JP2007111787A - Throwaway cutting tip of surface-coated cermet, with hard coating layer achieving excellent anti-chipping performance in high-speed cutting work - Google Patents
Throwaway cutting tip of surface-coated cermet, with hard coating layer achieving excellent anti-chipping performance in high-speed cutting work Download PDFInfo
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Abstract
Description
この発明は、特に各種の鋼や鋳鉄などの高速切削加工に用いた場合に、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スローアウエイチップ（以下、被覆切削チップという）に関するものである。 The present invention relates to a surface-coated cermet cutting throwaway tip (hereinafter referred to as a coated cutting tip) that exhibits excellent chipping resistance with a hard coating layer, particularly when used for high-speed cutting of various types of steel and cast iron. Is.
従来、一般に、図３に概略斜視図で示される通り、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、かつ中心部に工具取りつけ孔を有する基体（以下、これらを総称してチップ基体という）の切刃稜線部を含むすくい面および逃げ面の全面に、
下部層として、炭化チタン（以下、ＴｉＣで示す）層、窒化チタン（以下、同じくＴｉＮで示す）層、炭窒化チタン（以下、ＴｉＣＮで示す）層、炭酸化チタン（以下、ＴｉＣＯで示す）層、および炭窒酸化チタン（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、
上部層として、１〜１５μｍの平均層厚を有し、かつ化学蒸着した状態でα型の結晶構造を有する酸化アルミニウム層（以下、α型Ａｌ2Ｏ3層で示す）、
で構成された硬質被覆層を蒸着形成してなる被覆切削チップが知られており、この被覆切削チップが、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, as shown in a schematic perspective view in FIG. 3, it is composed of a tungsten carbide (hereinafter referred to as WC) -based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN) -based cermet, and a tool at the center. On the entire surface of the rake face and the flank face including the cutting edge ridge line portion of the base body (hereinafter collectively referred to as a chip base body) having mounting holes,
As a lower layer, a titanium carbide (hereinafter referred to as TiC) layer, a titanium nitride (hereinafter also referred to as TiN) layer, a titanium carbonitride (hereinafter referred to as TiCN) layer, a titanium carbonate (hereinafter referred to as TiCO) layer And a Ti compound layer comprising one or more of titanium carbonitride oxide (hereinafter referred to as TiCNO) layers and having an overall average layer thickness of 3 to 20 μm,
As an upper layer, an aluminum oxide layer (hereinafter referred to as an α-type Al 2 O 3 layer) having an average layer thickness of 1 to 15 μm and having an α-type crystal structure in a state of chemical vapor deposition,
It is well known that a coated cutting tip formed by vapor-depositing a hard coating layer composed of is used for continuous cutting and intermittent cutting of, for example, various types of steel and cast iron. Yes.
また、上記の被覆切削チップにおいて、これの硬質被覆層の構成層は、一般に粒状結晶組織を有し、さらに、下部層である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。
さらに、上記の被覆切削チップの硬質被覆層を構成するα型Ａｌ2Ｏ3層（上部層）の表面を、切削性能を向上させる目的でウエットブラスト処理して、平滑化することも知られている。
Furthermore, it is also known that the surface of the α-type Al 2 O 3 layer (upper layer) constituting the hard coating layer of the above-described coated cutting tip is smoothed by wet blasting for the purpose of improving cutting performance. Yes.
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、切削加工は高速化の傾向にあるが、上記の従来被覆切削チップにおいては、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、特に切削速度が３５０ｍ／ｍｉｎ．を越える高速で切削加工を行なうのに用いた場合には、硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層にチッピング（微少欠け）が発生し易く、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, and along with this, cutting tends to be faster. The cutting tip has no problem when it is used for continuous cutting or intermittent cutting under normal conditions such as steel or cast iron, but the cutting speed is 350 m / min. When it is used for cutting at a high speed exceeding 1, the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer is likely to chip (small chipping), and as a result, in a relatively short time. At present, the service life is reached.
そこで、本発明者等は、上述のような観点から、上記のα型Ａｌ2Ｏ3層が硬質被覆層の上部層を構成する被覆切削チップに着目し、特に前記α型Ａｌ2Ｏ3層の耐チッピング性向上を図るべく研究を行った結果、
（ａ）上記の従来被覆切削チップにおける硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の表面に、ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％の酸化アルミニウム（以下、Ａｌ2Ｏ3で示す）微粒を配合した研磨液を噴射して、研磨すると、前記α型Ａｌ2Ｏ3層は、準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定（以下の表面粗さは全てかかる準拠規格に基いた測定値を示す）で、Ｒａ：０．３〜０．６μｍの表面粗さを示すようになるが、この結果の前記α型Ａｌ2Ｏ3層の表面を、ウエットブラストにてＲａ：０．３〜０．６μｍの表面粗さに平滑化した被覆切削チップを用いても、切削速度が３５０ｍ／ｍｉｎ．を越えた高速切削加工では切刃部におけるチッピング発生を満足に抑制することはできないこと。
The present inventors have, from the viewpoint as described above, focuses on coated cutting tip α type the Al 2 O 3 layer described above constituting the upper layer of the hard coating layer, in particular the α-type the Al 2 O 3 layer As a result of research to improve chipping resistance of
(A) On the surface of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer in the above-mentioned conventional coated cutting chip, the ratio of the wet blasting material to the total amount of water as a spraying abrasive is 15 When the polishing liquid containing -60 mass% aluminum oxide (hereinafter referred to as Al 2 O 3 ) fine particles is sprayed and polished, the α-type Al 2 O 3 layer is based on the compliant standard JIS B0601-1994. (The following surface roughness indicates all measured values based on the standard), and Ra: 0.3-0.6 μm surface roughness is obtained. Even when a coated cutting tip having a surface roughness of Ra: 0.3 to 0.6 μm smoothed by wet blasting on the surface of the 2 O 3 layer was used, the cutting speed was 350 m / min. High-speed cutting that exceeds the limit cannot effectively suppress chipping at the cutting edge.
（ｂ）一方、図２に概略斜視図で示される通り、上記の従来被覆切削チップにおける硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の切刃稜線部を含むすくい面および逃げ面の全面に、通常の化学蒸着装置を用い、通常の条件、例えば表３に示される条件で、かつ、０．５〜５μｍの平均層厚で、窒化チタン（以下、ＴｉＮで示す）層を蒸着形成した状態で、
上記（ａ）におけると同じくウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％のＡｌ2Ｏ3微粒を配合した研磨液を噴射すると、上記ＴｉＮ層（以下、ＴｉＮ研磨材層という）は、前記Ａｌ2Ｏ3微粒によって粉砕微粒化し、ＴｉＮ微粒となって前記Ａｌ2Ｏ3微粒の共存下で研磨材として作用し、硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の表面を研磨することになり、この結果研磨後の前記α型Ａｌ2Ｏ3層の表面は、Ｒａ：０．２μｍ以下の表面粗さにまで平滑化されるようになり、この上部層であるα型Ａｌ2Ｏ3層の表面がＲａ：０．２μｍ以下の表面粗さに平滑化した被覆切削チップを用いて、高速切削加工を行った場合、３５０ｍ／ｍｉｎ．を越える切削速度でも切刃部におけるチッピング発生が防止され、前記硬質被覆層は長期に亘ってすぐれた耐摩耗性を発揮するようになること。
(B) On the other hand, as shown in the schematic perspective view of FIG. 2, the rake face and clearance including the cutting edge ridge line portion of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer in the conventional coated cutting tip described above. A titanium nitride (hereinafter referred to as TiN) layer is formed on the entire surface using a normal chemical vapor deposition apparatus under normal conditions, for example, the conditions shown in Table 3 and an average layer thickness of 0.5 to 5 μm. With vapor deposition formed,
When a polishing liquid containing 15 to 60% by mass of Al 2 O 3 fine particles as a spraying abrasive in a ratio to the total amount of water is sprayed by wet blasting as in (a) above, the TiN layer ( Hereinafter, the TiN abrasive layer is pulverized and pulverized by the Al 2 O 3 fine particles, becomes TiN fine particles and acts as an abrasive in the presence of the Al 2 O 3 fine particles, and constitutes the upper layer of the hard coating layer will be polishing the surface of the α-type the Al 2 O 3 layer to the α-type the Al 2 O 3 layer surface after the results polishing, Ra: is smoothed to a surface roughness of not more than 0.2μm When the high-speed cutting was performed using the coated cutting tip in which the surface of the α-type Al 2 O 3 layer as the upper layer was smoothed to a surface roughness of Ra: 0.2 μm or less, 350 m / min. Chipping at the cutting edge is prevented even at a cutting speed exceeding 1, and the hard coating layer exhibits excellent wear resistance over a long period of time.
（ｃ）上記の通り、切削速度が３５０ｍ／ｍｉｎ．を越えた高速切削加工では、被覆切削チップの切刃部に懸かる負荷はきわめて高いものになるため、特にフライス切削の場合、工具本体への被覆切削チップの取り付けに際しては、きわめて高い締め付け力で取り付けが行なわれることになり、この結果被覆切削チップの工具取り付け孔周辺部の硬質被覆層に対する圧縮応力はきわめて高いものとなるので、特に上部層を構成するα型Ａｌ2Ｏ3層は、ビッカース硬さ（Ｈｖ）で約３０００の高硬度を有することと相俟って、これに割れが発生し易くなり、これが原因で硬質被覆層に剥離やチッピングが発生するようになるが、図１に概略斜視図で示される通り、前記ウエットブラストに際して、工具取り付け孔周辺部を研磨せず、この部分のＴｉＮ研磨材層を残した状態にしておくと、前記ＴｉＮ研磨材層は前記α型Ａｌ2Ｏ3層に比して、相対的に高い高温強度をもち、かつ、硬さの低いもの（Ｈｖ：約１９５０）であるため、工具本体への被覆切削チップの取り付けに際して、高い締め付け力の緩衝層として作用し、この結果前記α型Ａｌ2Ｏ3層に対する圧縮応力が著しく小さなものとなるなることから、剥離やチッピング発生の原因となる割れ発生が防止されるようになること。
以上（ａ）〜（ｃ）に示される研究結果を得たのである。
(C) As described above, the cutting speed is 350 m / min. In high-speed cutting processing exceeding 1, the load applied to the cutting edge of the coated cutting tip is extremely high. Therefore, especially in the case of milling, the coated cutting tip is attached to the tool body with a very high clamping force. As a result, the compressive stress on the hard coating layer around the tool mounting hole of the coated cutting tip becomes extremely high. In particular, the α-type Al 2 O 3 layer constituting the upper layer has a Vickers hardness. In combination with having a high hardness of about 3000 at the height (Hv), cracks are likely to occur in this, and this causes peeling and chipping in the hard coating layer. As shown in the perspective view, during the wet blasting, the peripheral portion of the tool attachment hole is not polished, and the TiN abrasive layer in this portion is left. Since the iN abrasive layer has a relatively high high-temperature strength and low hardness (Hv: about 1950) compared to the α-type Al 2 O 3 layer, the coated cutting of the tool body is performed. When mounting the chip, it acts as a buffer layer with a high clamping force. As a result, the compressive stress on the α-type Al 2 O 3 layer becomes extremely small, preventing cracks that cause peeling and chipping. To be done.
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、かつ中心部に工具取り付け孔を有するチップ基体の切刃稜線部を含むすくい面および逃げ面の全面に、
下部層として、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の全体平均層厚を有するＴｉ化合物層、
上部層として、１〜１５μｍの平均層厚を有するα型Ａｌ2Ｏ3層、
で構成された硬質被覆層を蒸着形成してなる被覆切削チップにおいて、
上記硬質被覆層の上部層であるα型Ａｌ2Ｏ3層の全面に、０．５〜５μｍの平均層厚で、ＴｉＮ研磨材層を蒸着形成した状態で、
ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％のＡｌ2Ｏ3微粒を配合した研磨液を噴射し、
上記のＴｉＮ研磨材層のウエットブラストによる粉砕化ＴｉＮ微粒と、噴射研磨材としてのＡｌ2Ｏ3微粒の共存下で、上記工具取り付け孔周辺部の研磨材層を残して、上記硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の表面を研磨して、切刃稜線部を含むすくい面および逃げ面の表面粗さを準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定で、Ｒａ：０．２μｍ以下としてなる、硬質被覆層が高速切削加工ですぐれた耐チッピング性を発揮する被覆切削チップに特徴を有するものである。
The present invention has been made on the basis of the above research results, and includes a cutting edge ridge portion of a chip base made of a WC-based cemented carbide or TiCN-based cermet and having a tool mounting hole in the center. On the entire surface and flank,
As a lower layer, a Ti compound layer composed of one or more of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer, and a TiCNO layer and having an overall average layer thickness of 3 to 20 μm,
As an upper layer, an α-type Al 2 O 3 layer having an average layer thickness of 1 to 15 μm,
In a coated cutting chip formed by vapor-depositing a hard coating layer composed of
On the entire surface of the α-type Al 2 O 3 layer, which is the upper layer of the hard coating layer, with an average layer thickness of 0.5 to 5 μm, a TiN abrasive layer is formed by vapor deposition.
In wet blasting, as a spraying abrasive, a polishing liquid containing 15 to 60% by mass of Al 2 O 3 fine particles in a proportion of the total amount with water is sprayed,
In the presence of the TiN fine particles pulverized by wet blasting of the TiN abrasive layer and Al 2 O 3 fine particles as the spray abrasive, the abrasive layer around the tool mounting hole is left, and the hard coating layer The surface of the α-type Al 2 O 3 layer constituting the upper layer is polished, and the surface roughness of the rake face and flank face including the cutting edge ridge line portion is measured based on the compliant standard JIS B0601-1994, Ra: The hard coating layer having a thickness of 0.2 μm or less is characterized by a coated cutting tip that exhibits excellent chipping resistance in high-speed cutting.
以下に、この発明の被覆切削チップの硬質被覆層およびＴｉＮ研磨材層、さらにウエットブラストで用いられる研磨液のＡｌ2Ｏ3微粒に関して、上記の通りに数値限定した理由を説明する。
（ａ）硬質被覆層
（ａ−１）下部層のＴｉ化合物層
Ｔｉ化合物層は、α型Ａｌ2Ｏ3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、チップ基体とα型Ａｌ2Ｏ3層のいずれにも強固に密着し、よって硬質被覆層のチップ基体に対する密着性を向上させる作用を有するが、その全体平均層厚が３μｍ未満では、前記作用を十分に発揮させることができず、一方その全体平均層厚が２０μｍを越えると、特に高熱発生を伴なう高速切削では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、その全体平均層厚を３〜２０μｍと定めた。
The reason why the numerical values of the hard coating layer and the TiN abrasive layer of the coated cutting chip of the present invention and the Al 2 O 3 fine particles of the polishing liquid used in wet blasting are limited as described above will be described below.
(A) Hard coating layer (a-1) Ti compound layer of lower layer The Ti compound layer exists as a lower layer of the α-type Al 2 O 3 layer, and the high temperature strength of the hard coating layer is high due to its excellent high-temperature strength. In addition to contributing to strength improvement, it has a function of firmly adhering to both the chip base and the α-type Al 2 O 3 layer, thereby improving the adhesion of the hard coating layer to the chip base, but the overall average layer thickness is If the thickness is less than 3 μm, the above-mentioned effect cannot be sufficiently exerted. On the other hand, if the total average layer thickness exceeds 20 μm, it becomes easy to cause thermoplastic deformation particularly in high-speed cutting accompanied by generation of high heat. Since it becomes a cause, the whole average layer thickness was set to 3-20 micrometers.
（ａ−２）上部層のα型Ａｌ2Ｏ3層
上記のα型Ａｌ2Ｏ3層は、すぐれた高温硬さと耐熱性を有し、被覆切削チップの切削性能向上に寄与するが、その平均層厚が１μｍ未満では、所望のすぐれた切削性能を長期に亘って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、チッピングが発生し易くなることから、その平均層厚を１〜１５μｍと定めた。
(A-2) α-type Al 2 O 3 layer of the upper layer The α-type Al 2 O 3 layer has excellent high-temperature hardness and heat resistance, and contributes to improving the cutting performance of the coated cutting tip. If the average layer thickness is less than 1 μm, the desired excellent cutting performance cannot be exhibited over a long period of time. On the other hand, if the average layer thickness exceeds 15 μm, chipping tends to occur. The average layer thickness was set to 1 to 15 μm.
（ｂ）ＴｉＮ研磨材層
上記の通り、ＴｉＮ研磨材層は、ウエットブラスト時に、研磨液に噴射研磨材として配合したＡｌ2Ｏ3微粒によって粉砕微粒化し、ＴｉＮ微粒となって前記Ａｌ2Ｏ3微粒との共存下で研磨材として作用し、硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の表面を研磨するが、この場合、その平均層厚が０．５μｍ未満では、ウエットブラスト時における粉砕化ＴｉＮ微粒の割合が少な過ぎて、研磨機能を十分に発揮することができず、一方、その平均層厚が５μｍを越えると、研磨液に噴射研磨材として配合したＡｌ2Ｏ3微粒とのバランスがくずれて、相対的に多くなり過ぎ、この場合も研磨機能が急激に低下するようになり、いずれの場合もα型Ａｌ2Ｏ3層の表面をＲａ：０．２μｍ以下の表面粗さに研磨することができなくなるという理由で、その平均層厚を０．５〜５μｍと定めた。
(B) TiN abrasive layer As described above, TiN abrasive layer during wet blasting, the Al 2 O 3 fine formulated as injection abrasive in the polishing liquid milled micronized, the Al 2 O 3 becomes TiN fine Acts as an abrasive in the presence of fine particles, and polishes the surface of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer. In this case, if the average layer thickness is less than 0.5 μm, the wet When the ratio of the pulverized TiN fine particles at the time of blasting is too small, the polishing function cannot be sufficiently exerted. On the other hand, when the average layer thickness exceeds 5 μm, Al 2 O blended in the polishing liquid as a jetting abrasive is used. 3 The balance with the fine particles is lost and the amount is relatively too large. In this case as well, the polishing function suddenly decreases. In either case, the surface of the α-type Al 2 O 3 layer is Ra: 0.2 μm or less. Polish to a surface roughness of Because it becomes impossible to determine the average layer thickness and 0.5 to 5 [mu] m.
（ｃ）研磨液のＡｌ2Ｏ3微粒の割合
研磨液のＡｌ2Ｏ3微粒には、ウエットブラスト時にＴｉＮ研磨材層の粉砕化ＴｉＮ微粒と共存した状態で、α型Ａｌ2Ｏ3層の表面を研磨する作用があるが、その割合が水との合量に占める割合で１５質量％未満でも、また６０質量％を越えても研磨機能が急激に低下するようになることから、その割合を１５〜６０質量％と定めた。
The Al 2 O 3 fine of Al 2 O 3 fine fraction polishing solution of (c) polishing liquid, in a state where at the time of wet blast coexists with pulverized TiN fine of TiN abrasive layer, the α type the Al 2 O 3 layer There is an action to polish the surface, but even if the ratio is less than 15% by mass or more than 60% by mass with respect to the total amount with water, the polishing function will rapidly decrease, so that ratio Was determined to be 15 to 60% by mass.
この発明の被覆切削チップは、硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の切刃稜線部を含むすくい面および逃げ面が、Ｒａ：０．２μｍ以下の表面粗さに研磨され、さらに工具取り付け孔周辺部に存在するＴｉＮ研磨材層が、工具本体への被覆切削チップの取り付けに際して、高速切削加工では不可欠の高い締め付け力の緩衝層として作用することから、前記α型Ａｌ2Ｏ3層に対する圧縮応力が著しく小さなものとなり、この結果剥離やチッピング発生の原因となる割れ発生が防止されるようになることと相俟って、各種の鋼や鋳鉄などの切削加工を、切削速度が３５０ｍ／ｍｉｎ．を越える高速で行うのに用いた場合にも、すぐれた耐チッピング性を発揮し、使用寿命の一層の延命化を可能とするものである。 In the coated cutting tip of the present invention, the rake face and flank face including the cutting edge ridge line portion of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer are polished to a surface roughness of Ra: 0.2 μm or less. In addition, since the TiN abrasive layer existing around the tool mounting hole acts as a buffer layer having a high clamping force, which is indispensable in high-speed cutting when attaching the coated cutting tip to the tool body, the α-type Al Combined with the fact that the compressive stress on the 2 O 3 layer is extremely small and, as a result, the occurrence of cracks that cause peeling and chipping is prevented, cutting of various steels and cast irons, Cutting speed is 350 m / min. Even when used for high-speed operation exceeding the above, excellent chipping resistance is exhibited, and the service life can be further extended.
つぎに、この発明の被覆切削チップを実施例により具体的に説明する。 Next, the coated cutting tip 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、Ｃｒ3Ｃ2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基超硬合金製のチップ基体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 processing, chip bases A to F made of a WC-based cemented carbide having a throwaway tip shape defined 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、Ｍｏ2Ｃ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基サーメット製のチップ基体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. TiCN base cermet chip bases a to f having a standard / CNMG12041 chip shape were formed.
ついで、これらのチップ基体Ａ〜Ｆおよびチップ基体ａ〜ｆのそれぞれを、通常の化学蒸着装置に装入し、
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５に示される目標層厚のＴｉ化合物層およびα型Ａｌ2Ｏ3層を硬質被覆層の下部層および上部層として蒸着形成し（図３参照）、
ついで、同じく表３に示されるＴｉＮ層形成条件でＴｉＮ研磨材層を、同じく表５に示される目標層厚で蒸着形成し（図２参照）、
引き続いて、上記のＴｉＮ研磨材層形成の被覆切削チップに、表４に示されるブラスト条件で、かつ表５に示される組み合わせでウエットブラストを施して、工具取り付け孔周辺部にＴｉＮ研磨材層を存在させた状態で、前記α型Ａｌ2Ｏ3層（上部層）の切刃稜線部を含むすくい面および逃げ面を、同じく表５に示される表面粗さに研磨することにより本発明被覆切削チップ１〜１３をそれぞれ製造した（図１参照）。
Next, each of these chip bases A to F and chip bases a to f is charged into a normal chemical vapor deposition apparatus,
First, Table 3 (l-TiCN in Table 3 indicates the conditions for forming a TiCN layer having a vertically grown crystal structure described in JP-A No. 6-8010, and other than that, a normal granular crystal structure is shown. The Ti compound layer and the α-type Al 2 O 3 layer having the target layer thicknesses shown in Table 5 are vapor-deposited as the lower layer and the upper layer of the hard coating layer under the conditions shown in FIG. (See Fig. 3)
Next, a TiN abrasive material layer was formed by vapor deposition with the target layer thickness also shown in Table 5 under the TiN layer formation conditions shown in Table 3 (see FIG. 2).
Subsequently, the coated cutting tip for forming the TiN abrasive layer was wet-blasted under the blast conditions shown in Table 4 and in the combinations shown in Table 5, and the TiN abrasive layer was formed around the tool mounting hole. In the present state, the rake face and flank face including the cutting edge ridge line portion of the α-type Al 2 O 3 layer (upper layer) are polished to the surface roughness shown in Table 5 in the present invention. Chips 1 to 13 were manufactured (see FIG. 1).
また、比較の目的で、表６に示される通り、上記ＴｉＮ研磨材層の形成を行なわないで、ウエットブラストを硬質被覆層のα型Ａｌ2Ｏ3層の表面に直接施す以外は同一の条件で従来被覆切削チップ１〜１３をそれぞれ製造した。
この結果得られた従来被覆切削チップ１〜１３の硬質被覆層を構成するα型Ａｌ2Ｏ3層のウエットブラスト後の表面粗さを表６に示した。
For comparison purposes, as shown in Table 6, the same conditions except that the TiN abrasive layer is not formed and wet blasting is directly applied to the surface of the α-type Al 2 O 3 layer of the hard coating layer. Conventionally, the coated cutting chips 1 to 13 were manufactured.
Table 6 shows the surface roughness after wet blasting of the α-type Al 2 O 3 layer constituting the hard coating layer of the conventional coated cutting chips 1 to 13 obtained as a result.
また、上記本発明被覆切削チップ１〜１３の硬質被覆層および研磨材層の組成、さらに従来被覆切削チップ１〜１３の硬質被覆層の組成を、それぞれ厚さ方向中央部をオージェ分光分析装置で測定したところ、いずれも目標組成と実質的に同じ組成を示し、さらに同構成層の厚さを、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。 In addition, the composition of the hard coating layer and the abrasive layer of the above-described coated cutting chips 1 to 13 of the present invention, and the composition of the hard coating layer of the conventional coated cutting chips 1 to 13 are each measured with an Auger spectroscopic analyzer at the center in the thickness direction. When measured, all showed substantially the same composition as the target composition, and when the thickness of the same constituent layer was measured using a scanning electron microscope (longitudinal section measurement), both were substantially the same as the target layer thickness. The same average layer thickness (average value of 5-point measurement) was shown.
つぎに、上記の本発明被覆切削チップ１〜１３および従来被覆切削チップ１〜１３の各種の被覆切削チップについて、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、
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：４００ｍ／ｍｉｎ、
切り込み：２ｍｍ、
送り：０．３ｍｍ／ｒｅｖ、
切削時間：１０分、
の条件（切削条件Ａという）での鋳鉄の乾式断続高速切削試験（通常の切削速度は２００ｍ／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：４３０ｍ／ｍｉｎ、
切り込み：２ｍｍ、
送り：０．３５ｍｍ／ｒｅｖ、
切削時間：９分、
の条件（切削条件Ｂという）での炭素鋼の乾式断続高速切削試験（通常の切削速度は２００ｍ／ｍｉｎ）、さらに、
被削材：ＪＩＳ・ＳＣＭ４４０の丸棒、
切削速度：４５０ｍ／ｍｉｎ、
切り込み：２ｍｍ、
送り：０．４５ｍｍ／ｒｅｖ、
切削時間：７分、
の条件（切削条件Ｃという）での鋳鉄の乾式連続高速切削試験（通常の切削速度
は２００ｍ／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７に示した。
Next, for the various coated cutting chips of the present invention coated cutting chips 1 to 13 and the conventional coated cutting chips 1 to 13 described above, all of them are screwed to the tip of the tool steel tool with a fixing jig,
Work material: JIS / FC300 lengthwise equidistant 4 bars with vertical grooves,
Cutting speed: 400 m / min,
Cutting depth: 2mm,
Feed: 0.3mm / rev,
Cutting time: 10 minutes,
A dry interrupted high-speed cutting test of cast iron under the above conditions (referred to as cutting condition A) (normal cutting speed is 200 m / min),
Work material: JIS · S45C lengthwise equal 4 round grooved round bars,
Cutting speed: 430 m / min,
Cutting depth: 2mm,
Feed: 0.35mm / rev,
Cutting time: 9 minutes
Dry intermittent high speed cutting test (normal cutting speed is 200 m / min) of carbon steel under the above conditions (referred to as cutting conditions B),
Work material: JIS / SCM440 round bar,
Cutting speed: 450 m / min,
Cutting depth: 2mm,
Feed: 0.45mm / rev,
Cutting time: 7 minutes
The dry continuous high-speed cutting test (normal cutting speed is 200 m / min) of cast iron under the above conditions (referred to as cutting condition C), and the flank wear width of the cutting edge was measured in any cutting test. The measurement results are shown in Table 7.
表５〜７に示される結果から、本発明被覆切削チップ１〜１３は、いずれも硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の切刃稜線部を含むすくい面および逃げ面が、Ｒａ：０．２μｍ以下の表面粗さに研磨され、さらに工具取り付け孔周辺部に存在するＴｉＮ研磨材層が、工具本体への被覆切削チップの取り付けに際して、３５０ｍ／ｍｉｎを越える高速切削加工では不可欠の高い締め付け力の緩衝層として作用することから、剥離やチッピング発生の原因となる割れ発生が防止され、鋼および鋳鉄の高速切削加工で、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のに対して、硬質被覆層の上部層を構成するα型Ａｌ2Ｏ3層の表面粗さが、Ｒａ：０．３〜０．６μｍを示す従来被覆切削チップ１〜１３においては、いずれも３５０ｍ／ｍｉｎを越える高速切削加工では、工具取り付けに高い締め付け力を必要とすることと相俟って、前記α型Ａｌ2Ｏ3層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 5 to 7, the coated cutting tips 1 to 13 of the present invention each have a rake face and a flank face including the cutting edge ridge line portion of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer. Ra: Polished to a surface roughness of 0.2 μm or less, and the TiN abrasive layer existing around the tool mounting hole has a high-speed cutting process exceeding 350 m / min when the coated cutting tip is attached to the tool body. Since it acts as a buffer layer with an indispensable high clamping force, it prevents cracks that cause peeling and chipping, and exhibits excellent chipping resistance in high-speed cutting of steel and cast iron, over a long period of time. A conventional coated cutting tip 1 in which the surface roughness of the α-type Al 2 O 3 layer constituting the upper layer of the hard coating layer is Ra: 0.3 to 0.6 μm while exhibiting excellent cutting performance. ~ 13 Te, in both high-speed cutting of over 350 meters / min, I coupled with the fact that require high clamping force to the tool mounting, chipping occurs in the α-type the Al 2 O 3 layer, a relatively short period of time It is clear that the service life is reached.
上述のように、この発明の被覆切削チップは、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、特に切削加工を３５０ｍ／ｍｉｎを越えた高速で行う場合に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 cutting tip of the present invention can be used not only for continuous cutting and intermittent cutting under normal conditions such as various steels and cast iron, but also when cutting is performed at a high speed exceeding 350 m / min. Because it shows excellent chipping resistance and exhibits excellent cutting performance over a long period of time, it can sufficiently satisfy the high performance of cutting equipment, labor saving and energy saving of cutting work, and further cost reduction. Is.
Claims (1)
下部層として、炭化チタン層、窒化チタン層、炭窒化チタン層、炭酸化チタン層、および炭窒酸化チタン層のうちの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、
上部層として、１〜１５μｍの平均層厚を有し、かつ化学蒸着した状態でα型の結晶構造を有する酸化アルミニウム層、
で構成された硬質被覆層を蒸着形成してなる、表面被覆サーメット製切削スローアウエイチップにおいて、
上記硬質被覆層の上部層である酸化アルミニウム層の全面に、０．５〜５μｍの平均層厚を有する窒化チタン層で構成された研磨材層を蒸着形成した状態で、
ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％の酸化アルミニウム微粒を配合した研磨液を噴射し、
上記の研磨材層のウエットブラストによる粉砕化窒化チタン微粒と、噴射研磨材としての酸化アルミニウム微粒の共存下で、上記工具取り付け孔周辺部の研磨材層を残して、上記硬質被覆層の上部層を構成する酸化アルミニウム層の表面を研磨して、切刃稜線部を含むすくい面および逃げ面の表面粗さを準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定で、Ｒａ：０．２μｍ以下としたことを特徴とする、硬質被覆層が高速切削加工で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スローアウエイチップ。 It is composed of a tungsten carbide base cemented carbide or a titanium carbonitride base cermet, and the entire rake face and flank face including the cutting edge ridge line part of the chip base having a tool attachment hole in the center part,
The lower layer is composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carbonate layer, and a titanium carbonitride oxide layer, and has an overall average layer thickness of 3 to 20 μm. Having a Ti compound layer,
As an upper layer, an aluminum oxide layer having an average layer thickness of 1 to 15 μm and having an α-type crystal structure in a state of chemical vapor deposition,
In the cutting throwaway tip made of surface-covered cermet formed by vapor-depositing a hard coating layer composed of
In a state where an abrasive layer composed of a titanium nitride layer having an average layer thickness of 0.5 to 5 μm is vapor-deposited on the entire surface of the aluminum oxide layer which is the upper layer of the hard coating layer,
In wet blasting, as a spraying abrasive, a polishing liquid containing 15 to 60% by mass of aluminum oxide fine particles in a proportion of the total amount with water is sprayed,
The upper layer of the hard coating layer in the presence of the abrasive layer around the tool mounting hole in the presence of the ground titanium nitride fine particles by wet blasting of the abrasive layer and the aluminum oxide fine particles as the spray abrasive The surface roughness of the rake face and the flank face including the cutting edge ridge line portion is polished, and the surface roughness Ra is set to 0.2 μm or less by measurement based on the compliant standard JIS / B0601-1994. A surface-coated cermet cutting throwaway tip with a hard coating layer that exhibits excellent chipping resistance in high-speed cutting.
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| JP2005212045A (en) * | 2004-01-29 | 2005-08-11 | Kyocera Corp | Holder for cutting tool and cutting tool using this holder |
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- 2005-10-18 JP JP2005303110A patent/JP4888688B2/en active Active
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| JPS54136489A (en) * | 1978-04-14 | 1979-10-23 | Ngk Spark Plug Co Ltd | Keeper |
| JPH0557507A (en) * | 1991-08-29 | 1993-03-09 | Kyocera Corp | Coating tool and manufacture thereof |
| JPH0852603A (en) * | 1994-07-20 | 1996-02-27 | Sandvik Ab | Cutting tool insert and manufacture thereof |
| JP2003170311A (en) * | 2001-11-30 | 2003-06-17 | Sumitomo Electric Ind Ltd | Rotary cutting tool and its accessory |
| JP2004308008A (en) * | 2003-04-01 | 2004-11-04 | Sandvik Ab | Cutting tool and method for manufacturing the same |
| JP2005212045A (en) * | 2004-01-29 | 2005-08-11 | Kyocera Corp | Holder for cutting tool and cutting tool using this holder |
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| JP4888688B2 (en) | 2012-02-29 |
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