JP2015062992A - Edm切削可能な高cbn含有率ソリッドpcbnコンパクト - Google Patents
Edm切削可能な高cbn含有率ソリッドpcbnコンパクト Download PDFInfo
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Abstract
Description
代わりに、cBN粒子は、存在する基板なしにHPHT焼結されてもよく、この場合、得られるPCBNコンパクトは、「ソリッド」または「自己焼結(self−sintering)」または「自己焼結(self−sintered)」または「無支持(free−standing)」と表されることがある。触媒/バインダー材料は、HPHT焼結の間のPCBN構造体の形成を促進するために、焼結の前にcBN粒子と混合されても、あるいは、触媒/バインダー材料は、cBN粒子に近接して置かれてもよい。基板のない焼結は、基板が、高圧プレス内の利用価値のある作業スペースを占有せず、そのスペースがcBN混合物によって完全に占有できるので、利点があり得る。例として、高圧プレスは、約50cm3の作業容積を有し得る。また、触媒/バインダー材料は、基板からcBN層に溶侵するのでなく、cBN混合物の全体に渡って均一に分散され得るので、結果として、自己焼結PCBNコンパクトは、より均一な組成および材料特性を有し得る。
自己焼結PCBNコンパクトを形成するために用いられるバインダー材料は、通常、導電性でなく、その結果、得られるPCBNコンパクトは、EDMによって切削できない。例えば、自己焼結PCBNを形成するのに用いられているバインダー前駆体材料の1つは、アルミニウムである。HPHT焼結後、得られる自己焼結PCBNコンパクトは、PCBNグレインの間に、アルミニウムセラミックバインダー相を有する。このアルミニウムセラミックバインダー相は、非導電性である。別のタイプのバインダー相を有するPCBNコンパクトが、過去において、試みられたが、このようなコンパクトは、通常、低cBN含有率に限定されていて、EDM切削可能でなく、および/または、意図される用途にとって十分な硬さおよび強度特性を有さない。
別の実施形態において、自己焼結多結晶立方晶窒化ホウ素(PCBN)切削要素の形成方法が提供される。この方法は、複数のcBN粒子をバインダー前駆体と混合して、混合物を形成することを含む。この混合物は、80体積%を超えるcBN粒子を含む。前記方法は、また、基板の支持なしに混合物をHPHT焼結して、自己焼結PCBNコンパクトを形成することと、自己焼結PCBNコンパクトを放電加工によって切削することと、を含む。
本開示の一実施形態が、図1〜2に例示されている。図1は、所望の大きさまたは大きさの範囲のcBN粒子からなるcBN混合物12を含む粉末混合物10を示す。このcBN混合物12は、また、cBN粒子と均一に混合されたバインダー前駆体14を含む。バインダー前駆体14は、HPHT焼結の間のPCBNの形成を容易にする触媒/バインダー材料を含む。図1に例示されるように、cBNと前駆体の混合物10は、高圧プレス内に置かれ、高温、高圧で焼結される。例えば、一実施形態において、粉末混合物10は、1300〜1500℃の範囲の高温で、3〜6.5GPaの範囲の圧力で加圧される。
このHPHT焼結法は、図2の例で示されるように、結晶間結合したcBNグレイン16のネットワークを有する多結晶構造体を生み出し、前駆体材料は、結合したPCBNグレイン16の間の空間または間隙に残るバインダー相18を形成する。HPHT焼結の後、焼結PCBNコンパクトは、例えばEDM切削によって、特定の切削工具に望まれる形状に切削され得る。
試験にかけたPCBNコンパクトを、下の表1に要約する。各PCBNコンパクトの曲げ強さもまた、比較のために記載する。
相対的な大きさは、明確さのために、図では、誇張されており、必ずしも一定の率による縮尺ではない。
次に、本発明の好ましい態様を示す。
1. 立方晶窒化ホウ素(cBN)粒子の第1相とチタン化合物を含むセラミックバインダー相とを含む自己焼結多結晶立方晶窒化ホウ素(PCBN)コンパクトを含み、
第1相が自己焼結PCBNコンパクトの80体積%超を占め、
自己焼結PCBNコンパクトが、放電加工によって切削可能であるのに十分な導電性を有する、切削要素。
2. 自己焼結PCBNコンパクトが、3,200kg/mm 2 を超えるビッカース硬さを備える、上記1に記載の切削要素。
3. 自己焼結PCBNコンパクトにおけるチタンとアルミニウムの比が、約2または3である、上記1に記載の切削要素。
4. 自己焼結PCBNコンパクトが、約1mm〜50mmの範囲の厚さを有する、上記1に記載の切削要素。
5. バインダー相が、窒化チタンおよび炭化チタンを含む、上記1に記載の切削要素。
6. 第1相が、自己焼結PCBNコンパクトの85体積%超を占める、上記1に記載の切削要素。
7. 第1相が、自己焼結PCBNコンパクトの約85体積%を占める、上記1に記載の切削要素。
8. 第1相が、自己焼結PCBNコンパクトの90体積%超を占める、上記1に記載の切削要素。
9. 第1相が、自己焼結PCBNコンパクトの約85体積%〜約95体積%の間を占める、上記1に記載の切削要素。
10. 第1相が、自己焼結PCBNコンパクトの81体積%超を占める、上記1に記載の切削要素。
11. 自己焼結PCBNコンパクトが、約10 -2 オーム−m未満の電気抵抗率を有する、上記1に記載の切削要素。
12. 自己焼結多結晶立方晶窒化ホウ素(PCBN)切削要素の形成方法であって、
複数のcBN粒子をバインダー前駆体と混合して、80体積%を超えるcBN粒子を含む混合物を形成することと、
基板の支持なしに、混合物をHPHT焼結して、自己焼結PCBNコンパクトを形成することと、
自己焼結PCBNコンパクトを放電加工によって切削することと
を含む、形成方法。
13. バインダー前駆体がチタンを含む、上記12に記載の方法。
14. バインダー前駆体が、Ti 3 AlC、またはTi 3 AlN、またはTi 2 AlC、またはTi 2 AlNからの1つまたは複数を含む、上記13に記載の方法。
15. 混合物が、85体積%を超えるcBN粒子を含む、上記12に記載の方法。
16. 混合物が、約85体積%のcBN粒子を含む、上記12に記載の方法。
17. HPHT焼結の前に、混合物を真空下に加熱することをさらに含む、上記12に記載の方法。
18. HPHT焼結の前に、バインダー前駆体をcBN粒子と部分的に反応させることをさらに含む、上記12に記載の方法。
19. HPHT焼結が、自己焼結PCBNコンパクトにおけるバインダー相を形成するための、反応焼結を含む、上記12に記載の方法。
20. 反応焼結が、HPHT焼結の間に、バインダー前駆体をcBN粒子と反応させて、バインダー相を形成させることを含む、上記19に記載の方法。
21. バインダー相が、炭化チタン、炭窒化チタン、窒化チタン、二ホウ化チタン、窒化アルミニウム、または酸化アルミニウムの少なくとも1つを含む、上記20に記載の方法。
Claims (21)
- 立方晶窒化ホウ素(cBN)粒子の第1相と、チタン化合物を含むセラミックバインダー相とを含む自己焼結多結晶立方晶窒化ホウ素(PCBN)コンパクトを含み、
第1相が自己焼結PCBNコンパクトの80体積%超を占め、
自己焼結PCBNコンパクトが、放電加工によって切削可能であるのに十分な導電性を有する、切削要素。 - 自己焼結PCBNコンパクトが、3,200kg/mm2を超えるビッカース硬さを備える、請求項1に記載の切削要素。
- 自己焼結PCBNコンパクトにおけるチタンとアルミニウムの比が、約2または3である、請求項1に記載の切削要素。
- 自己焼結PCBNコンパクトが、約1mm〜50mmの範囲の厚さを有する、請求項1に記載の切削要素。
- バインダー相が、窒化チタンおよび炭化チタンを含む、請求項1に記載の切削要素。
- 第1相が、自己焼結PCBNコンパクトの85体積%超を占める、請求項1に記載の切削要素。
- 第1相が、自己焼結PCBNコンパクトの約85体積%を占める、請求項1に記載の切削要素。
- 第1相が、自己焼結PCBNコンパクトの90体積%超を占める、請求項1に記載の切削要素。
- 第1相が、自己焼結PCBNコンパクトの約85体積%〜約95体積%の間を占める、請求項1に記載の切削要素。
- 第1相が、自己焼結PCBNコンパクトの81体積%超を占める、請求項1に記載の切削要素。
- 自己焼結PCBNコンパクトが、約10-2オーム−m未満の電気抵抗率を有する、請求項1に記載の切削要素。
- 自己焼結多結晶立方晶窒化ホウ素(PCBN)切削要素の形成方法であって、
複数のcBN粒子をバインダー前駆体と混合して、80体積%を超えるcBN粒子を含む混合物を形成することと、
基板の支持なしに、混合物をHPHT焼結して、自己焼結PCBNコンパクトを形成することと、
自己焼結PCBNコンパクトを放電加工によって切削することと
を含む、形成方法。 - バインダー前駆体がチタンを含む、請求項12に記載の方法。
- バインダー前駆体が、Ti3AlC、またはTi3AlN、またはTi2AlC、またはTi2AlNからの1つまたは複数を含む、請求項13に記載の方法。
- 混合物が、85体積%を超えるcBN粒子を含む、請求項12に記載の方法。
- 混合物が、約85体積%のcBN粒子を含む、請求項12に記載の方法。
- HPHT焼結の前に、混合物を真空下に加熱することをさらに含む、請求項12に記載の方法。
- HPHT焼結の前に、バインダー前駆体をcBN粒子と部分的に反応させることをさらに含む、請求項12に記載の方法。
- HPHT焼結が、自己焼結PCBNコンパクトにおけるバインダー相を形成するための、反応焼結を含む、請求項12に記載の方法。
- 反応焼結が、HPHT焼結の間に、バインダー前駆体をcBN粒子と反応させて、バインダー相を形成させることを含む、請求項19に記載の方法。
- バインダー相が、炭化チタン、炭窒化チタン、窒化チタン、二ホウ化チタン、窒化アルミニウム、または酸化アルミニウムの少なくとも1つを含む、請求項20に記載の方法。
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2011
- 2011-09-08 KR KR1020137008663A patent/KR101530455B1/ko active IP Right Grant
- 2011-09-08 EP EP11824136.3A patent/EP2613900B1/en not_active Not-in-force
- 2011-09-08 JP JP2013528288A patent/JP2013537116A/ja not_active Ceased
- 2011-09-08 CN CN201180050407.XA patent/CN103209794B/zh not_active Expired - Fee Related
- 2011-09-08 WO PCT/US2011/050853 patent/WO2012033930A2/en active Application Filing
- 2011-09-08 US US13/820,744 patent/US9028573B2/en not_active Expired - Fee Related
- 2011-09-08 US US13/228,240 patent/US9028575B2/en not_active Expired - Fee Related
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2014
- 2014-11-14 JP JP2014231980A patent/JP5688180B1/ja not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
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CN103209794A (zh) | 2013-07-17 |
WO2012033930A2 (en) | 2012-03-15 |
KR20130099962A (ko) | 2013-09-06 |
WO2012033930A3 (en) | 2012-06-07 |
EP2613900A2 (en) | 2013-07-17 |
EP2613900A4 (en) | 2014-04-30 |
US9028573B2 (en) | 2015-05-12 |
EP2613900B1 (en) | 2016-03-23 |
US9028575B2 (en) | 2015-05-12 |
CN103209794B (zh) | 2015-11-25 |
KR101530455B1 (ko) | 2015-06-19 |
US20120055099A1 (en) | 2012-03-08 |
JP5688180B1 (ja) | 2015-03-25 |
JP2013537116A (ja) | 2013-09-30 |
US20130298475A1 (en) | 2013-11-14 |
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