JP2013053344A - Method of manufacturing surface-coated cutting tool excellent in wear resistance - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a surface-coated cutting tool excellent in wear resistance.SOLUTION: In the method of manufacturing the surface-coated cutting tool excellent in wear resistance, at least the outermost surface of a tool base body is coated with an aluminum oxide layer of a corundum type α alumina structure having a film thickness of 0.05-5 μm. For forming the aluminum oxide layer, alcohol (preferably, containing α alumina particles whose average grain size is 10-300 nm) is added to alkoxide of aluminum, acid (for instance, dilute hydrochloric acid) is added further, then they are agitated at a low temperature of 10°C or below to generate sol, high crystallization treatment of adding water to the sol so that a molar ratio of the aluminum contained in the sol and the water becomes 1:30-1:150 and then heating/agitating it at the temperature of 15-80°C is executed, the sol to which the high crystallization treatment is executed is applied to the surface of the tool base body or to the surface of a hard coating formed on the surface, drying treatment is successively performed at least once, and then calcination treatment is performed in the temperature range of 500-1,000°C.

Description

  The present invention relates to a method of manufacturing a surface-coated cutting tool having excellent wear resistance, and particularly comprises a tungsten carbide-based cemented carbide, titanium carbonitride-based cermet, high-speed steel, or cubic boron nitride-based ultrahigh-pressure sintered body. Abrasion resistance characterized by forming an aluminum oxide layer by a sol-gel method on the surface of a tool substrate (hereinafter simply referred to as a tool substrate) or on the outermost surface of a hard coating formed on the surface of the tool substrate. The present invention relates to a method for manufacturing an excellent surface-coated cutting tool.

Conventionally, cutting is performed by coating a hard film made of carbide, nitride, carbonitride, or the like of at least one element selected from groups 4a, 5a, and 6a of the periodic table on the tool base surface. It is known to improve the wear resistance of tools.
Among the hard coatings, the α-type aluminum oxide layer is selected from groups 4a, 5a, and 6a in the periodic table from the viewpoints of excellent thermal stability, low reactivity, and high hardness. In addition, an α-type aluminum oxide layer is often formed as an outermost surface layer of a hard coating made of carbide, nitride, carbonitride, or the like of at least one element.
The chemical vapor deposition (CVD) method is usually adopted as the method for forming the aluminum oxide layer, but it is also known that the aluminum oxide layer is formed by physical vapor deposition (PVD) method or sol-gel method. It has been.
For example, as shown in Patent Document 1, as a method for forming an α-type alumina layer under a low temperature condition (1000 ° C. or less) in order to prevent deterioration and deformation of the characteristics of the tool base and the hard coating, , Al, and nitride, carbide, carbonitride, boride, nitride oxide, carbonitride containing at least one element selected from the group consisting of 4a group, 5a group, 6a group and Si as essential components After forming a hard film made of an oxide by physical vapor deposition (PVD) method, an oxide-containing layer is formed by oxidizing the hard film, and by physical vapor deposition (PVD) on the oxide-containing layer, It has been proposed to vapor-deposit an alumina layer mainly composed of an α-type crystal structure having excellent wear resistance and heat resistance as the outermost surface layer.
Further, as shown in Patent Document 2, in a surface-coated cutting tool in which a hard coating layer is formed by physical vapor deposition (PVD), the first layer is composed of a (Ti, Al) N layer, It has been proposed that the second layer is composed of an aluminum oxide layer (preferably a γ-type alumina layer).
Furthermore, as shown in Patent Document 3, as a method of manufacturing an aluminum oxide-coated structure having mechanical properties and durability, a crystal structure is made of an amorphous structure, γ-type alumina, or a mixture thereof on a base material. It has been proposed to coat and form a second alumina layer mainly composed of γ-type by sputtering after coating the first alumina layer by a sol-gel method.

JP 2004-124246 A JP 2007-75990 A JP 2006-205558 A

  In the above conventional surface-coated cutting tool (hereinafter simply referred to as a coated tool) in which a hard coating layer composed of a hard coating and an aluminum oxide formed on the outermost surface thereof is coated, the outermost aluminum oxide layer is formed by cutting steel or the like. In the processing, the wear resistance on the rake face of the coated tool can be improved. This is because, in particular, the thermal stability and non-reactivity of α-type alumina are high.

  In Patent Document 1, formation of an α-type alumina layer under a low temperature condition by a physical vapor deposition (PVD) method has been proposed. In vapor deposition formation of an aluminum oxide layer, first, a hard film is oxidized to Although it is necessary to form an oxide-containing layer on the surface, adhesion between the oxide-containing layer and the aluminum oxide layer is not sufficient, and not only α-type alumina but also γ-type alumina exists as aluminum oxide. As a result, there has been a problem that satisfactory heat resistance cannot be exhibited over a long period of use.

  Further, in Patent Documents 2 and 3, since the formed aluminum oxide is γ-alumina, the stability at high temperature is poor, and satisfactory cutting performance cannot be exhibited in high-speed cutting. was there.

  Therefore, the inventors of the present invention, after forming a hard film on the surface of the tool base by the physical vapor deposition (PVD) method and then intensively examining the sol-gel method for coating the outermost surface layer, Applying and drying alumina sol prepared by adding alcohol and acid, subjecting to long-term hydrolysis and low-temperature aging under low-temperature conditions, followed by high crystallization treatment by adding water It was found that an aluminum oxide layer having an α-type crystal structure can be formed by coating after firing.

That is, in the preparation of the alumina sol, as a low temperature aging treatment, the reaction rate of hydrolysis and polycondensation is suppressed by performing stirring at a lower temperature than usual and holding for a long time, and an oxidation consisting of an Al-O bond. After forming the aluminum precursor densely, when adding water so that the amount of aluminum in the aluminum alkoxide becomes a predetermined concentration as a high crystallization treatment and heating at a predetermined temperature, further aluminum alkoxide As the hydrolysis and polycondensation reaction of the resin is promoted and more octahedral AlO ₆ close to a corundum type structure can be formed, this alumina sol is applied as the outermost surface layer of the hard film, dried and fired, It was found that the outermost surface layer of a hard coating composed of an α-alumina layer having a highly crystalline corundum type crystal structure can be formed. .

  Further, when the hard film in contact with the aluminum oxide layer of the outermost surface layer is formed as a nitride film in which the Al content in the metal component in the hard film is 40 atomic% or more, the outermost surface layer is oxidized. Since the adhesive strength with the aluminum layer is increased, it is preferable from the viewpoint of suppressing the occurrence of peeling, chipping and the like of the aluminum oxide layer due to impact during cutting.

  And the surface-coated cutting tool manufactured by the manufacturing method of the present invention is excellent over a long period of use, combined with a smooth surface of the outermost aluminum oxide layer and excellent resistance to welding to chips. It has been found that it exhibits wear resistance.

This invention has been made based on the above findings,
“(1) The outermost surface of the tool base made of tungsten carbide base cemented carbide, titanium carbonitride base cermet, high speed steel or cubic boron nitride base ultra high pressure sintered body has a film thickness of 0.05 to 5 μm. In the method for producing a surface-coated cutting tool for coating an aluminum oxide layer having an α-alumina structure having a corundum type crystal structure,
In the aluminum oxide layer, an alcohol is added to an aluminum alkoxide, an acid is further added, and then a sol is produced by stirring in a temperature range of 10 ° C. or less. The molar ratio of aluminum to water contained in the sol is After adding water to the sol so as to be 1:30 to 1: 150, a high crystallization treatment is performed by heating and stirring at a temperature of 15 to 80 ° C., and the sol subjected to the high crystallization treatment It is applied to the surface of the tool base or the outermost surface of the hard coating formed on the surface of the tool base, followed by repeated drying at 100 to 400 ° C. one or more times, followed by firing at a temperature range of 500 to 1000 ° C. Forming a coating by the sol-gel method
A method for producing a surface-coated cutting tool having excellent wear resistance.

  (2) A nitride containing at least one element selected from groups 4a, 5a, 6a, Al, and Si of the periodic table as a hard coating on the surface of the tool base is used as a physical vapor deposition method, a chemical vapor deposition method, or The method for producing a surface-coated cutting tool having excellent wear resistance as described in (1) above, wherein the aluminum oxide layer is formed on the outermost surface of the hard film by coating with a sol-gel method.

  (3) The method for producing a surface-coated cutting tool having excellent wear resistance according to (1), wherein the surface of the tool base is previously subjected to nitriding treatment.

(4) The alcohol according to any one of (1) to (3), wherein an alcohol containing α-alumina particles having an average particle diameter of 10 to 300 nm is added when the alcohol is added to the aluminum alkoxide. A method for producing a surface-coated cutting tool having excellent wear resistance. "
It is characterized by.

  Hereinafter, the present invention will be described in detail.

  In the method of manufacturing a surface-coated cutting tool according to the present invention, a corundum type is directly applied to the surface of a tool base made of a tungsten carbide-based cemented carbide, a titanium carbonitride-based cermet, a high-speed steel, or a cubic boron nitride-based ultrahigh-pressure sintered body. An aluminum oxide layer having an α-alumina structure having the following crystal structure is coated by a sol-gel method.

  In the method for producing a surface-coated cutting tool according to the present invention, a hard coating already known to those skilled in the art, that is, at least selected from the groups 4a, 5a, 6a and Si in the periodic table is applied to the surface of the tool base. After forming at least one layer of hard film (for example, TiAlN film, CrAlN film, etc.) made of a nitride containing one or more elements and Al by physical vapor deposition (PVD), the outermost surface of the hard film In addition, an α-alumina-structured aluminum oxide layer having a corundum crystal structure can be formed by coating using a sol-gel method.

  In the formation of the hard film by the physical vapor deposition (PVD) method, the hard film in contact with the aluminum oxide layer has an Al content of 40% of the metal component in the hard film from the viewpoint of improving adhesion. It is desirable to form a nitride film that is at least atomic percent.

  This is because when the content ratio of Al in the metal component in the hard film is a nitride film of 40 atomic% or more, an oxide with a high aluminum concentration is formed at the interface between the nitride film and the aluminum oxide film. This is because the oxide has a function of firmly bonding the nitride film and the aluminum oxide film.

Specifically, the coating formation step of the aluminum oxide layer by the sol-gel method of the present invention is as follows.
Preparation of alumina sol:
First, an alcohol (eg, ethanol, 1-butanol) is added to an aluminum alkoxide (eg, aluminum secondary butoxide, aluminum propoxide), and then an acid (eg, hydrochloric acid, nitric acid) is added (at the same time, the average particle size) Then, 10 to 300 nm α-alumina particles may be added), followed by stirring in a temperature range of 10 ° C. or less and, for example, aging treatment for 12 hours or more to form an alumina sol.

In addition, when adding an alcohol, an alcohol preliminarily containing α-alumina particles having an average particle diameter of 10 to 300 nm is added for low-temperature film formation and crystallinity improvement by promoting crystal nucleation during the formation of an aluminum oxide layer. Is preferable from the viewpoint of producing a uniform sol. It is because α alumina particles become the nucleus that becomes the starting point of crystal growth when coated, and this is because there is an effect of crystallization at an early stage of the firing process, but when adding alcohol containing α alumina particles, When the average particle size of the α alumina particles is less than 10 nm, the critical nucleus size that can be the starting point of crystal growth is not reached, so crystal growth from the alumina sol around the α alumina particles does not occur and is isolated. It tends to be a place where the bonding strength with surrounding crystal grains is weak. On the other hand, if the average particle diameter exceeds 300 nm, the crystal nuclei starting from α-alumina particles grow excessively as coarse particles, leading to a decrease in film hardness and defects in the film. The average particle size is 10 to 300 nm.
Further, when the content of α-alumina particles in the alcohol is less than 0.5% by mass with respect to the alkoxide of aluminum, the number of nucleation necessary for uniformly distributing crystal nuclei in the film at a certain density or more is satisfied. This is not possible, and the crystallinity in the film becomes uneven depending on the location, so that abnormal wear is likely to be induced during cutting. The reason why α-alumina particles are likely to aggregate in the alumina sol when the amount exceeds 5% by mass with respect to the aluminum alkoxide, and the agglomerated part is formed as coarse particles in the film when forming the aluminum oxide layer, thereby inducing defects in the film. To α-alumina particles are preferably added in an amount of 0.5 to 5% by mass relative to the aluminum alkoxide.

  The concentration of the acid to be added is preferably 0.01 to 4.0 N, and the amount of acid added to the alcohol is preferably 0.5 to 5 times (volume).

  In the usual preparation of alumina sol, stirring at 40 to 80 ° C. and aging treatment for about several hours are performed at the stirring temperature. In the present invention, stirring in a low temperature range of 10 ° C. or less is performed, for example, , A low temperature aging treatment is performed for a long time of 12 hours or more.

  Here, when the temperature at the time of stirring exceeds 10 ° C., hydrolysis proceeds rapidly, so the precursor is not formed densely, and α-alumina is not formed in the subsequent baking step. The temperature was set to a low temperature range of 10 ° C. or lower.

  The reason why the aging time is set to 12 hours or longer is that the hydrolysis is gradually promoted at a low temperature to form an aluminum oxide precursor densely.

Next, in the present invention, after adding water to the sol so that the molar ratio of aluminum to water contained in the sol is 1:30 to 1: 150 with respect to the alumina sol subjected to the low temperature aging treatment, A high crystallization treatment is performed by heating and stirring at a temperature of 15 to 80 ° C.
Technical reasons for adding water to the sol so that the molar ratio of aluminum to water contained in the alumina sol subjected to low temperature aging treatment is 1:30 to 1: 150, and at a temperature of 15 to 80 ° C. The technical reason for heating and stirring is close to α-alumina corundum by accelerating further Al-O bonding by adding water and heating from the aluminum oxide precursor formed densely by low temperature aging treatment. Octahedral AlO ₆ can be formed more strongly, and if the final molar ratio of the amount of water after addition is less than 30, the supply of O contained in the water is not sufficient, so the hydrolysis of aluminum alkoxide and The polycondensation reaction does not proceed sufficiently, and a large amount of octahedral AlO ₆ close to α-alumina corundum is formed, and the number of Al—O bonds necessary for achieving improved crystallinity is not satisfied. On the other hand, if it exceeds 150, the number of Al—O bonds per volume of the alumina sol decreases, and a dense aluminum oxide film does not form when coated, so the molar ratio of aluminum to water is 1:30 to 1. : 150.
Further, when the heating / stirring temperature of the high crystallization treatment is less than 15 ° C., the hydrolysis and polycondensation reaction of the aluminum alkoxide is not sufficiently promoted, so that octahedral AlO ₆ close to α-alumina corundum is not formed in a sufficient number. A highly crystalline aluminum oxide layer cannot be formed.
On the other hand, when the heating / stirring temperature exceeds 80 ° C., the volatilization of the solvent proceeds, the aluminum oxide precursor densely formed by the low temperature aging treatment is destroyed, and a highly crystalline aluminum oxide layer cannot be formed.
Therefore, the heating / stirring temperature for the high crystallization treatment was set to 15 to 80 ° C.

Drying and firing:
The alumina sol prepared above is applied directly to the surface of the tool substrate or to the outermost surface of the hard coating formed on the surface of the tool substrate by physical vapor deposition (PVD), followed by 100 to 400 ° C., more preferably 250 to A drying treatment at 350 ° C. is repeated one or more times, and then a baking treatment is carried out in a temperature range of 500 to 1000 ° C., more preferably 600 to 900 ° C., to form an aluminum oxide layer.

  A dry gel of alumina is formed by the above drying treatment, and an aluminum oxide layer having an α-alumina structure having a corundum type crystal structure is formed on the hard coating surface by a subsequent baking treatment.

  The film thickness of the aluminum oxide layer depends on the coating thickness and the number of coatings of the alumina sol. However, when the film thickness of the coated aluminum oxide layer is less than 0.05 μm, it was excellent as a surface coating tool over a long period of use. On the other hand, the wear resistance cannot be exhibited. On the other hand, if the film thickness exceeds 5 μm, the aluminum oxide layer tends to peel off. Therefore, the film thickness of the aluminum oxide layer is set to 0.05 to 5 μm.

  In addition, the temperature range of the drying treatment is set to 100 to 400 ° C., more preferably 250 to 350 ° C., and the temperature range of the baking treatment is set to 500 to 1000 ° C., more preferably 600 to 900 ° C. If the temperature is lower than 100 ° C., sufficient drying cannot be performed, and if the temperature exceeds 400 ° C., the baking proceeds at the same time to cause cracks or the like in the film, and the film is liable to peel off. If it is less than ℃, an aluminum oxide layer having sufficient crystallinity for cutting is not formed, and there is no particular problem when fired at a temperature exceeding 1000 ℃, but a hard film such as (Ti, Al) N formed as a base This is because the film is decomposed or oxidized, or the cemented carbide or cermet substrate is oxidized, so that the advantage of low-temperature film formation cannot be seen.

Nitriding treatment:
The aluminum oxide layer can exert its performance even by directly forming a film on a tool base, but particularly when a cemented carbide, titanium carbonitride-based cermet, or high-speed steel is used as the base, The surface of the tool base is previously hardened by nitriding a metal binder phase near the tool surface by nitriding, and an aluminum oxide layer is formed on the surface, thereby improving the adhesion strength between the aluminum oxide layer and the tool base, The tool life can be extended.

  According to the method for producing a surface-coated cutting tool of the present invention, the corundum is formed directly on the surface of the tool base or on the outermost surface through a hard film formed by a physical vapor deposition (PVD) method by a sol-gel method. The aluminum oxide layer having an α-alumina structure having a type crystal structure is formed by coating, and the formed aluminum oxide layer has excellent welding resistance and wear resistance, and also has an outermost surface through a hard film. Since the aluminum oxide layer formed on the surface has excellent adhesion strength with the hard coating, the surface-coated cutting tool produced by the manufacturing method of the present invention exhibits excellent cutting performance over a long period of use, and the tool life The service life is extended.

The X-ray-diffraction figure obtained about the aluminum oxide layer of this invention tool 4 and the comparative example tool 4 is shown.

  Next, the present invention will be specifically described with reference to examples.

(A1) 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 as raw material powder These raw material powders are blended in a predetermined composition, further added with wax, ball mill mixed in acetone for 24 hours, dried under reduced pressure, and then pressed into a green compact of a predetermined shape at a pressure of 98 MPa, This green compact was vacuum sintered in a vacuum of 5 Pa at a predetermined temperature within a range of 1370 to 1470 ° C. for 1 hour, and after sintering, the cutting edge was subjected to a honing process of R: 0.07 mm. As a result, tool bases A, B, C, and D (made of carbide bases A, B, C, and D) made of a WC base cemented carbide having an insert shape defined in ISO / CNMG120408 were manufactured.

(B1) Next, the above carbide substrate A is inserted into an arc ion plating apparatus which is a kind of physical vapor deposition apparatus, and a hard film composed of a Ti _0.5 Al _0.5 N layer having a thickness of 2.0 μm is physically formed. A coating was formed by vapor deposition.
Also, the superhard substrate B was similarly loaded into an arc ion plating apparatus, and a hard film composed of an Al _0.7 Cr _0.3 N layer having a thickness of 2.0 μm was formed by physical vapor deposition.
In addition, the above-mentioned superhard substrate C is inserted into a plasma nitriding apparatus, the substrate is heated to 600 ° C., and in a stream of ammonia and hydrogen (flow rate ratio is 1: 4), under a pressure of 200 Pa. Then, a DC voltage of −300 V was applied to the substrate, and plasma nitridation was performed for about 1 hour.

(C1) On the other hand, an alumina sol for coating an aluminum oxide layer on the outermost surface of the hard film by a sol-gel method was prepared as follows.
A predetermined amount of ethanol shown in Table 1 is added as an alcohol to aluminum secondary butoxide, which is an alkoxide of a predetermined amount of aluminum shown in Table 1, and stirred at 0 ° C. in a thermostatic bath. Hydrochloric acid with added was added dropwise over 1 hour.

(D1) As shown in Table 1, stirring was continued for 12 hours or more while being kept at 10 ° C. or lower in a thermostatic bath, and further, a low temperature aging treatment was performed at 3 ° C. for 24 hours to prepare an alumina sol.
The ratio of the amount of water added to the sol relative to the aluminum contained in the alumina sol was 1:20 to 1: 100.

(E1) Addition of a predetermined amount of water shown in Table 1 and heating and stirring under predetermined conditions so that the molar ratio of aluminum to water in the alumina sol prepared above is in the range of 1:30 to 1: 150. A high crystallization treatment was performed.

(F1) Next, a super-nitridation process was performed on the hard coating composed of the Ti _0.5 Al _0.5 N layer and the Al _0.7 Cr _0.3 N layer formed on the carbide substrates A and B. The above-mentioned alumina sol was applied onto the hard substrate C and the superhard substrate D that had not been subjected to a special surface treatment.

(G1) Next, the coated alumina sol was dried at 300 ° C. in the atmosphere for 0.5 hours, and after further repeated coating and drying for a total of 5 times, it was fired at 600 ° C. in the atmosphere for 1 hour. The surface-coated cutting tools 1, 2, 3, 4 of the present invention (the present invention tools 1, 2) are formed by coating the outermost surface with an α-alumina-structured aluminum oxide layer having a corundum type crystal structure with a film thickness of 1 μm. 3 and 4).

  About the said invention tools 1-4, when the aluminum oxide layer was structurally analyzed using the X-ray-diffraction apparatus, it was confirmed that the aluminum oxide layer has the alpha alumina structure which has a corundum type crystal structure.

  FIG. 1 shows, as an example, an X-ray diffraction pattern obtained for an aluminum oxide layer of the tool 1 of the present invention. From FIG. 1, the aluminum oxide layer of the tool of the present invention has an α-alumina structure having a corundum type crystal structure. It is confirmed that

Comparative Example 1

  For comparison, a surface-coated cutting tool was manufactured by the following manufacturing method.

  That is, a hard film is formed in the step (b1) on the tool bases A, B, C, and D in (a1), and an alumina sol is prepared in the step (c1) (see Table 1). did.

  Next, in place of the step (d1), alumina sol was prepared by performing a treatment of continuing stirring for 12 hours while maintaining the temperature at 40 ° C. in a thermostatic bath, and further aging at 40 ° C. for 24 hours.

Next, in the same manner as in the above (f1), plasma nitriding treatment is performed on the hard film made of the Ti _0.5 Al _0.5 N layer and the Al _0.7 Cr _0.3 N layer formed on the carbide substrates A and B. The above-mentioned alumina sol was applied onto the cemented carbide substrate C subjected to the above and onto the cemented carbide substrate D not subjected to special surface treatment.

  Next, the coated alumina sol was dried in the atmosphere at 300 ° C. for 0.5 hours in the same manner as in the above (g1). Further, the coating and drying treatment were repeated a total of 5 times, and then in the atmosphere at 600 ° C. The surface-coated cutting tools 1, 2, 3, 4 (comparative example tools 1, 2, 3, 4) of the comparative example are formed by performing a baking process for 1 hour and coating the outermost surface with an aluminum oxide layer having a thickness of 1 μm. Manufactured).

Reference example 1

  For reference, a surface-coated cutting tool was manufactured by the following manufacturing method.

  That is, a hard film is formed in the step (b1) on the tool bases A, B, C, and D in (a1), and an alumina sol is prepared in the step (c1) (see Table 1). In the step (d1) (see Table 1), after the low temperature aging treatment, the sol not subjected to the high crystallization treatment of the present invention, and the above conditions under conditions different from the range of the high crystallization treatment of the present invention The sol subjected to the high crystallization process in the step (e1) was applied onto the carbide substrates A, B, C, and D in the step (f1), respectively.

  Next, the coated alumina sol was dried in the atmosphere at 300 ° C. for 0.5 hours in the same manner as in the above (g1). Further, the coating and drying treatment were repeated a total of 5 times, and then in the atmosphere at 600 ° C. The surface-coated cutting tools 1 to 4 (referred to as reference example tools 1 to 4) of the reference example were manufactured by performing a baking process for 1 hour and coating the outermost surface with a 1 μm-thick aluminum oxide layer.

  When the aluminum oxide layer was structurally analyzed using an X-ray diffractometer for the comparative tools 1 to 4 and the reference tools 1 to 4, no clear peak was detected, and the aluminum oxide layer was amorphous with low crystallinity. It was confirmed to have a close crystal structure.

  Next, a cutting test of chromium molybdenum steel was performed on the above-described present invention tools 1 to 4, comparative example tools 1 to 4 and reference example tools 1 to 4 under the following conditions.

Work material: JIS / SCM415 round bar,
Cutting speed: 180 m / min,
Cutting depth: 1.5mm,
Feed: 0.3mm / rev,
Cutting time: The wear state of each tool after a 5-minute cutting test was observed, and the amount of flank wear was measured.

  These results are shown in Table 2.

(A2) As raw material powders, all TiCN (mass ratio TiC / TiN = 50/50) powder, Mo ₂ C powder, ZrC powder, NbC powder, TaC powder, WC having an average particle diameter of 0.5-2 μm Powder, Co powder, and Ni powder are prepared, blended in a predetermined composition, wet mixed in a ball mill for 24 hours, dried, and pressed into a green compact at a pressure of 98 MPa. Is sintered in a nitrogen atmosphere of 1.3 kPa at a temperature of 1540 ° C. for 1 hour, and after sintering, the cutting edge portion is subjected to a honing process of R: 0.07 mm to insert a chip of ISO standard / CNMG190612 TiCN-based cermet tool bases E and F (referred to as cermet bases E and F) having a shape were manufactured.

(B2) Next, the cermet substrate E was placed in an arc ion plating apparatus which is a kind of physical vapor deposition apparatus, and a hard film composed of a Ti _0.5 Al _0.5 N layer having a thickness of 2.0 μm was physically vapor deposited. To form a coating.
Further, the cermet substrate F was also loaded into an arc ion plating apparatus, and a hard film composed of an Al _0.7 Cr _0.3 N layer having a thickness of 2.0 μm was formed by physical vapor deposition.

(C2) On the other hand, an alumina sol for coating an aluminum oxide layer on the outermost surface of the hard film by a sol-gel method was prepared as follows.
A predetermined amount of 1-butanol containing α-alumina particles having a predetermined average particle size shown in Table 3 is added as an alcohol to aluminum isopropoxide, which is an alkoxide of a predetermined amount of aluminum shown in Table 3, While stirring at 0 ° C. in a thermostatic bath, nitric acid diluted with a predetermined amount of water was added dropwise over 1 hour.

(D2) An alumina sol was prepared by continuing stirring for 12 hours while maintaining this at 0 ° C. in a thermostatic bath, and further subjecting to low temperature aging treatment at 3 ° C. for 24 hours.
The ratio of the amount of water added to the sol relative to the aluminum contained in the alumina sol was 1:20 to 1: 100.

(E2) Addition of a predetermined amount of water shown in Table 3 and heating and stirring under predetermined conditions so that the molar ratio of aluminum to water contained in the alumina sol prepared above is 1:30 to 1: 150 A high crystallization treatment was performed.

(F2) Next, the above-mentioned alumina sol was applied on the hard film composed of the Ti _0.5 Al _0.5 N layer and the Al _0.7 Cr _0.3 N layer formed on the cermet substrates E and F.

(G2) Next, the coated alumina sol was dried at 300 ° C. for 0.5 hours in the atmosphere, and after repeated coating and drying for a total of 4 times, a firing treatment was performed at 600 ° C. for 1 hour in the atmosphere. The surface-coated cutting tools 5 and 6 of the present invention (referred to as the present invention tools 5 and 6) are manufactured by coating the outermost surface with an α-alumina-structured aluminum oxide layer having a corundum type crystal structure with a thickness of 1 μm. did.

(A3) Moreover, TiN powder, TiC powder, TiCN powder, TiAl ₃ powder, Al ₂ O ₃ powder, WC powder, and cBN all having an average particle diameter in the range of 0.3 to 0.9 μm as the raw material powder. Powders are prepared, blended in a predetermined composition, wet-mixed with acetone for 48 hours using a ball mill, dried, and then pressed by a hydraulic press with a molding pressure of 1 MPa, diameter: 50 mm × thickness: 1.5 mm. The molded body is press-molded to a size, and then the molded body is heat-treated in a vacuum atmosphere at a pressure of 1 Pa at a predetermined temperature within a range of 1000 to 1300 ° C. for 30 to 60 minutes, and the volatile components and components adsorbed on the powder surface To obtain a pre-sintered body for a cutting edge piece, and this pre-sintered body has separately prepared dimensions of Co: 8% by mass, WC: remaining composition, and diameter: 50 mm × thickness: 2 mm. The In a state of being superposed with a C-base cemented carbide support piece, it was inserted into a normal ultra-high pressure sintering apparatus, and under normal conditions of pressure: 5 GPa, temperature: 1500 ° C., holding time: 30 minutes High-pressure and high-temperature sintering is performed to obtain a cBN sintered material. cBN sintered material disc was cut to a predetermined size with a wire electric discharge machine, Co: 5 mass%, TaC: 5 mass%, WC: remaining composition and WC-based carbide with ISO CNCN120408 insert shape The brazing part (corner part) of the alloy insert body is brazed using a brazing material of an Ag alloy having a composition of Cu: 26%, Ti: 5%, and Ag: the rest, and the upper and lower surfaces. Further, the tool bases G, H, and I made of a cBN sintered body having an insert shape of ISO standard CNGA120408 were manufactured by performing peripheral grinding and honing treatment.

  The tool bases G, H and I made of cBN sintered bodies are subjected to the above steps (b2) to (g2), and the tool bases G and H are each formed with a hard film. With no treatment, alumina films were formed on the respective surfaces to produce surface-coated cutting tools 7, 8, 9 (referred to as the present invention tools 7, 8, 9) of the present invention.

  About the said invention tools 5-9, when the aluminum oxide layer was structural-analyzed using the X-ray-diffraction apparatus, it was confirmed that the aluminum oxide layer has the alpha alumina structure which has a corundum type crystal structure.

Comparative Example 2

For comparison, surface coated cutting tools 5 to 9 (referred to as comparative example tools 5 to 9) of comparative examples were manufactured using the tool bases E to I.
That is, in the step (b2), a Ti _0.5 Al _0.5 N layer is formed on the cermet substrate E, an Al _0.7 Cr _0.3 N layer is formed on the cermet substrate F, and a tool substrate G made of a cBN sintered body is formed. A hard coating composed of an Al _0.7 Cr _0.3 N layer is formed on a tool base H made of Ti _0.5 Al _0.5 N layer and cBN sintered body, respectively, and a tool base made of cBN sintered body I was left untreated and an alumina sol was prepared in the step (c2).

  Next, in the step (d2), the alumina sol was prepared by performing the treatment of continuing the stirring for 12 hours while maintaining the temperature in the thermostatic bath at 40 ° C., and further aging at 40 ° C. for 24 hours.

  Next, the alumina sol was applied on the hard coating formed on the cermet bases E and F and the tool bases G and H made of the cBN sintered body and on the tool base I made of an untreated cBN sintered body.

  Next, the coated alumina sol was dried in the atmosphere at 300 ° C. for 0.5 hours in the same manner as in the above (g2). Further, the coating and drying treatment were repeated a total of 5 times, and then in the atmosphere at 600 ° C. The surface-coated cutting tools 5 to 9 (referred to as comparative example tools 5 to 9) of comparative examples were manufactured by performing a baking treatment for 1 hour and coating the outermost surface with an aluminum oxide layer having a thickness of 1 μm.

Reference example 2

  For reference, a surface-coated cutting tool was manufactured by the following manufacturing method.

  That is, a hard film is formed in the step (b2) on the tool bases E to F of (a2) and the tool bases G to I of (a3), and alumina sol is formed in the step (c2). And a sol that is not subjected to the high crystallization treatment of the present invention after being subjected to the low temperature aging treatment in the step (d2), and the above (e2) under conditions different from the range of the high crystallization treatment of the present invention. The sol subjected to the high crystallization process in the step (2) was applied on the tool bases E to I in the step (f2).

  Next, the coated alumina sol was dried in the atmosphere at 300 ° C. for 0.5 hours in the same manner as in the above (g2). Further, the coating and drying treatment were repeated a total of 5 times, and then in the atmosphere at 600 ° C. The surface-coated cutting tools 5 to 9 (referred to as reference example tools 5 to 9) of the reference example were manufactured by performing a baking process for 1 hour and coating the outermost surface with a 1 μm-thick aluminum oxide layer.

  When the aluminum oxide layer was structurally analyzed using an X-ray diffractometer for the comparative tool 5-9 and the reference tool 5-9, a clear peak was not detected, and the aluminum oxide layer was amorphous with low crystallinity. It was confirmed to have a crystal structure close to.

  Next, a cutting test of carbon steel was performed under the following conditions for the above-described inventive tools 5, 6, comparative example tools 5, 6 and reference example tools 5, 6.

Work material: JIS / S45C round bar,
Cutting speed: 220 m / min,
Cutting depth: 0.5mm,
Feed: 2.0mm / rev,
Cutting time: The wear state of each tool after a 5-minute cutting test was observed, and the amount of flank wear was measured.

Moreover, the cutting test of hardened steel was done on the following conditions about the said invention tools 7-9, comparative example tools 7-9, and reference example tools 7-9.

Work material: JIS / SCr415 round bar,
Cutting speed: 180 m / min,
Cutting depth: 0.5mm,
Feed: 2.0mm / rev,
Cutting time: The wear state of each tool after a 5-minute cutting test was observed, and the amount of flank wear was measured.

  Table 4 shows the observation results on the wear damage status of each tool after the cutting test.

  From the results shown in Tables 2 and 4, in the surface-coated cutting tools 1 to 9 manufactured by the manufacturing method of the present invention, the outermost aluminum oxide layer has a film thickness of 0.05 to 5 μm with excellent smoothness. Since it is formed as an aluminum oxide layer having an α-alumina structure having a type crystal structure, it exhibits no wear or the like, and exhibits excellent wear resistance over a long period of use.

  On the other hand, in the surface-coated cutting tools 1 to 9 of the comparative examples in which the outermost aluminum oxide layer has an amorphous structure with low crystallinity, the rake face is damaged during the cutting or severe rake face wear. It is clear that the wear resistance is inferior and the service life is reached in a short time.

  Further, although the outermost aluminum oxide layer has an α-alumina structure having a corundum type crystal structure, the high crystallization process in the step (e1) or the step (e2) is omitted in the preparation process of the alumina sol, or the present In the surface-coated cutting tools 1 to 9 of the reference examples subjected to the treatment outside the scope of the invention, crater wear was present, and no defects were generated from the crater wear, but the flank wear resistance was poor. The service life was reached in a short time.

According to the method for producing a surface-coated cutting tool of the present invention, an α having a corundum type crystal structure excellent in thermal stability and wear resistance is obtained by a sol-gel method for preparing an alumina sol in a relatively low temperature region. The aluminum oxide layer with an alumina structure can be formed by simple operations, so that not only can the tool life be extended, but it can also contribute to resource and energy savings in the manufacturing process. The effect is great.

Claims (4)

A corundum type having a film thickness of 0.05 to 5 μm on the outermost surface of a tool base made of tungsten carbide based cemented carbide, titanium carbonitride based cermet, high speed steel or cubic boron nitride based ultra high pressure sintered body In the method of manufacturing a surface-coated cutting tool for coating an aluminum oxide layer having an α-alumina structure having a crystal structure of
In the aluminum oxide layer, an alcohol is added to an aluminum alkoxide, an acid is further added, and then a sol is formed by stirring in a temperature range of 10 ° C. or less, and the molar ratio of aluminum and water contained in the sol After adding water to the sol so that the ratio becomes 1:30 to 1: 150, it is subjected to high crystallization treatment by heating and stirring at a temperature of 15 to 80 ° C., and the sol subjected to the high crystallization treatment is subjected to The surface of the tool base or the hard coating formed on the surface of the tool base is applied to the outermost surface, followed by drying at 100 to 400 ° C. one or more times, and then firing at a temperature range of 500 to 1000 ° C. Forming a coating by a sol-gel method.
A method for producing a surface-coated cutting tool having excellent wear resistance.   A nitride containing at least one element selected from groups 4a, 5a, 6a, Al, and Si of the periodic table is used as a hard coating on the surface of the tool base. Physical vapor deposition, chemical vapor deposition, or sol-gel 2. The method for producing a surface-coated cutting tool with excellent wear resistance according to claim 1, wherein the aluminum oxide layer is formed on the outermost surface of the hard coating.   2. The method for producing a surface-coated cutting tool with excellent wear resistance according to claim 1, wherein the surface of the tool base is previously subjected to nitriding treatment. The wear resistance according to any one of claims 1 to 3, wherein an alcohol containing α-alumina particles having an average particle diameter of 10 to 300 nm is added when the alcohol is added to the aluminum alkoxide. A method for manufacturing surface-coated cutting tools with excellent properties.