JP2012135828A - Carbon film-coated insert tip, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carbon film-coated insert tip coated with a carbon film such as a diamond coating having a sharper edge compared to conventional ones, and to provide a manufacturing method capable of highly accurately working and preparing the insert tip.SOLUTION: In the carbon film-coated insert tip 1, the carbon film 3 is formed on a surface of a cutting edge 2a of a tool base body 2. The surface of the carbon film 3 on a cutting face 4a side and the surface of the carbon film 3 on a flank 4b side which are adjacent to each other are recessed surfaces 3a in the vicinity of a blade edge 2b of the cutting edge 2a, and the carbon film 3 formed on the cutting edge 2a has a cross sectional shape having a more acute angle than an angle between the cutting face 4a and the flank 4b.

Description

  The present invention relates to a carbon film-coated insert chip capable of sharply machining a work material and a method for manufacturing the same.

  In a diamond-coated cutting tool whose surface of the cutting edge is coated with a diamond film, conventionally, for example, a substantially arc portion is ground on the cutting edge of the cutting edge, and the chamfer is partially chamfered so that the angle of the approximately arc portion is 40 ° or less. Has been proposed (see Patent Document 1). Further, there has also been proposed a method in which the substantially arc portion is ground and the clearance angle is smaller than the original angle (see Patent Document 2).

  In addition, the laser focus is scanned over the surface of the diamond coating, and the diamond coating is shifted to impart relative motion to the two to remove the convex portions formed on the surface of the diamond coating. A method has been proposed (see Patent Document 3). Furthermore, a manufacturing method of a processing tool has been proposed in which a laser beam having a wavelength of 266 nm is irradiated and processed perpendicularly to the diamond coating (see Patent Document 4).

Japanese Patent No. 3477182 Japanese Patent No. 3477183 Japanese Patent No. 3096943 JP 2009-6436 A

The following problems remain in the conventional technology.
That is, in the formation of the cutting edge by grinding, since diamond is harder than the grindstone, the shape of the grindstone changes during the machining, and it is difficult to perform the desired shape processing with high accuracy. Further, the method of performing scanning processing while relatively moving the laser and the diamond film together has a problem that the workpiece movement according to the form is further required and the control is complicated. Furthermore, in the processing method in which laser light is irradiated perpendicularly to the diamond film, the shape after processing may follow the undulation of the film before processing, and it is essential to form a uniform diamond film, which is also highly accurate. There was the inconvenience that processing was difficult. In particular, when a diamond coating is formed on a cutting edge such as a cutting edge of an insert tip, the coating is formed on the cutting edge depending on the thickness, so that it is difficult to process the cutting edge. For this reason, conventionally, it has been difficult to produce an insert tip that is coated with a diamond coating and has sharp edges.

  The present invention has been made in view of the above-described problems, and provides a carbon film-coated insert chip coated with a carbon film such as a diamond film having a sharper edge than the conventional one, and the insert chip is highly accurate. It aims at providing the manufacturing method which can be processed and produced.

  The present invention employs the following configuration in order to solve the above problems. That is, the carbon film-coated insert tip of the present invention is a carbon film-coated insert chip in which a carbon film is formed on the surface of the cutting edge of the tool base, and the surface of the carbon film adjacent to the rake face side and the flank face. The surface of the carbon film on the side is a concave surface in the vicinity of the cutting edge of the cutting edge, and the carbon film formed on the cutting edge of the cutting edge is sharper than the angle formed by the rake face and the flank face It has a shape.

  In this carbon film-coated insert tip, the surface of the carbon film on the rake face side and the surface of the carbon film on the flank side adjacent to each other are concave in the vicinity of the cutting edge of the cutting edge, and carbon formed on the cutting edge of the cutting edge Since the film has a cross-sectional shape that is sharper than the angle formed by the rake face and the flank face, it can have a sharper edge than before. In other words, the carbon film surface of the cutting edge portion of the cutting edge is recessed against the rake face and the extended surface of the flank surface, so that the carbon film of the cutting edge portion is formed sharply and a conventional chamfer is formed. A sharper edge than that can be obtained.

  The method for producing the carbon film-coated insert chip of the present invention is a method for producing the carbon film-coated insert chip of the present invention, wherein a carbon film forming step of forming a carbon film on the surface of the cutting edge of the tool base, and a laser A laser processing step of processing the carbon film on the surface of the cutting edge by irradiating a beam, and in the laser processing step, the laser beam whose light intensity distribution in the beam cross section is a Gaussian distribution, Irradiating the carbon film on the rake face side or the flank face side in the vicinity of the cutting edge and scanning along the extending direction of the cutting edge to form the concave surface.

  That is, in this carbon film-coated insert chip manufacturing method, in the laser processing step, a laser beam having a Gaussian distribution in the beam cross section is applied to the carbon film on the rake face side or flank face side from the front of the blade edge to the vicinity of the blade edge. Since the concave surface is formed by scanning along the extending direction of the blade edge, the cut mark of the carbon film by the laser beam irradiated from the front of the blade edge becomes a circular arc shape, and the concave surface is highly accurately It can be formed along. In addition, since the outer peripheral side of the laser beam hits the tip portion (edge portion) of the carbon film, the power density of the laser beam at the tip portion can be weakened, and the tip portion of the carbon film is cut off more than necessary, and the obtuse angle Can be prevented.

Moreover, it is preferable that the manufacturing method of the carbon film covering insert chip | tip of this invention forms the said carbon film on the blade edge | tip of the said cutting blade from the other part in the said carbon film formation process.
That is, in this carbon film-coated insert chip manufacturing method, in the carbon film forming process, the carbon film is raised on the cutting edge in advance from other parts, so that the carbon film in the laser processing process can be cut off. It is possible to form a deeper concave surface and a sharper edge. Since the cutting edge of the cutting edge where the two surfaces of the rake face and the flank face are close to each other is a place where the carbon film is easy to grow, the cutting edge of the cutting edge can be formed by coating the carbon film with a thick CVD film. In addition, the carbon film can be formed so as to be raised from other portions.

The carbon film-coated insert chip manufacturing method of the present invention is characterized in that the carbon film is a diamond film and the wavelength of the laser beam is 360 nm or less.
That is, in this carbon film-coated insert chip manufacturing method, since the carbon film is a diamond film and the wavelength of the laser beam is 360 nm or less, the diamond film is formed with high accuracy by a laser beam having a wavelength suitable for diamond processing. Can be processed.

The present invention has the following effects.
That is, according to the carbon film-coated insert chip according to the present invention, the surface of the carbon film on the rake face side and the surface of the carbon film on the flank face side that are adjacent to each other are concave in the vicinity of the cutting edge of the cutting edge. Since the carbon film formed on the blade edge has a sharper cross-sectional shape than the angle formed by the rake face and the flank face, it can have a sharper edge than before.
Further, according to the method of manufacturing the carbon film-coated insert tip according to the present invention, in the laser processing step, the laser beam whose light intensity distribution in the beam cross section is Gaussian distribution Since the concave surface is formed by irradiating toward the carbon film on the side and scanning along the extending direction of the blade edge, the concave surface can be formed along the blade edge with high accuracy, and a sharp edge is formed. be able to.
Therefore, the carbon film-coated insert chip of the present invention and the carbon film-coated insert chip produced by the above-described method are excellent not only in wear resistance due to the carbon film but also in sharpness, and are suitable as insert chips for processing non-ferrous metals and composite materials. Yes.

It is an expanded sectional view of the important section showing a cutting edge of a carbon film covering insert chip, and a laser processing process in one embodiment of a carbon film covering insert chip concerning the present invention, and its manufacturing method. It is a perspective view showing the carbon film covering insert tip concerning this embodiment. It is a rough whole block diagram which shows the laser processing apparatus used for the manufacturing method of the carbon film covering insert chip concerning this embodiment. In this embodiment, it is explanatory drawing which shows the relationship between the scanning direction of a laser beam, and the cross-sectional shape of a laser beam. In this embodiment, it is a conceptual diagram which shows the excision trace of the carbon film by a laser beam. In the Example of the carbon film covering insert chip concerning the present invention and its manufacturing method, it is an expanded sectional view of the important section showing the carbon film covering insert chip at the time of a laser processing process. In the Example of the carbon film covering insert chip concerning the present invention, and its manufacturing method, it is an enlarged picture showing the cutting edge before a laser processing process and after a laser processing process.

  Hereinafter, an embodiment of a carbon film-coated insert chip and a manufacturing method thereof according to the present invention will be described with reference to FIGS. 1 to 5. In each drawing used in the following description, there is a portion where the scale is appropriately changed as necessary in order to make each member recognizable or easily recognizable.

As shown in FIG. 1, the carbon film-coated insert tip 1 of the present embodiment has a carbon film-coated insert tip for blade edge replacement (replacement blade) in which a carbon film 3 is formed on the surface of the cutting edge 2 a of the tool base 2 ( The surface of the carbon film 3 on the rake face 4a side and the surface of the carbon film 3 on the flank face 4b side which are adjacent to each other are formed into a concave surface 3a in the vicinity of the cutting edge 2b of the cutting edge 2a. The carbon film 3 formed on the cutting edge 2b of 2a has a cross-sectional shape that is sharper than the angle θ0 formed by the rake face 4a and the flank face 4b.
As shown in FIG. 2, the carbon film-coated insert chip 1 has, for example, a substantially square plate shape, and an edge formed between two adjacent corner portions on the upper surface is a cutting edge 2a. Negative insert without holes.

  The tool base 2 is made of a cemented carbide such as WC (tungsten carbide), and the carbon film 3 is a diamond film, graphite film or DLC (diamond) formed by CVD (chemical vapor deposition) or the like. Like carbon) film.

  As described above, the concave surface 3a is formed in the vicinity of the cutting edge 2b of the cutting edge 2a on the surface of the carbon film 3 on the rake face 4a side and the surface of the carbon film 3 on the flank face 4b side which are adjacent to each other. For this reason, the angle θ1 of the cross section at the tip (edge) of the carbon film 3 constituted by the pair of concave surfaces 3a (the tip angle of the cross section in the plane perpendicular to the rake face 4a and the flank 4b) is the rake face 4a and the flank face. It is set smaller than the angle θ0 formed with 4b. That is, the carbon film 3 coated with the cutting edge 2a is processed so that “θ1 <θ0”. The tip of the carbon film 3 formed on the cutting edge 2b of the cutting edge 2a is processed to have a curvature radius of 2 μm or less.

  Next, a method for manufacturing the carbon film-coated insert chip of the present embodiment will be described with reference to FIGS.

The method for manufacturing the carbon film-coated insert tip 1 of the present embodiment includes a carbon film forming step of forming the carbon film 3 on the surface of the cutting edge 2a of the tool base 2, and a surface of the cutting edge 2a by irradiating the laser beam L. A laser processing step for processing the carbon film 3.
In the carbon film forming step, the carbon film 3 is formed on the cutting edge 2b of the cutting edge 2a in advance from other portions. That is, the cutting edge 2b of the cutting edge 2a where the two faces of the rake face 4a and the flank face 4b are close to each other is a place where the carbon film 3 is easy to grow, so that the carbon film 3 is thickly coated by CVD film formation. Thus, the carbon film 3 can be formed on the cutting edge 2b of the cutting edge 2a by raising it from other portions.

  As shown in FIG. 3, a laser processing apparatus 21 used in the laser processing step is an apparatus that irradiates a carbon film 3 covered with a tool base 2 with a laser beam (laser light) L and processes the laser beam. A laser beam irradiation mechanism 22 that irradiates and scans the carbon film 3 with a constant repetition frequency by oscillating L, and a rotation mechanism 23 such as a motor that can rotate while holding the tool base 2 coated with the carbon film 3. And a moving mechanism 24 that is installed and movable, and a control unit 25 that controls them.

  The moving mechanism 24 includes an X-axis stage unit 24x that can move in the X direction parallel to the horizontal plane, and a moving direction in the Y direction that is provided on the X-axis stage unit 24x and is perpendicular to the X direction and parallel to the horizontal plane. A Y-axis stage unit 24y, and a Z-axis stage unit 24z provided on the Y-axis stage unit 24y, the rotation mechanism 23 being fixed to hold the tool base 2 and movable in a direction perpendicular to the horizontal plane, It consists of

  The laser light irradiation mechanism 22 includes a laser light source 26 that also has an optical system that oscillates a laser beam that becomes a laser beam L in response to a trigger signal of a Q switch and collects it in a spot shape, and a galvano scanner that scans the laser beam L to be irradiated 27 and a CCD camera 28 for imaging to confirm the processing position of the held coated tool base 2.

The laser beam L emitted by the laser beam irradiation mechanism 22 is single mode, and the light intensity distribution of the beam cross section is a Gaussian distribution, and as shown in FIG. 4, the light intensity of the beam cross section at the focal point. The distribution is elliptical.
Further, the laser beam irradiation mechanism 22 makes the scanning direction of the laser beam L coincide with the major axis direction or minor axis direction of the light intensity distribution having an elliptical shape. This is because when the scanning direction of the laser beam L is a direction inclined with respect to the major axis or the minor axis without matching the major axis direction or the minor axis direction of the light intensity distribution, the processing shape of the scanning end portion is This is because a tilt occurs and a deviation occurs. In the present embodiment, the scanning direction of the laser beam L is matched with the minor axis direction of the light intensity distribution.

As the laser light source 26, one that can irradiate laser light having any wavelength of 190 to 550 nm can be used. For example, in this embodiment, laser light having a wavelength of 355 nm (third harmonic of Nd: YAG laser) is used. What can oscillate and emit is used.
When the carbon film 3 is a diamond film, an ultraviolet laser beam with a wavelength of 360 nm or less is used for the laser beam L.
The galvano scanner 27 is disposed immediately above the moving mechanism 24. The CCD camera 28 is installed adjacent to the galvano scanner 27.

  In the laser processing step, the laser beam L having a Gaussian distribution in the beam cross section is irradiated from the front of the blade edge 2b toward the rake face 4a side or the flank face 4b side near the blade edge 2b and the blade edge. The concave surface 3a is formed by scanning along the extending direction of 2b.

  In the laser processing step, the laser beam L is irradiated from the front of the cutting edge 2b, and the carbon film is controlled at an angle of 20 ° or less with respect to the rake face 4a or the flank face 4b by controlling the moving mechanism 24 and the galvano scanner 27, for example. 3 is irradiated. Further, the laser beam L is scanned in the extending direction of the blade edge 2b, that is, the direction perpendicular to the paper surface of FIG. 1, and as shown in FIG. Irradiation is performed in a state where scanning lines are partially overlapped. Note that the number of scanning lines is appropriately set according to the condensing angle and the focal position of the laser beam L. In the present embodiment, the laser beam L hits the wall surface of the tool base 2 before being focused, and it is difficult to irradiate a desired part.

In this laser processing, since the light intensity distribution in the beam cross section of the laser beam L has a Gaussian distribution, the intensity is higher as the center of the laser beam L is processed deeper as the center of the laser beam L and is processed as shallower as the periphery. As a result, the power density of the laser beam L hitting the tip (edge portion) of the carbon film 3 becomes weak.
Depending on the carbon film 3, structural changes such as diamond becoming amorphous carbon can occur up to about 1 μm from the processed surface.

  Thus, in the carbon film-coated insert tip 1 of the present embodiment, the surface of the carbon film 3 on the rake face 4a side and the surface of the carbon film 3 on the flank face 4b side that are adjacent to each other are near the cutting edge 2b of the cutting edge 2a. The carbon film 3 that is concave and formed on the cutting edge 2b of the cutting edge 2a has a sharper cross-sectional shape than the angle θ0 formed by the rake face 4a and the flank face 4b, so that the edge is sharper than before. Can have. That is, the carbon film 3 surface of the cutting edge 2a portion of the cutting edge 2b is scooped and concaved with respect to the extended surface of the rake face 4a and the relief surface 4b, thereby forming the carbon film 3 of the cutting edge 2b portion sharply, A sharper edge can be obtained than when forming a conventional chamfer.

  Further, in the method of manufacturing the carbon film-coated insert chip 1, in the laser processing step, the laser beam L having a Gaussian light intensity distribution in the beam cross section is applied to the rake face 4a side or the flank face from the front of the blade edge 2b to the vicinity of the blade edge 2b. Since the concave surface 3a is formed by irradiating toward the carbon film 3 on the 4b side and scanning along the extending direction of the blade edge 2b, as shown in FIG. 5, the carbon by the laser beam L irradiated from the front of the blade edge 2b. The excision mark of the film 3 has an arc shape in cross section, and the concave surface 3a can be formed along the cutting edge 2b with high accuracy.

Further, since the outer peripheral side of the laser beam L hits the tip portion (edge portion) of the carbon film 3, the power density of the laser beam L at the tip portion can be weakened, and the tip portion (edge portion) of the carbon film 3. Can be prevented from being cut more than necessary and becoming obtuse.
Further, in the carbon film forming step, the carbon film 3 is formed on the cutting edge 2b of the cutting edge 2a in advance from other portions, thereby providing a larger cutting margin for the carbon film 3 in the laser processing step and deeper. It becomes possible to form the concave surface 3a and a sharper edge.

  Next, an example of the carbon film-coated insert chip actually produced by the carbon film-coated insert chip manufacturing method of the present embodiment will be described with reference to FIGS. 6 and 7.

  In this embodiment, the laser beam is fθ by the above laser processing apparatus capable of irradiating laser beam having a wavelength of 262 nm (Nd: YLF laser (4th harmonic wave of fundamental wave: wavelength 1047 nm)), repetition of 10 kHz, and average output of 0.1 W. The insert chip 1 is focused by a lens (focal length f = 150 mm), and the same locus is scanned four times at a scanning speed of 25 mm / s using a galvano scanner, and a diamond coating by vapor phase synthesis is applied as a carbon film 3 The cutting blade 2a was sharply processed.

As a preparation, as shown in FIG. 6, diamond having an average film thickness of 17 μm is formed on a cemented carbide insert (tool base 2) by vapor phase synthesis, and the flank 4b and the rake face are the cutting edges 2a. A diamond carbon film 3 having a thickness larger than the average film thickness was formed on the ridge line (cutting edge 2b) formed with 4a. For the measurement of carbon film quality, Raman spectroscopy was used.
Further, as described above, since the portion of the cutting edge 2a has more film formation sites than the plane, the diamond film (carbon film 3) is formed thick and rounded.

  For example, as shown in FIG. 1, in the carbon film 3 that is separated from the tip of the cutting edge 2a (the cutting edge 2b) of the tool base 2 by 50 μm or more along the rake face 4a, the rake face 4a has a thickness of 100 μm or more. When the film thickness around the cutting edge 2a is the average film thickness te from the tip of the cutting edge 2a (the cutting edge 2b) of the tool base 2 to the rake face 4a up to 50 μm. The thickness ta was set to 5 μm or more, and the film was formed so as to satisfy the relationship of “te> ta”.

  Next, the rake face 4a and the flank face 4b were tilted by 10 ° with respect to the irradiation direction of the laser beam L, and the laser beam L was scanned from each direction in parallel with the ridgeline that becomes the cutting edge 2a. As shown in FIG. 5, the initial beam irradiation target position P1 is set at a position of 4 μm from the intersection of the average height extension lines 4c and 4d of the rake face 4a and flank 4b and the carbon film 3 at the cutting edge portion. did.

As described above, in the carbon film-coated insert chip 1 manufactured by the above manufacturing method, the cutting edge angle θ0 of the tool base 2 is 90 °, and the cutting edge angle θ1 of the edge formed by laser processing of the carbon film 3 is 88. ° and more sharpened. The film thickness ta was 17 μm, and the film thickness te was 19 μm. Moreover, the laser microscope was mainly used for these dimensional accuracy.
In addition, an enlarged image of the cutting edge portion before the laser processing step is shown in FIG. 7A, and an enlarged image of the cutting edge portion after the laser processing step is shown in FIG. 7B. A portion surrounded by an imaginary line (two-dot chain line) in the image is a cutting edge portion. As can be seen from these images, after the laser processing step, the cutting edge portion is sharpened much sharper than before the laser processing step.

  Next, the carbon film-coated insert tip of this example was subjected to a cutting test when used as a cutting tool, and the surface roughness Rz (maximum height) of the processed surface and the required power for cutting were determined. Is shown in Table 1. In addition, as a comparative example, Table 1 also shows the results of measurement in the same manner with respect to an insert chip coated with a conventional carbon film (diamond film) that has not been laser processed. As a workpiece, aluminum alloy A7075 is used, and cutting conditions are as shown in Table 1.

  As can be seen from the results, the carbon film-coated insert chip of the comparative example has a surface roughness Rz of 20 μm, whereas the carbon film-coated insert chip of the present example has a surface roughness Rz of 12 μm. Therefore, it is possible to cut more flatly. Further, in the carbon film-coated insert chip of the comparative example, the required power is as high as 700 W, whereas in the carbon film-coated insert chip of this example, the required power is reduced to less than half as 300 W, and the cutting resistance is greatly reduced. You can see that

  The technical scope of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Carbon film coating | insert insert chip, 2 ... Tool base | substrate, 2a ... Cutting blade, 2b ... Cutting-edge of a cutting blade, 3 ... Carbon film, 3a ... Concave surface, 4a ... Rake face, 4b ... Relief face, (theta) 0 ... Rake face and relief The angle formed with the surface, θ1... Angle of the cross section of the tip of the carbon film composed of a pair of concave surfaces

Claims (4)

A carbon film-coated insert chip in which a carbon film is formed on the surface of the cutting edge of the tool base,
The surface of the carbon film on the rake face side adjacent to each other and the surface of the carbon film on the flank face side are concave in the vicinity of the cutting edge of the cutting edge,
The carbon film-coated insert tip, wherein the carbon film formed on the cutting edge of the cutting edge has a cross-sectional shape that is sharper than an angle formed by the rake face and the flank face. A method for producing the carbon film-coated insert chip according to claim 1,
A carbon film forming step of forming a carbon film on the surface of the cutting edge of the tool base;
A laser processing step of processing the carbon film on the surface of the cutting edge by irradiating a laser beam,
In the laser processing step, the laser beam whose beam cross-section has a Gaussian distribution is irradiated from the front of the blade edge toward the rake face side or the flank face side near the blade edge and the carbon film. A method for producing a carbon film-coated insert chip, wherein the concave surface is formed by scanning along the extending direction of the blade edge. In the manufacturing method of the carbon film covering insert chip according to claim 2,
In the carbon film forming step, the carbon film-covered insert chip manufacturing method, wherein the carbon film is raised and formed on the cutting edge of the cutting edge from other portions. In the manufacturing method of the carbon film covering insert chip according to claim 2 or 3,
The carbon film is a diamond film;
The method of manufacturing a carbon film-coated insert chip, wherein the wavelength of the laser beam is 360 nm or less.