. The Ti compound layer is deposited as a lower layer of the hard coating layer, and then,
Reaction gas composition: volume%, AlCl 3 : 6.5%, CO 2 : 1.6%, C 2 H 4 : 0.13%, H 2 : remaining,
Reaction atmosphere temperature: 820 ° C.
Reaction atmosphere pressure: 8 kPa,
Time: 5-80 minutes
After forming the Al 2 O 3 nucleus thin film having the target layer thickness shown in Table 4 under the low temperature condition (the relation between the layer thickness of the Al 2 O 3 nucleus thin film and the processing time is the same as in the case of the Ti compound layer) The reaction atmosphere was changed to a hydrogen atmosphere with a pressure of 8 kPa and the reaction atmosphere temperature was raised to 1135 ° C., and the Al 2 O 3 core thin film was subjected to heat treatment. under the conditions shown in Table 3, like-α type the Al 2 O 3 layer of the target layer thicknesses shown in Table 4 was vapor deposited as an upper layer of the hard coating layer, wherein the α-type the Al 2 O 3 layer if necessary The coated cermet tools 1 to 13 of the present invention were manufactured by vapor-depositing a TiN layer having a target layer thickness shown in Table 4 as the outermost surface layer of the hard coating layer under the same conditions as shown in Table 3 above. .

また、比較の目的で、表5に示される通り、硬質被覆層のα型Al23層を形成するに先だって、上記のAl23核薄膜の形成およびこれの加熱処理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1〜13をそれぞれ製造した。 For the purpose of comparison, as shown in Table 5, prior to the formation of the α-type Al 2 O 3 layer of the hard coating layer, the formation of the Al 2 O 3 core thin film and the heat treatment thereof are not performed. Produced the conventional coated cermet tools 1 to 13 under the same conditions.

さらに、上記の本発明被覆サーメット工具1〜13と従来被覆サーメット工具1〜13の硬質被覆層を構成するα型Al23層について、電界放出型走査電子顕微鏡を用いて、傾斜角度数分布グラフをそれぞれ作成した。
すなわち、上記傾斜角度数分布グラフは、上記のα型Al23層の表面を研磨面とした状態で、電界放出型走査電子顕微鏡の鏡筒内にセットし、前記研磨面に70度の入射角度で15kVの加速電圧の電子線を1nAの照射電流で、前記表面研磨面の測定範囲内に存在する六方晶結晶格子を有する結晶粒個々に照射し、電子後方散乱回折像装置を用いて、30×50μmの領域を0.1μm/stepの間隔で、前記表面研磨面の法線に対して、前記結晶粒の結晶面である(0001)面の法線がなす傾斜角を測定し、この測定結果に基づいて、前記測定傾斜角のうち、0〜45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分すると共に、各区分内に存在する度数を集計することにより作成した。
Furthermore, with respect to the α-type Al 2 O 3 layer constituting the hard coating layers of the above-described coated cermet tools 1 to 13 of the present invention and the conventional coated cermet tools 1 to 13, the inclination angle number distribution is obtained using a field emission scanning electron microscope. Each graph was created.
That is, the inclination angle number distribution graph is set in a lens barrel of a field emission scanning electron microscope in a state where the surface of the α-type Al 2 O 3 layer is a polished surface, and 70 ° on the polished surface. An electron beam having an acceleration voltage of 15 kV at an incident angle is irradiated with an irradiation current of 1 nA on each crystal grain having a hexagonal crystal lattice existing within the measurement range of the surface polished surface, and an electron backscatter diffraction image apparatus is used. , And measuring the inclination angle formed by the normal of the (0001) plane, which is the crystal plane of the crystal grain, with respect to the normal of the polished surface at an interval of 0.1 μm / step in a 30 × 50 μm region, Based on the measurement results, the measurement inclination angles within the range of 0 to 45 degrees out of the measurement inclination angles are divided for each pitch of 0.25 degrees, and the frequencies existing in each division are tabulated. Created by.

この結果得られた各種のα型Al23層の傾斜角度数分布グラフにおいて、(0001)面が最高ピークを示す傾斜角区分、並びに0〜10度の範囲内の傾斜角区分内に存在する傾斜角度数の傾斜角度数分布グラフ全体の傾斜角度数に占める割合をそれぞれ表4,5にそれぞれ示した。 In the slope angle distribution graphs of the various α-type Al 2 O 3 layers obtained as a result, the (0001) plane is present in the slope section where the highest peak is present, and the slope section within the range of 0 to 10 degrees. Tables 4 and 5 show the ratios of the tilt angle numbers to the tilt angle number distribution graph as a whole.

上記の各種のα型Al23層の傾斜角度数分布グラフにおいて、表4,5にそれぞれ示される通り、本発明被覆サーメット工具の加熱処理Al23核薄膜上に形成されたα型Al23層は、いずれも(0001)面の測定傾斜角の分布が0〜10度の範囲内の傾斜角区分に最高ピークが現れ、かつ0〜10度の範囲内の傾斜角区分内に存在する傾斜角度数の割合が45%以上である傾斜角度数分布グラフを示すのに対して、従来被覆サーメット工具のα型Al23層は、いずれも(0001)面の測定傾斜角の分布が0〜45度の範囲内で不偏的で、最高ピークが存在せず、0〜10度の範囲内の傾斜角区分内に存在する傾斜角度数の割合も30%以下である傾斜角度数分布グラフを示すものであった。
なお、図2は、本発明被覆サーメット工具10のα型Al23層の傾斜角度数分布グラフ、図3は、従来被覆サーメット工具10のα型Al23層の傾斜角度数分布グラフをそれぞれ示すものである。
In the inclination angle number distribution graphs of the various α-type Al 2 O 3 layers described above, as shown in Tables 4 and 5, α-type formed on the heat-treated Al 2 O 3 core thin film of the coated cermet tool of the present invention. In the Al 2 O 3 layer, the highest peak appears in the tilt angle section where the distribution of the measured tilt angle on the (0001) plane is in the range of 0 to 10 degrees, and the tilt angle section is in the range of 0 to 10 degrees. 2 shows an inclination angle number distribution graph in which the ratio of the inclination angle number existing in the graph is 45% or more, whereas the α-type Al 2 O 3 layer of the conventional coated cermet tool has a measured inclination angle of the (0001) plane. An inclination angle in which the distribution of the angle is unbiased in the range of 0 to 45 degrees, the highest peak does not exist, and the ratio of the number of inclination angles existing in the inclination angle section in the range of 0 to 10 degrees is 30% or less. A number distribution graph was shown.
2 is an inclination angle number distribution graph of the α-type Al 2 O 3 layer of the coated cermet tool 10 of the present invention, and FIG. 3 is an inclination angle number distribution graph of the α-type Al 2 O 3 layer of the conventional coated cermet tool 10. Respectively.

また、この結果得られた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(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。
なお、上記本発明被覆サーメット工具1〜13の硬質被覆層における加熱処理Al23核薄膜の層厚測定はきわめて困難であった。
Moreover, when the thickness of the constituent layer of the hard coating layer of the present coated cermet tools 1 to 13 and the conventional coated cermet tools 1 to 13 obtained as a result was measured using a scanning electron microscope (longitudinal section measurement). , Each showed an average layer thickness (average value of 5-point measurement) substantially the same as the target layer thickness.
Note that it was extremely difficult to measure the thickness of the heat-treated Al 2 O 3 core thin film in the hard coating layers of the above-described coated cermet tools 1 to 13 of the present invention.

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:1mm、
送り:0.25mm/rev、
切削時間:5分、
の条件での合金鋼の乾式高速断続切削試験(通常の切削速度は250m/min)、
被削材:JIS・S45Cの長さ方向等間隔4本縦溝入り丸棒、
切削速度:400m/min、
切り込み:1mm、
送り:0.25mm/rev、
切削時間:5分、
の条件での炭素鋼の乾式高速断続切削試験(通常の切削速度は300m/min)、さらに、
被削材:JIS・FC300の長さ方向等間隔4本縦溝入り丸棒、
切削速度:450m/min、
切り込み:1.5mm、
送り:0.25mm/rev、
切削時間:5分、
の条件での鋳鉄の乾式高速断続切削試験(通常の切削速度は300m/min)を行った。
Next, with respect to the present invention coated cermet tools 1 to 7 and the conventional coated cermet tools 1 to 7 in a state where any of the above various coated cermet tools is screwed to the tip of the tool steel tool with a fixing jig. ,
Work material: JIS · SCM440 lengthwise equidistant 4 vertical grooved round bar,
Cutting speed: 350 m / min,
Cutting depth: 1mm,
Feed: 0.25mm / rev,
Cutting time: 5 minutes
Dry high-speed intermittent cutting test of alloy steel under the conditions (normal cutting speed is 250 m / min),
Work material: JIS · S45C lengthwise equal 4 round grooved round bars,
Cutting speed: 400 m / min,
Cutting depth: 1mm,
Feed: 0.25mm / rev,
Cutting time: 5 minutes
Dry high-speed intermittent cutting test of carbon steel under the conditions (normal cutting speed is 300 m / min),
Work material: JIS / FC300 lengthwise equidistant 4 bars with vertical grooves,
Cutting speed: 450 m / min,
Incision: 1.5mm,
Feed: 0.25mm / rev,
Cutting time: 5 minutes
The dry high-speed intermittent cutting test (normal cutting speed is 300 m / min) of cast iron under the conditions of

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:400m/min、
切り込み:0.7mm、
送り:0.15mm/rev、
切削時間:5分、
の条件での合金鋼の乾式高速断続切削試験(通常の切削速度は250m/min)、
被削材:JIS・S45Cの長さ方向等間隔4本縦溝入り丸棒、
切削速度:400m/min、
切り込み:0.7mm、
送り:0.15mm/rev、
切削時間:5分、
の条件での炭素鋼の乾式高速断続切削試験(通常の切削速度は300m/min)、
被削材:JIS・FC300の長さ方向等間隔4本縦溝入り丸棒、
切削速度:450m/min、
切り込み:0.7mm、
送り:0.15mm/rev、
切削時間:5分、
の条件での鋳鉄の乾式高速断続切削試験(通常の切削速度は300m/min)、
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。
Furthermore, about this invention coated cermet tool 8-13 and conventional coated cermet tool 8-13,
Work material: JIS · SCM440 lengthwise equidistant 4 vertical grooved round bar,
Cutting speed: 400 m / min,
Cutting depth: 0.7mm,
Feed: 0.15mm / rev,
Cutting time: 5 minutes
Dry high-speed intermittent cutting test of alloy steel under the conditions (normal cutting speed is 250 m / min),
Work material: JIS · S45C lengthwise equal 4 round grooved round bars,
Cutting speed: 400 m / min,
Cutting depth: 0.7mm,
Feed: 0.15mm / rev,
Cutting time: 5 minutes
Dry high-speed intermittent cutting test of carbon steel under the conditions (normal cutting speed is 300 m / min),
Work material: JIS / FC300 lengthwise equidistant 4 bars with vertical grooves,
Cutting speed: 450 m / min,
Cutting depth: 0.7mm,
Feed: 0.15mm / rev,
Cutting time: 5 minutes
A dry high-speed intermittent cutting test of cast iron under the conditions (normal cutting speed is 300 m / min),
In each cutting test, the flank wear width of the cutting edge was measured. The measurement results are shown in Table 6.

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Figure 2005205586
Figure 2005205586

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、いずれも硬質被覆層の上部層が、(0001)面の傾斜角が0〜10度の範囲内の傾斜角区分で最高ピークを示すと共に、前記0〜10度の範囲内に存在する合計度数割合が45%以上を占める傾斜角度数分布グラフを示すα型Al23層で構成され、機械的熱的衝撃がきわめて高く、かつ高い発熱を伴なう鋼や鋳鉄の高速断続切削でも、前記α型Al23層がすぐれた耐チッピング性を発揮することから、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示すのに対して、硬質被覆層の上部層が、(0001)面の測定傾斜角の分布が0〜45度の範囲内で不偏的で、最高ピークが存在しない傾斜角度数分布グラフを示すα型Al23層で構成された従来被覆サーメット工具1〜13においては、いずれも高速断続切削では前記α型Al23層が激しい機械的熱的衝撃に耐えられず、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。 From the results shown in Tables 4 to 6, in the coated cermet tools 1 to 13 of the present invention, the upper layer of the hard coating layer is an inclination angle section within the range where the inclination angle of the (0001) plane is 0 to 10 degrees. It is composed of an α-type Al 2 O 3 layer showing an inclination angle number distribution graph showing a maximum peak and a total frequency ratio existing in the range of 0 to 10 degrees occupying 45% or more, and mechanical thermal shock is Even in high-speed intermittent cutting of steel and cast iron with extremely high heat generation, the α-type Al 2 O 3 layer exhibits excellent chipping resistance, so the occurrence of chipping at the cutting edge is remarkably suppressed, In contrast to the excellent wear resistance, the upper layer of the hard coating layer has an inclination angle in which the distribution of the measured inclination angle of the (0001) plane is unbiased within the range of 0 to 45 degrees and there is no maximum peak. composed of α-type the Al 2 O 3 layer indicating the number distribution graph In came coated cermet tools 1 to 13, neither withstand the mechanical and thermal shock the α type the Al 2 O 3 layer is severe in high speed interrupted cutting, chipping occurs in the cutting edge, a relatively short time It is clear that the service life is reached.

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、特に機械的熱的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。   As described above, the coated cermet tool of the present invention has extremely high mechanical thermal shock and high heat generation as well as continuous cutting and interrupted cutting under normal conditions such as various steels and cast iron. Because it exhibits excellent chipping resistance even in high-speed intermittent cutting with the most severe cutting conditions, and exhibits excellent cutting performance over a long period of time, it is possible to improve the performance of the cutting equipment and save labor and energy in cutting. Furthermore, it can cope with cost reduction sufficiently satisfactorily.

硬質被覆層を構成する各種α型Al23層における結晶粒の(0001)面の傾斜角の測定範囲を示す概略説明図である。Is a schematic diagram illustrating a measurement range of the inclination angle of the crystal grains (0001) plane in various α type the Al 2 O 3 layer constituting the hard coating layer. 本発明被覆サーメット工具10の硬質被覆層を構成するα型Al23層の(0001)面の傾斜角度数分布グラフである。It is an inclination angle number distribution graph of the (0001) plane of the α-type Al 2 O 3 layer constituting the hard coating layer of the coated cermet tool 10 of the present invention. 従来被覆サーメット工具10の硬質被覆層を構成するα型Al23層の(0001)面の傾斜角度数分布グラフである。4 is an inclination angle number distribution graph of the (0001) plane of the α-type Al 2 O 3 layer constituting the hard coating layer of the conventional coated cermet tool 10.

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)下部層として、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、酸化物、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の全体平均層厚を有するTi化合物層、
(b)上部層として、化学蒸着形成された状態でα型の結晶構造を有し、電界放出型走査電子顕微鏡を用い、表面研磨面の測定範囲内に存在する六方晶結晶格子を有する結晶粒個々に電子線を照射して、前記表面研磨面の法線に対して、前記結晶粒の結晶面である(0001)面の法線がなす傾斜角を測定し、前記測定傾斜角のうち、0〜45度の範囲内にある測定傾斜角を0.25度のピッチ毎に区分すると共に、各区分内に存在する度数を集計してなる傾斜角度数分布グラフにおいて、0〜10度の範囲内の傾斜角区分に最高ピークが存在すると共に、前記0〜10度の範囲内に存在する度数の合計が、傾斜角度数分布グラフにおける度数全体の45%以上の割合を占める傾斜角度数分布グラフを示し、かつ1〜30μmの平均層厚を有する酸化アルミニウム層、
以上(a)および(b)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チッピング性を発揮する表面被覆サーメット製切削工具。
On the surface of the tool base composed of tungsten carbide based cemented carbide or titanium carbonitride based cermet,
(A) As the lower layer, one or more of Ti carbide layer, nitride layer, carbonitride layer, oxide, carbonate layer, and carbonitride layer formed by chemical vapor deposition And a Ti compound layer having an overall average layer thickness of 3 to 20 μm,
(B) Crystal grains having an α-type crystal structure in the state of chemical vapor deposition as an upper layer and having a hexagonal crystal lattice existing within the measurement range of the surface polished surface using a field emission scanning electron microscope Individually irradiate an electron beam, measure the tilt angle formed by the normal of the (0001) plane that is the crystal plane of the crystal grain with respect to the normal of the polished surface, and among the measured tilt angles, In the inclination angle number distribution graph formed by dividing the measured inclination angles within the range of 0 to 45 degrees for each pitch of 0.25 degrees and counting the frequencies existing in each section, the range of 0 to 10 degrees Inclination angle distribution graph in which the highest peak exists in the inclination angle section and the total of the frequencies existing in the range of 0 to 10 degrees occupies 45% or more of the entire frequency in the inclination angle distribution graph And has an average layer thickness of 1 to 30 μm An aluminum oxide layer,
A surface-coated cermet cutting tool that exhibits the excellent chipping resistance of the hard coating layer formed by forming the hard coating layer constituted by (a) and (b) above.
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