JP3948020B2 - Surface-coated cemented carbide cutting tool with excellent wear resistance under high-speed heavy cutting conditions. - Google Patents

Surface-coated cemented carbide cutting tool with excellent wear resistance under high-speed heavy cutting conditions. Download PDF

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JP3948020B2
JP3948020B2 JP2002231265A JP2002231265A JP3948020B2 JP 3948020 B2 JP3948020 B2 JP 3948020B2 JP 2002231265 A JP2002231265 A JP 2002231265A JP 2002231265 A JP2002231265 A JP 2002231265A JP 3948020 B2 JP3948020 B2 JP 3948020B2
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JP2004066424A (en
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晃 長田
哲彦 本間
西田  真
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Mitsubishi Materials Corp
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Description

【0001】
【発明の属する技術分野】
この発明は、硬質被覆層が高強度と高硬度を有し、したがって各種の鋼や鋳鉄などの切削加工を、特に高速で、かつ高い機械的衝撃を伴う高切り込みや高送りなどの重切削条件で行なった場合に、硬質被覆層がチッピング(微小欠け)などの発生なく、すぐれた耐摩耗性を発揮する表面被覆超硬合金製切削工具(以下、被覆超硬工具という)に関するものである。
【0002】
【従来の技術】
一般に、被覆超硬工具には、各種の鋼や鋳鉄などの被削材の旋削加工や平削り加工にバイトの先端部に着脱自在に取り付けて用いられるスローアウエイチップ、穴あけ切削加工などに用いられるドリルやミニチュアドリル、さらに面削加工や溝加工、肩加工などに用いられるソリッドタイプのエンドミルなどがあり、また前記スローアウエイチップを着脱自在に取り付けて前記ソリッドタイプのエンドミルと同様に切削加工を行うスローアウエイエンドミル工具などが知られている。
【0003】
また、被覆超硬工具として、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)基サーメットからなる基体(以下、これらを総称して超硬基体と云う)の表面に、原子比で、
組成式:(Zr1-XTiX)C1-ZZ(ただし、原子比で、X:0.40〜0.60、Z:0.40〜0.60)、
を満足するZrとTiの複合炭窒化物[以下、(Zr,Ti)CNで示す]層からなる硬質被覆層を1〜15μmの平均層厚で蒸着してなる被覆超硬工具が提案され、各種の鋼や鋳鉄などの連続切削や断続切削加工に用いた場合にすぐれた切削性能を発揮することも知られている(例えば特許文献1参照)。
【0004】
さらに、上記の被覆超硬工具が、例えば図1に概略縦断面図で示される通り、中央部にステンレス鋼製の反応ガス吹き出し管が立設され、前記反応ガス吹き出し管には、図2(a)に概略斜視図で、同(b)に概略平面図で例示される黒鉛製の超硬基体支持パレットが串刺し積層嵌着され、かつこれらがステンレス鋼製のカバーを介してヒーターで加熱される構造を有する化学蒸着装置を用い、超硬基体を前記超硬基体支持パレットの底面に形成された多数の反応ガス通過穴位置に図示される通りに載置した状態で前記化学蒸着装置に装入し、
反応ガス組成(容量%で):ZrCl4:0.05〜5%、TiCl4:0.1〜6%、CH3CN:0.6〜5%、N2:0.5〜40%、H2:残り、
反応雰囲気温度:900〜1050℃、
反応雰囲気圧力:5〜50kPa、
の条件で(Zr,Ti)CNからなる硬質被覆層を形成することにより製造されることも知られている(例えば特許文献2参照)。
【0005】
【特許文献1】
特開昭62−56564号公報
【特許文献2】
特開2001−11632号公報
【0006】
【発明が解決しようとする課題】
近年の切削加工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も強く、これに伴い、切削加工は高速化の傾向を深め、かつ高切り込みや高送りなどの重切削条件での切削加工が強く求められる傾向にあるが、上記の従来被覆超硬工具においては、これを通常の切削加工条件で用いた場合には問題はないが、特に切削加工を高速で、かつ高い機械的衝撃を伴う高切り込みや高送りなどの重切削条件で行なった場合には、硬質被覆層の強度および硬さ不足が原因で、硬質被覆層の摩耗進行が一段と促進し、かつチッピングも発生し易くなることから、比較的短時間で使用寿命に至るのが現状である。
【0007】
【課題を解決するための手段】
そこで、本発明者等は、上述のような観点から、特に高速重切削加工条件で硬質被覆層がすぐれた耐摩耗性を発揮する被覆超硬工具を開発すべく、上記の従来被覆超硬工具を構成する硬質被覆層に着目し、研究を行った結果、
(a)上記の図1,2に示される化学蒸着図装置を用いて形成された従来被覆超硬工具を構成する(Zr,Ti)CN層は、厚さ全体に亘って実質的に均一な組成を有し、したがって均質な硬さと強度を有するが、(Zr,Ti)CN層を形成するに際して、例えば図3に反応ガス組成自動制御システムが概略チャート図で示される通り、反応ガス組成および流量中央制御装置に、前記(Zr,Ti)CN層からなる硬質被覆層に層厚方向にそってZr最高含有点とTi最高含有点とを所定間隔をおいて交互に繰り返し形成させる目的で、前記Zr最高含有点およびTi最高含有点に対応した反応ガス組成、並びに前記両点間のZrおよびTiの連続変化に対応した反応ガス組成、さらに前記両点間の間隔および硬質被覆層の全体層厚を、過去の実績データに基づいてインプットし、この反応ガス組成および流量中央制御装置からの制御信号にしたがって、原料ガスボンベからのH2ガス、CH4ガス、N2ガス、およびHClガスの流量、さらにZrCl4ガスおよびTiCl4ガスの流量をそれぞれの原料流量自動制御装置にて制御しながら、化学蒸着装置の反応ガス吹き出し管に導入すると、層厚方向にそって、Zr最高含有点とTi最高含有点とが所定間隔をおいて交互に繰り返し存在し、かつ前記Zr最高含有点から前記Ti最高含有点、前記Ti最高含有点から前記Zr最高含有点へZrおよびTiの含有量が連続的に変化する成分濃度分布構造をもつた(Zr,Ti)CN層からなる硬質被覆層が形成されるようになること。
【0008】
(b)上記(a)の繰り返し連続変化成分濃度分布構造の(Zr,Ti)CN層において、
上記Zr最高含有点が、
組成式:(Zr1-XTiX)C1-ZZ(ただし、原子比で、X:0.02〜0.20、Z:0.40〜0.60)、
上記Ti最高含有点が、
組成式:(Ti1-YZrY)C1-ZZ(ただし、原子比で、Y:0.02〜0.20、Z:0.40〜0.60)、
を満足し、かつ隣り合う上記Zr最高含有点と上記Ti最高含有点の厚さ方向の間隔を0.01〜0.2μmとすると、
上記Zr最高含有点部分では、Zrが主体を占め、これの作用によってきわめて高い強度を示し、一方上記Ti最高含有点部分では、Tiが主体を占め、これの作用によって高い硬さを示すようになり、かつこれらZr最高含有点と上記Ti最高含有点の間隔をきわめて小さくしたことから、層全体の特性として高強度と高硬度を具備するようになり、したがって、硬質被覆層がかかる構成の(Zr,Ti)CN層からなる被覆超硬工具は、各種の鋼や鋳鉄などの切削加工を、特に高い機械的衝撃を伴う重切削を、高速切削条件で行なった場合にも、硬質被覆層にチッピングの発生なく、すぐれた耐摩耗性を発揮するようになること。
以上(a)および(b)に示される研究結果を得たのである。
【0009】
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、超硬基体の表面に、(Zr,Ti)CN層からなる硬質被覆層を1〜15μmの全体平均層厚で蒸着してなる被覆超硬工具において、
上記硬質被覆層が、層厚方向にそって、Zr最高含有点とTi最高含有点とが所定間隔をおいて交互に繰り返し存在し、かつ前記Zr最高含有点から前記Ti最高含有点、前記Ti最高含有点から前記Zr最高含有点へZrとTiの含有量が連続的に変化する成分濃度分布構造を有し、
さらに、上記Zr最高含有点が、
組成式:(Zr1-XTiX)C1-ZZ(ただし、原子比で、X:0.02〜0.20、Z:0.40〜0.60)、
上記Ti最高含有点が、
組成式:(Ti1-YZrY)C1-ZZ(ただし、原子比で、Y:0.02〜0.20、Z:0.40〜0.60)、
を満足し、かつ隣り合う上記Zr最高含有点と上記Ti最高含有点の間隔が、0.01〜0.2μmである、
高速重切削条件で硬質被覆層がすぐれた耐摩耗性を発揮する被覆超硬工具に特徴を有するものである。
【0010】
つぎに、この発明の被覆超硬工具において、これを構成する硬質被覆層の組成を上記の通りに限定した理由を説明する。
(a)Zr最高含有点のX値
上記の通り硬質被覆層である(Zr,Ti)CN層において、Zr成分には層の強度を向上させ、一方Ti成分には層の硬さを向上させる作用があり、したがって、層の厚さ方向に沿ってZr分の高いZr最高含有点を繰り返し形成して層自体の強度を全体的に向上させ、同じくTi成分の高いTi最高含有点を繰り返し形成して層自体の硬さを全体的に向上させるものであるが、この場合Tiの割合を示すX値がZrとの合量に占める割合(原子比、以下同じ)で0.02未満になると、高硬度を有するTi最高含有点が隣接して存在しても、Zr最高含有点に所定の硬さを確保することができず、これが摩耗促進の原因となり、一方同値が0.20を越えると、急激な強度低下が起り、この結果チッピングが発生し易くなることから、X値を0.02〜0.20と定めた。
【0011】
(b)Ti最高含有点のY値
上記の通りZr最高含有点は高強度を有するが、反面硬さが不十分であるため、このZr最高含有点の硬さ不足を補う目的で、高硬度を有するTi最高含有点を厚さ方向に交互に介在させるものである。しかし、Zrの割合を示すY値がTiとの合量に占める割合(原子比)で0.02未満になると、高強度を有するZr最高含有点が隣接して存在しても、Ti最高含有点に所定の強度を確保することができず、この結果チッピングが発生し易くなり、一方同値が0.20を越えると、急激な硬さ低下が起り、これが摩耗促進の原因となることから、Y値を0.02〜0.20と定めた。
【0012】
(c)Zr最高含有点およびTi最高含有点のZ値
また、上記の(Zr,Ti)CN層において、C成分には層の硬さを向上させ、一方N成分には層の強度を向上させる作用があるが、この(Zr,Ti)CN層では、層の強度および硬さの制御は上記の通りZr最高含有点およびTi最高含有点によって行なうようにし、層の硬さおよび強度に及ぼすC成分およびN成分の影響をほぼ同じものとするために、Zr最高含有点およびTi最高含有点におけるZ値を0.4〜0.60と定めたのである。すなわち、Z値が0.60を越えると、相対的にN成分の割合がC成分に比して多くなり過ぎ、一方Z値が0.40未満では相対的にC成分の割合がN成分の割合に比して多くなり過ぎ、いずれの場合も層の強度がおよび硬さに著しい変化が現れるようになり、層の強度および硬さを制御することが困難になることから、Z値を0.4〜0.60と定めたのである。
【0013】
(d)Zr最高含有点とTi最高含有点間の間隔
その間隔が0.01μm未満ではそれぞれの点を上記の組成で明確に形成することが困難であり、この結果層に所望のすぐれた高強度と高硬度を確保することができなくなり、またその間隔が0.2μmを越えるとそれぞれの点がもつ欠点、すなわちZr最高含有点であれば硬さ不足、Ti最高含有点であれば強度不足が層内に局部的に現れ、これが摩耗進行を促進したり、チッピングを発生し易くしたりする原因となることから、その間隔を0.01〜0.2μmと定めた。
【0014】
(d)硬質被覆層の全体平均層厚
その層厚が1μm未満では、所望の耐摩耗性を確保することができず、一方その平均層厚が15μmを越えると、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。
【0015】
【発明の実施の形態】
つぎに、この発明の被覆超硬工具を実施例により具体的に説明する。
原料粉末として、平均粒径:6.5μmを有する粗粒WC粉末、同3.5μmを有する中粒WC粉末、同0.8μmの微粒WC粉末、同1.3μmのTaC粉末、同1.2μmのNbC粉末、同1.2μmのZrC粉末、同2.3μmのCr32粉末、同1.0μmの(Ti,W)CN(質量比で、TiC/TiN/WC=24/20/56)粉末、および同1.8μmのCo粉末を用意し、これら原料粉末をそれぞれ表1に示される配合組成に配合し、ボールミルで72時間混合し、減圧乾燥した後、100MPa の圧力で圧粉体にプレス成形し、この圧粉体を、表面部にCo富化層を形成するものについては13.3Pa、そして全体に亘って均一組織を有するものについては6.7Paの真空中、温度:1430℃に1時間保持の条件で焼結し、焼結後、切刃部分にR:0.08のホーニング加工を施してISO規格・CNMG160612のチップ形状をもったWC基超硬合金製の超硬基体A1〜A10を形成した。なお、超硬基体A−1、A−3、A−4、A−6、A−7、およびA−9の表面部にCo富化層の形成が見られた。
【0016】
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(重量比でTiC/TiN=50/50)粉末、Mo2 C粉末、ZrC粉末、NbC粉末、TaC粉末、WC粉末、Co粉末、およびNi粉末を用意し、これら原料粉末を、表2に示される配合組成に配合し、ボールミルで24時間湿式混合し、乾燥した後、100MPaの圧力で圧粉体にプレス成形し、この圧粉体を2kPaの炭素雰囲気中、温度:1500℃に1時間保持の条件で焼結し、焼結後、切刃部分にR:0.10のホーニング加工を施してISO規格・CNMG160612のチップ形状をもったTiCN系サーメット製の超硬基体B1〜B6を形成した。
【0017】
つぎに、上記の超硬基体A1〜A10およびB1〜B6のそれぞれを、アセトン中で超音波洗浄し、乾燥した後、図1に示される化学蒸着装置内に、第2図に示される超硬基体支持パレットの位置決め穴に載置した状態で装入し、まず、装置内をヒーターで900℃に加熱したところで、TiCl4:4.2%、N2:30%、H2:残りからなる組成を有する反応ガスを反応ガス吹き出し管を通して導入して、装置内の反応雰囲気圧力を30kPaとし、この状態で20分間保持して前記超硬基体表面に、下地密着層として0.3μmの平均層厚をもった窒化チタン(TiN)層を形成し、ついで、同じく装置内の雰囲気温度をヒーターにて加熱して1020℃とした後、図3に示される反応ガス組成自動制御システムの反応ガス組成および流量中央制御装置に、過去の実績データにしたがって、表3,4にそれぞれ示される目標組成のZr最高含有点(Zr−1〜Zr−8)およびTi最高含有点(Ti−1〜Ti−8)に対応する反応ガス組成、前記Zr最高含有点とTi最高含有点間のZrとTiの含有量の連続変化および炭素と窒素の含有量に対応する反応ガス組成、さらに表5に示される前記両点間の目標間隔および硬質被覆層の目標全体層厚をインプットし、この反応ガス組成および流量中央制御装置からの信号にしたがって作動するコントロールバルブ内蔵の原料ガス流量自動制御装置を通して、原料ガスであるH2ガス、N2ガス、CH4ガス、TiCl4ガス、およびZrCl4ガス(この場合、前記TiCl4ガスは図示の通り流量制御されたH2ガスをキャリアガスとしてTiCl4ガス気化器に送り、ここで液体から気化されたTiCl4と共に原料ガス流量自動制御装置に送られ、また前記ZrCl4ガスは、ZrCl4発生器で金属Zrと流量制御されたHClガスを反応させることにより形成される)を、それぞれのガス流量を自動制御しながら、図1の化学蒸着装置の反応ガス吹き出し管から装置内に導入し(装置内の反応雰囲気圧力は常に7kPaに保持される)、もって前記超硬基体の表面に、層厚方向に沿って表3,4に示される目標組成のZr最高含有点とTi最高含有点とが交互に同じく表5に示される目標間隔で繰り返し存在し、かつ前記Zr最高含有点から前記Ti最高含有点、前記Ti最高含有点から前記Zr最高含有点へ実質的にZrとTiの含有量がそれぞれ連続的に変化する成分濃度分布構造を有し、かつ同じく表5に示される目標全体層厚の硬質被覆層を蒸着することにより、本発明被覆超硬工具としての本発明表面被覆超硬合金製スローアウエイチップ(以下、本発明被覆超硬チップと云う)1〜16をそれぞれ製造した。
【0018】
また、比較の目的で、上記の超硬基体A1〜A10およびB1〜B6を、アセトン中で超音波洗浄し、乾燥した後、同じくそれぞれ図1,2に示される通常の化学蒸着装置に装入し、上記したTiN層形成条件と同じ条件で下地密着層として0.3μmの平均層厚を有するTiN層を形成し、ついで反応雰囲気温度を1020℃に加熱した後、それぞれ表6に示される目標組成に対応した組成の反応ガスを反応ガス吹き出し管から導入し、反応雰囲気圧力を7kPaに一定とした条件で、前記超硬基体A1〜A10およびB1〜B6のそれぞれの表面に、表6,7に示される目標組成および目標層厚を有し、かつ層厚方向に沿って実質的に組成変化のない(Zr,Ti)CN層からなる硬質被覆層を蒸着することにより、従来被覆超硬工具としての従来表面被覆超硬合金製スローアウエイチップ(以下、従来被覆超硬チップと云う)1〜16をそれぞれ製造した。
【0019】
つぎに、上記本発明被覆超硬チップ1〜16および従来被覆超硬チップ1〜16について、これを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・SCM415の丸棒、
切削速度:360m/min.、
切り込み:5.0mm、
送り:0.28mm/rev.、
切削時間:10分、
の条件での合金鋼の乾式連続高速高切り込み切削加工試験、
被削材:JIS・S25Cの長さ方向等間隔4本縦溝入り丸棒、
切削速度:360m/min.、
切り込み:1.0mm、
送り:0.5mm/rev.、
切削時間:10分、
の条件での炭素鋼の乾式断続高速高送り切削加工試験、さらに、
被削材:JIS・FC250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:5.5mm、
送り:0.30mm/rev.、
切削時間:10分、
の条件での鋳鉄の乾式断続高速高切り込み切削加工試験を行い、いずれの切削加工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4〜7に示した。
【0020】
【表1】

Figure 0003948020
【0021】
【表2】
Figure 0003948020
【0022】
【表3】
Figure 0003948020
【0023】
【表4】
Figure 0003948020
【0024】
【表5】
Figure 0003948020
【0025】
【表6】
Figure 0003948020
【0026】
【表7】
Figure 0003948020
【0027】
この結果得られた本発明被覆超硬チップ1〜16および従来被覆超硬チップ1〜16を構成する硬質被覆層について、厚さ方向に沿ってZr、Ti、炭素、および窒素の含有量をオージェ分光分析装置を用いて測定したところ、本発明被覆超硬チップ1〜16の硬質被覆層では、Zr最高含有点とTi最高含有点とがそれぞれ目標値と実質的に同じ組成および間隔で交互に繰り返し存在し、かつZr最高含有点からTi最高含有点、前記Ti最高含有点からZr最高含有点へZrとTiの含有量が連続的に変化する成分濃度分布構造を有することが確認され、また、硬質被覆層の全体平均層厚も目標全体層厚と実質的に同じ値を示した。一方前記従来被覆超硬チップ1〜16の硬質被覆層では厚さ方向に沿って組成変化が見られず、かつ目標組成と実質的に同じ組成および目標全体層厚と実質的に同じ全体平均層厚を示すことが確認された。
【0028】
【発明の効果】
表3〜7に示される結果から、硬質被覆層が層厚方向に、相対的にすぐれた高強度を有するZr最高含有点と相対的に高硬度を有するTi最高含有点とが交互に所定間隔をおいて繰り返し存在し、かつ前記Zr最高含有点から前記Ti最高含有点、前記Ti最高含有点から前記Zr最高含有点へZrとTiの含有量が連続的に変化する成分濃度分布構造を有する本発明被覆超硬チップ1〜16は、いずれも各種の鋼や鋳鉄などの切削加工を、高速で、かつ高い機械的衝撃を伴う高切り込みや高送りなどの重切削条件で行なった場合にも、硬質被覆層がチッピングの発生なく、すぐれた耐摩耗性を発揮するのに対して、硬質被覆層が層厚方向に沿って実質的に組成変化のない従来被覆超硬チップ1〜16においては、特に高い機械的衝撃を伴う高速重切削条件では強度不足が原因でチッピングが発生し、硬さ不足と相俟って、比較的短時間で使用寿命に至ることが明らかである。
上述のように、この発明の被覆超硬工具は、通常の条件での切削加工は勿論のこと、特に各種の鋼や鋳鉄などの切削加工を、高速で、かつ高い機械的衝撃を伴う高切り込みや高送りなどの重切削条件で行なった場合にも、すぐれた耐摩耗性と耐チッピング性を発揮し、長期に亘ってすぐれた切削性能を示すものであるから、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。
【図面の簡単な説明】
【図1】被覆超硬工具を構成する硬質被覆層を形成するのに用いられている化学蒸着装置を例示する概略縦断面図である。
【図2】化学蒸着装置の構造部材である超硬基体支持パレットを示し、(a)が概略斜視図、(b)が概略平面図である。
【図3】この発明の被覆超硬工具を構成する硬質被覆層の形成に用いられる反応ガス組成自動制御システムの概略チャート図である。[0001]
BACKGROUND OF THE INVENTION
In this invention, the hard coating layer has high strength and high hardness. Therefore, cutting of various steels and cast irons is performed at high speeds, particularly at high speeds and with high mechanical impacts such as high cutting and high feed. The present invention relates to a surface-coated cemented carbide cutting tool (hereinafter referred to as a coated cemented carbide tool) that exhibits excellent wear resistance without occurrence of chipping (microchips) or the like.
[0002]
[Prior art]
In general, coated carbide tools are used for throwaway inserts that are detachably attached to the tip of a cutting tool for drilling and cutting of various materials such as steel and cast iron, and for flat cutting. There are drills, miniature drills, solid type end mills used for chamfering, grooving, shoulder processing, etc. Also, the throwaway tip is detachably attached and cutting is performed in the same way as the solid type end mill Throwaway end mill tools are known.
[0003]
Further, as a coated carbide tool, a substrate made of tungsten carbide (hereinafter referred to as WC) -based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN) -based cermet (hereinafter collectively referred to as a cemented carbide substrate). ) On the surface, in atomic ratio,
Composition formula: (Zr 1-X Ti X ) C 1-Z N Z (in terms of atomic ratio, X: 0.40 to 0.60, Z: 0.40 to 0.60),
A coated carbide tool formed by vapor-depositing a hard coating layer composed of a Zr and Ti composite carbonitride [hereinafter referred to as (Zr, Ti) CN] layer satisfying the following conditions is proposed: It is also known to exhibit excellent cutting performance when used for continuous cutting and intermittent cutting of various steels and cast iron (see, for example, Patent Document 1).
[0004]
Furthermore, as shown in the schematic longitudinal sectional view of FIG. 1, for example, the coated carbide tool has a stainless steel reaction gas blowing pipe standing at the center thereof. A graphite cemented carbide substrate support pallet illustrated in a schematic perspective view in (a) and a schematic plan view in (b) is skewered and laminated, and these are heated by a heater through a stainless steel cover. A chemical vapor deposition apparatus having a structure is used, and the cemented carbide substrate is mounted on the chemical vapor deposition apparatus in a state where the carbide substrate is placed as illustrated in a number of reaction gas passage hole positions formed on the bottom surface of the carbide substrate support pallet. Enter
Reaction gas composition (by volume%): ZrCl 4: 0.05~5% , TiCl 4: 0.1~6%, CH 3 CN: 0.6~5%, N 2: 0.5~40%, H 2 : Remaining
Reaction atmosphere temperature: 900-1050 ° C.
Reaction atmosphere pressure: 5 to 50 kPa,
It is also known that it is manufactured by forming a hard coating layer made of (Zr, Ti) CN under the conditions (see, for example, Patent Document 2).
[0005]
[Patent Document 1]
Japanese Patent Laid-Open No. 62-56564 [Patent Document 2]
Japanese Patent Laid-Open No. 2001-11632
[Problems to be solved by the invention]
In recent years, there has been a remarkable increase in performance of cutting devices. On the other hand, there is a strong demand for labor saving, energy saving, and cost reduction for cutting processing. Although there is a tendency to require cutting under heavy cutting conditions such as high feed, there is no problem when using the above conventional coated carbide tools under normal cutting conditions. When machining is performed at high speed and under heavy cutting conditions such as high cutting and high feed with high mechanical impact, the wear of the hard coating layer is further progressed due to insufficient strength and hardness of the hard coating layer. Since it promotes and chipping easily occurs, the service life is reached in a relatively short time.
[0007]
[Means for Solving the Problems]
In view of the above, the present inventors have developed the above-mentioned conventional coated carbide tool in order to develop a coated carbide tool that exhibits excellent wear resistance with a hard coating layer particularly under high-speed heavy cutting conditions. As a result of conducting research focusing on the hard coating layer that composes
(A) The (Zr, Ti) CN layer constituting the conventional coated carbide tool formed using the chemical vapor deposition apparatus shown in FIGS. 1 and 2 is substantially uniform over the entire thickness. In forming a (Zr, Ti) CN layer, which has a composition and thus a uniform hardness and strength, for example, the reaction gas composition automatic control system shown in FIG. For the purpose of alternately forming the Zr highest content point and the Ti highest content point at predetermined intervals along the layer thickness direction in the hard coating layer made of the (Zr, Ti) CN layer in the flow rate central control device, Reaction gas composition corresponding to the Zr highest content point and Ti highest content point, reaction gas composition corresponding to the continuous change of Zr and Ti between the two points, and the distance between the two points and the entire hard coating layer Over thickness And input on the basis of the actual data, in accordance with a control signal from the reaction gas composition and flow rates central controller, H 2 gas from the raw material gas cylinder, CH 4 gas, N 2 gas, and the HCl gas flow rate, further ZrCl 4 When the gas and TiCl 4 gas flow rates are controlled by the respective raw material flow rate automatic control devices and introduced into the reaction gas blowing pipe of the chemical vapor deposition device, the Zr highest content point and the Ti highest content point along the layer thickness direction In which Zr and Ti contents continuously change from the highest Zr content point to the highest Ti content point and from the highest Ti content point to the highest Zr content point. A hard coating layer composed of a (Zr, Ti) CN layer having a concentration distribution structure is formed.
[0008]
(B) In the (Zr, Ti) CN layer having the repeated continuous change component concentration distribution structure of (a) above,
The Zr highest content point is
Composition formula: (Zr 1-X Ti X ) C 1-Z N Z (in terms of atomic ratio, X: 0.02 to 0.20, Z: 0.40 to 0.60),
The highest Ti content point is
Composition formula: (Ti 1-Y Zr Y ) C 1-Z N Z (in terms of atomic ratio, Y: 0.02 to 0.20, Z: 0.40 to 0.60),
And the distance in the thickness direction between the adjacent highest Zr content point and the highest Ti content point is 0.01 to 0.2 μm,
In the Zr highest content point portion, Zr occupies the main body and exhibits an extremely high strength by its action, while in the Ti highest content point portion, Ti occupies the main body and exhibits a high hardness by the action. And the distance between the highest Zr content point and the highest Ti content point is extremely small, so that the entire layer has high strength and high hardness. Coated carbide tools composed of Zr, Ti) CN layers are hard coating layers even when cutting various steels and cast iron, especially when heavy cutting with high mechanical impact is performed under high-speed cutting conditions. Exhibit excellent wear resistance without chipping.
The research results shown in (a) and (b) above were obtained.
[0009]
The present invention has been made on the basis of the above research results, and a hard coating layer composed of a (Zr, Ti) CN layer is deposited on the surface of a cemented carbide substrate with an overall average layer thickness of 1 to 15 μm. In the coated carbide tool
In the hard coating layer, the Zr highest content point and the Ti highest content point are alternately present at predetermined intervals along the layer thickness direction, and from the Zr highest content point, the Ti highest content point, the Ti A component concentration distribution structure in which the content of Zr and Ti continuously changes from the highest content point to the Zr highest content point,
Furthermore, the Zr highest content point is
Composition formula: (Zr 1-X Ti X ) C 1-Z N Z (in terms of atomic ratio, X: 0.02 to 0.20, Z: 0.40 to 0.60),
The highest Ti content point is
Composition formula: (Ti 1-Y Zr Y ) C 1-Z N Z (in terms of atomic ratio, Y: 0.02 to 0.20, Z: 0.40 to 0.60),
And the interval between the adjacent highest Zr content point and the highest Ti content point is 0.01 to 0.2 μm.
It is characterized by a coated carbide tool that exhibits excellent wear resistance with a hard coating layer under high-speed heavy cutting conditions.
[0010]
Next, the reason why the composition of the hard coating layer constituting the coated carbide tool of the present invention is limited as described above will be described.
(A) X value of highest Zr content point As described above, in the (Zr, Ti) CN layer that is a hard coating layer, the Zr component improves the layer strength, while the Ti component improves the layer hardness. Therefore, the highest Zr content point with a high Zr content is repeatedly formed along the thickness direction of the layer to improve the overall strength of the layer itself, and the highest Ti content point with a high Ti component is also repeatedly formed. In this case, when the X value indicating the proportion of Ti is less than 0.02 in terms of the proportion of the total amount with Zr (atomic ratio, hereinafter the same). Even if the highest Ti content point having high hardness exists adjacently, the predetermined hardness cannot be secured at the highest Zr content point, which causes wear promotion, while the same value exceeds 0.20. And sudden drop in strength, resulting in chipping Since the easily without, defining the X value as 0.02 to 0.20.
[0011]
(B) Y value of the highest Ti content point As described above, the highest Zr content point has high strength, but on the other hand, the hardness is insufficient. Ti highest content points having s are alternately interposed in the thickness direction. However, if the Y value indicating the ratio of Zr is less than 0.02 in terms of the total amount with Ti (atomic ratio), even if there are adjacent Zr highest content points having high strength, the highest Ti content The predetermined strength cannot be ensured at the point, and as a result, chipping is likely to occur. On the other hand, if the same value exceeds 0.20, a rapid decrease in hardness occurs, which causes acceleration of wear. The Y value was determined to be 0.02 to 0.20.
[0012]
(C) Z value of highest Zr content point and highest Ti content point In the above (Zr, Ti) CN layer, the C component improves the layer hardness, while the N component improves the layer strength. In this (Zr, Ti) CN layer, the strength and hardness of the layer are controlled by the Zr highest content point and the Ti highest content point as described above, and this affects the hardness and strength of the layer. In order to make the influence of the C component and the N component almost the same, the Z value at the Zr highest content point and the Ti highest content point was set to 0.4 to 0.60. That is, when the Z value exceeds 0.60, the proportion of the N component is relatively larger than that of the C component, whereas when the Z value is less than 0.40, the proportion of the C component is relatively small. The Z value is reduced to 0 because the strength and hardness of the layer will change significantly in each case, and it will be difficult to control the strength and hardness of the layer. .4 to 0.60.
[0013]
(D) Interval between the highest Zr content point and the highest Ti content point If the distance is less than 0.01 μm, it is difficult to clearly form each point with the above composition. Strength and high hardness cannot be ensured, and if the distance exceeds 0.2 μm, each point has a defect, that is, if the Zr highest content point is insufficient hardness, if the Ti highest content point is insufficient strength Appear locally in the layer, which promotes the progress of wear and facilitates chipping, so the interval was determined to be 0.01 to 0.2 μm.
[0014]
(D) Overall average layer thickness of hard coating layer If the layer thickness is less than 1 μm, desired wear resistance cannot be ensured. On the other hand, if the average layer thickness exceeds 15 μm, chipping tends to occur. Therefore, the average layer thickness was determined to be 1 to 15 μm.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Next, the coated carbide tool of the present invention will be specifically described with reference to examples.
As raw material powder, a coarse WC powder having an average particle size of 6.5 μm, a medium WC powder having the same 3.5 μm, a fine WC powder having the same 0.8 μm, a TaC powder having the same 1.3 μm, and 1.2 μm being the same. NbC powder, 1.2 μm ZrC powder, 2.3 μm Cr 3 C 2 powder, 1.0 μm (Ti, W) CN (by mass ratio, TiC / TiN / WC = 24/20/56) ) Powder and Co powder of 1.8 μm were prepared, and each of these raw material powders was blended in the blending composition shown in Table 1, mixed in a ball mill for 72 hours, dried under reduced pressure, and then compacted at a pressure of 100 MPa. In this case, the green compact is formed into a vacuum at 13.3 Pa for the one having a Co-enriched layer on the surface and 6.7 Pa for one having a uniform structure throughout, and the temperature: 1430 Baked at ℃ for 1 hour And, after sintering, R the cutting edge portion: forming a WC-based cemented carbide superhard substrate A1~A10 having a tip shape of ISO standard · CNMG160612 subjected to honing of 0.08. In addition, formation of Co-enriched layers was observed on the surface portions of the carbide substrates A-1, A-3, A-4, A-6, A-7, and A-9.
[0016]
In addition, as raw material powders, all are TiCN (weight ratio TiC / TiN = 50/50) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder 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 then pressed into a compact at a pressure of 100 MPa. The green compact was sintered in a carbon atmosphere of 2 kPa at a temperature of 1500 ° C. for 1 hour, and after sintering, the cutting edge portion was subjected to a honing process of R: 0.10, and ISO standard / CNMG160612. TiCN-based cermet carbide substrates B1 to B6 having the following chip shape were formed.
[0017]
Next, each of the above-mentioned carbide substrates A1 to A10 and B1 to B6 is ultrasonically cleaned in acetone and dried, and then the carbide shown in FIG. 2 is placed in the chemical vapor deposition apparatus shown in FIG. First, when the inside of the apparatus was heated to 900 ° C. with a heater, it was loaded with TiCl 4 : 4.2%, N 2 : 30%, H 2 : remaining. A reaction gas having a composition is introduced through a reaction gas blowing tube, the reaction atmosphere pressure in the apparatus is set to 30 kPa, and this state is maintained for 20 minutes, and an average layer of 0.3 μm is formed on the surface of the cemented carbide substrate as a base adhesion layer. After forming a titanium nitride (TiN) layer having a thickness and then heating the atmospheric temperature in the apparatus to 1020 ° C. with a heater, the reaction gas composition of the reaction gas composition automatic control system shown in FIG. and In accordance with the past actual data, the Zr highest content point (Zr-1 to Zr-8) and the Ti highest content point (Ti-1 to Ti-8) of the target compositions shown in Tables 3 and 4, respectively. ), The reaction gas composition corresponding to the continuous change of the Zr and Ti contents between the highest Zr content point and the highest Ti content point, and the carbon and nitrogen contents, and the above-mentioned composition shown in Table 5 The target distance between the two points and the total target layer thickness of the hard coating layer are input, and the feed gas is fed through the feed gas automatic control device with a built-in control valve that operates according to the reaction gas composition and the signal from the central flow control device. A certain H 2 gas, N 2 gas, CH 4 gas, TiCl 4 gas, and ZrCl 4 gas (in this case, the TiCl 4 gas is a H 2 gas whose flow rate is controlled as shown in the figure. To the TiCl 4 gas vaporizer, where it is sent together with TiCl 4 vaporized from the liquid to the raw material gas flow rate automatic control device, and the ZrCl 4 gas is flow-controlled with ZrCl 4 metal and Zr metal flow rate 1 is introduced into the apparatus from the reaction gas blowing pipe of the chemical vapor deposition apparatus in FIG. 1 (the reaction atmosphere pressure in the apparatus is always 7 kPa). Therefore, the Zr highest content point and Ti highest content point of the target composition shown in Tables 3 and 4 along the layer thickness direction are alternately arranged on the surface of the cemented carbide substrate. Repeatedly exist at intervals, and the Zr and Ti content changes substantially continuously from the highest Zr content point to the highest Ti content point and from the highest Ti content point to the highest Zr content point. The surface-coated cemented carbide throwaway tip of the present invention as a coated carbide tool of the present invention is deposited by vapor-depositing a hard coating layer having a component concentration distribution structure as shown in Table 5 and also having the target total layer thickness shown in Table 5 Hereinafter, the coated carbide chips of the present invention were produced.
[0018]
Further, for the purpose of comparison, the above-mentioned carbide substrates A1 to A10 and B1 to B6 are ultrasonically cleaned in acetone and dried, and then charged into ordinary chemical vapor deposition apparatuses shown in FIGS. Then, a TiN layer having an average layer thickness of 0.3 μm is formed as a base adhesion layer under the same conditions as the TiN layer formation conditions described above, and then the reaction atmosphere temperature is heated to 1020 ° C. A reaction gas having a composition corresponding to the composition was introduced from the reaction gas blowing tube, and the reaction atmosphere pressure was kept constant at 7 kPa, on the surfaces of the carbide substrates A1 to A10 and B1 to B6. A conventional coated carbide tool is formed by depositing a hard coating layer composed of a (Zr, Ti) CN layer having a target composition and a target layer thickness shown in FIG. When Te conventional surface-coated cemented carbide indexable (hereinafter, conventional coating called carbide inserts) were 1-16 were prepared, respectively.
[0019]
Next, with the present invention coated carbide tips 1-16 and conventional coated carbide tips 1-16, in a state where this is screwed to the tip of the tool steel tool with a fixing jig,
Work material: JIS / SCM415 round bar,
Cutting speed: 360 m / min. ,
Cutting depth: 5.0mm,
Feed: 0.28 mm / rev. ,
Cutting time: 10 minutes,
Dry-type continuous high-speed high-cut cutting test of alloy steel under the conditions of
Work material: JIS-S25C round bar with four equal grooves in the longitudinal direction,
Cutting speed: 360 m / min. ,
Cutting depth: 1.0 mm,
Feed: 0.5 mm / rev. ,
Cutting time: 10 minutes,
Dry intermittent high-speed high-feed cutting test of carbon steel under the conditions of
Work material: JIS · FC250 lengthwise equal length 4 round bar with round groove,
Cutting speed: 400 m / min. ,
Cutting depth: 5.5 mm,
Feed: 0.30 mm / rev. ,
Cutting time: 10 minutes,
A dry interrupted high-speed high-cut cutting test of cast iron was performed under the conditions described above, and the flank wear width of the cutting edge was measured in any cutting test. The measurement results are shown in Tables 4-7.
[0020]
[Table 1]
Figure 0003948020
[0021]
[Table 2]
Figure 0003948020
[0022]
[Table 3]
Figure 0003948020
[0023]
[Table 4]
Figure 0003948020
[0024]
[Table 5]
Figure 0003948020
[0025]
[Table 6]
Figure 0003948020
[0026]
[Table 7]
Figure 0003948020
[0027]
For the hard coating layers constituting the coated carbide chips 1 to 16 of the present invention and the conventional coated carbide chips 1 to 16 obtained as a result, the contents of Zr, Ti, carbon, and nitrogen along the thickness direction were Auger. When measured using a spectroscopic analyzer, in the hard coating layers of the coated carbide chips 1 to 16 of the present invention, the highest Zr content point and the highest Ti content point alternately with the same composition and interval as the target value, respectively. It is confirmed that it has a component concentration distribution structure that repeatedly exists and the Zr and Ti contents continuously change from the highest Zr content point to the highest Ti content point and from the highest Ti content point to the highest Zr content point. The overall average layer thickness of the hard coating layer also showed substantially the same value as the target overall layer thickness. On the other hand, in the hard coating layers of the conventional coated carbide chips 1 to 16, no composition change is observed along the thickness direction, and the composition is substantially the same as the target composition and the overall average layer thickness is substantially the same as the target overall layer thickness. It was confirmed to show thickness.
[0028]
【The invention's effect】
From the results shown in Tables 3 to 7, the hard coating layer has a Zr highest content point having a relatively high strength and a Ti highest content point having a relatively high hardness alternately in the layer thickness direction at predetermined intervals. And a component concentration distribution structure in which the Zr and Ti contents continuously change from the highest Zr content point to the highest Ti content point and from the highest Ti content point to the highest Zr content point. The coated carbide tips 1 to 16 of the present invention can be used when cutting various steels and cast irons at high speeds and under heavy cutting conditions such as high cutting and high feed with high mechanical impact. In the conventional coated carbide chips 1-16, the hard coating layer exhibits excellent wear resistance without occurrence of chipping, whereas the hard coating layer has substantially no composition change along the layer thickness direction. With particularly high mechanical shock Fast chipping occurs because insufficient strength in severe cutting conditions, I hardness shortage coupled with, it is clear that lead to a relatively short time service life.
As described above, the coated carbide tool of the present invention is capable of cutting various steels and cast irons as well as cutting under normal conditions at high speed and with high mechanical impact. Even under heavy cutting conditions such as high feed and high feed, it exhibits excellent wear resistance and chipping resistance and exhibits excellent cutting performance over a long period of time. It is possible to cope with the reduction of cost and cost.
[Brief description of the drawings]
FIG. 1 is a schematic longitudinal sectional view illustrating a chemical vapor deposition apparatus used for forming a hard coating layer constituting a coated carbide tool.
2A and 2B show a cemented carbide substrate support pallet that is a structural member of a chemical vapor deposition apparatus, in which FIG. 2A is a schematic perspective view, and FIG. 2B is a schematic plan view.
FIG. 3 is a schematic chart of a reaction gas composition automatic control system used for forming a hard coating layer constituting the coated carbide tool of the present invention.

Claims (1)

炭化タングステン基超硬合金基体または炭窒化チタン系サーメット基体の表面に、ZrとTiの複合炭窒化物層からなる硬質被覆層を1〜15μmの全体平均層厚で蒸着してなる表面被覆超硬合金製切削工具において、
上記硬質被覆層が、層厚方向にそって、Zr最高含有点とTi最高含有点とが所定間隔をおいて交互に繰り返し存在し、かつ前記Zr最高含有点から前記Ti最高含有点、前記Ti最高含有点から前記Zr最高含有点へZrとTiの含有量が連続的に変化する成分濃度分布構造を有し、
さらに、上記Zr最高含有点が、
組成式:(Zr1-XTiX)C1-ZZ(ただし、原子比で、X:0.02〜0.20、Z:0.40〜0.60)、
上記Ti最高含有点が、
組成式:(Ti1-YZrY)C1-ZZ(ただし、原子比で、Y:0.02〜0.20、Z:0.40〜0.60)、
を満足し、かつ隣り合う上記Zr最高含有点と上記Ti最高含有点の間隔が、0.01〜0.2μmであること、
を特徴とする高速重切削条件で硬質被覆層がすぐれた耐摩耗性を発揮する表面被覆超硬合金製切削工具。
Surface-coated carbide formed by vapor-depositing a hard coating layer composed of a composite carbonitride layer of Zr and Ti on the surface of a tungsten carbide-based cemented carbide substrate or a titanium carbonitride cermet substrate with an overall average layer thickness of 1 to 15 μm. In alloy cutting tools,
In the hard coating layer, the Zr highest content point and the Ti highest content point are alternately present at predetermined intervals along the layer thickness direction, and from the Zr highest content point, the Ti highest content point, the Ti A component concentration distribution structure in which the contents of Zr and Ti continuously change from the highest content point to the highest Zr content point,
Furthermore, the Zr highest content point is
Composition formula: (Zr 1-X Ti X ) C 1-Z N Z (in terms of atomic ratio, X: 0.02 to 0.20, Z: 0.40 to 0.60),
The highest Ti content point is
Composition formula: (Ti 1-Y Zr Y ) C 1-Z N Z (however, in atomic ratio, Y: 0.02 to 0.20, Z: 0.40 to 0.60),
And the interval between the adjacent highest Zr content point and the highest Ti content point is 0.01 to 0.2 μm,
A surface-coated cemented carbide cutting tool that exhibits excellent wear resistance under high-speed heavy cutting conditions.
JP2002231265A 2002-08-08 2002-08-08 Surface-coated cemented carbide cutting tool with excellent wear resistance under high-speed heavy cutting conditions. Expired - Fee Related JP3948020B2 (en)

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