JP4853621B2 - Surface polishing method for cutting throwaway tip made of surface-covered cermet whose hard coating layer exhibits excellent chipping resistance in high-speed cutting - Google Patents
Surface polishing method for cutting throwaway tip made of surface-covered cermet whose hard coating layer exhibits excellent chipping resistance in high-speed cutting Download PDFInfo
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この発明は、特に各種の鋼や鋳鉄などの高速切削加工に用いた場合に、硬質被覆層がすぐれた耐チッピング性を発揮する表面被覆サーメット製切削スローアウエイチップ（以下、被覆切削チップという）の表面研磨方法に関するものである。 The present invention is a surface-coated cermet cutting throwaway tip (hereinafter referred to as a coated cutting tip) that exhibits excellent chipping resistance with a hard coating layer, particularly when used for high-speed cutting of various steels and cast irons . The present invention relates to a surface polishing method .
従来、一般に、図３に概略斜視図で示される通り、炭化タングステン（以下、ＷＣで示す）基超硬合金または炭窒化チタン（以下、ＴｉＣＮで示す）基サーメットで構成され、かつ中心部に工具取りつけ孔を有する基体（以下、これらを総称してチップ基体という）の切刃稜線部を含むすくい面および逃げ面の全面に、
（ａ−１）下部層として、炭化チタン（以下、ＴｉＣで示す）層、窒化チタン（以下、同じくＴｉＮで示す）層、炭窒化チタン（以下、ＴｉＣＮで示す）層、炭酸化チタン（以下、ＴｉＣＯで示す）層、および炭窒酸化チタン（以下、ＴｉＣＮＯで示す）層のうちの１層または２層以上からなり、かつ３〜２０μｍの全体平均層厚を有するＴｉ化合物層、
（ａ−２）上部層として、１〜１５μｍの平均層厚を有し、かつ化学蒸着した状態で酸化アルミニウム（以下、Ａｌ ２ Ｏ ３ で示す）と酸化ジルコニウム（以下、ＺｒＯ ２ で示す）の２相混合酸化物組織を有する２相混合酸化物層（以下、Ａｌ２Ｏ３−ＺｒＯ２層で示す）、
以上（ａ−１）および（ａ−２）で構成された硬質被覆層を蒸着形成してなる被覆切削チップが知られており、この被覆切削チップが、例えば各種の鋼や鋳鉄などの連続切削や断続切削に用いられることは良く知られている。
Conventionally, generally, as shown in a schematic perspective view in FIG. 3, it is composed of a tungsten carbide (hereinafter referred to as WC) -based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN) -based cermet, and a tool at the center. On the entire surface of the rake face and the flank face including the cutting edge ridge line portion of the base body (hereinafter collectively referred to as a chip base body) having mounting holes,
(A-1) As a lower layer, a titanium carbide (hereinafter referred to as TiC) layer, a titanium nitride (hereinafter also referred to as TiN) layer, a titanium carbonitride (hereinafter referred to as TiCN) layer, a titanium carbonate (hereinafter referred to as "TiN"). A Ti compound layer composed of one or more of a layer represented by TiCO) and a titanium carbonitride oxide (hereinafter represented by TiCNO) layer and having an overall average layer thickness of 3 to 20 μm,
As (a-2) an upper layer has an average layer thickness of 1 to 15 m, and chemical in vapor state aluminum oxide (hereinafter, Al 2 O indicated by 3) and zirconium oxide (hereinafter indicated by ZrO 2) of A two-phase mixed oxide layer having a two-phase mixed oxide structure (hereinafter referred to as an Al 2 O 3 —ZrO 2 layer),
A coated cutting tip formed by vapor-depositing the hard coating layer constituted by the above (a-1) and (a-2) is known, and this coated cutting tip is, for example, continuous cutting of various types of steel and cast iron. It is well known that it is used for intermittent cutting.
そして、上記Ａｌ２Ｏ３−ＺｒＯ２層は、次のような条件で化学蒸着することにより形成されることが知られている。
（イ）反応ガス組成（体積％）
ＡｌＣｌ３： １〜１０ ％、
ＺｒＣｌ４： ０．０１〜１０ ％、
ＣＯ2 ： １〜３０ ％、
ＨＣｌ： １〜３０ ％、
Ｈ２Ｓ： ０．０１〜１ ％、
Ｈ2：残り、
（ロ）反応雰囲気温度 ： ９００〜１０５０ ℃、
（ハ）反応雰囲気圧力 ： ４〜７０ ｋＰａ（３０〜５２５ ｔｏｒｒ）。
The Al 2 O 3 —ZrO 2 layer is known to be formed by chemical vapor deposition under the following conditions.
(B) Reaction gas composition (volume%)
AlCl 3 : 1 to 10%,
ZrCl 4: 0.01~10%,
CO 2: 1~30%,
HCl: 1-30%,
H 2 S: 0.01~1%,
H 2 : Remaining
(B) Reaction atmosphere temperature: 900 to 1050 ° C.
(C) Reaction atmosphere pressure: 4 to 70 kPa (30 to 525 torr).
また、上記の被覆切削チップにおいて、これの硬質被覆層の構成層は、一般に粒状結晶組織を有し、さらに、下部層であるＴｉ化合物層を構成するＴｉＣＮ層を、層自身の強度向上を目的として、通常の化学蒸着装置にて、反応ガスとして有機炭窒化物を含む混合ガスを使用し、７００〜９５０℃の中温温度域で化学蒸着することにより形成して縦長成長結晶組織をもつようにすることも知られている。
さらに、被覆切削チップの硬質被覆層を構成する上部層の表面を、切削性能を向上させる目的でウエットブラスト処理して、平滑化することも知られている。
Furthermore, it is also known to smooth the surface of the upper layer constituting the hard coating layer of the coated cutting tip by wet blasting for the purpose of improving the cutting performance.
近年の切削装置の高性能化はめざましく、一方で切削加工に対する省力化および省エネ化、さらに低コスト化の要求は強く、これに伴い、切削加工は高速化の傾向にあるが、上記の従来被覆切削チップにおいては、これを鋼や鋳鉄などの通常の条件での連続切削や断続切削に用いた場合には問題はないが、特に切削速度が３５０ｍ／ｍｉｎ．を越える高速で切削加工を行なうのに用いた場合には、硬質被覆層の上部層を構成する２相混合酸化物層にチッピング（微少欠け）が発生し易く、この結果比較的短時間で使用寿命に至るのが現状である。 In recent years, the performance of cutting equipment has been remarkable. On the other hand, there is a strong demand for labor saving and energy saving and further cost reduction for cutting, and along with this, cutting tends to be faster. The cutting tip has no problem when it is used for continuous cutting or intermittent cutting under normal conditions such as steel or cast iron, but the cutting speed is 350 m / min. When used for cutting at a high speed exceeding 1, the two-phase mixed oxide layer constituting the upper layer of the hard coating layer is likely to chip (small chipping), and as a result, used in a relatively short time. The current situation is that it reaches the end of its life.
そこで、本発明者等は、上述のような観点から、上記Ａｌ２Ｏ３−ＺｒＯ２層が硬質被覆層の上部層を構成する被覆切削チップに着目し、特にＡｌ２Ｏ３−ＺｒＯ２層の耐チッピング性向上を図るべく研究を行った結果、
（ａ）上記の従来被覆切削チップにおける硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の表面に、ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％の酸化アルミニウム微粒（以下、Ａｌ2Ｏ3微粒で示す）を配合した研磨液を噴射して、研磨すると、前記Ａｌ２Ｏ３−ＺｒＯ２層は、準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定（以下の表面粗さは全てかかる準拠規格に基いた測定値を示す）で、Ｒａ：０．３〜０．６μｍの表面粗さを示すようになるが、この結果の前記Ａｌ２Ｏ３−ＺｒＯ２層の表面を、ウエットブラストにてＲａ：０．３〜０．６μｍの表面粗さに平滑化した被覆切削チップを用いても、切削速度が３５０ｍ／ｍｉｎ．を越えた高速切削加工では切刃部におけるチッピング発生を満足に抑制することはできないこと。
The present inventors have, from the viewpoint as described above, focuses on coated cutting tip the Al 2 O 3 -ZrO 2 layers constituting the upper layer of the hard coating layer, in particular Al 2 O 3 -ZrO 2 layers As a result of research to improve chipping resistance of
(A) On the surface of the Al 2 O 3 —ZrO 2 layer constituting the upper layer of the hard coating layer in the above-mentioned conventional coated cutting tip, the ratio of the wet blast to the total amount of water as the spray abrasive When a polishing liquid containing 15 to 60% by mass of aluminum oxide fine particles (hereinafter referred to as Al 2 O 3 fine particles) is sprayed and polished, the Al 2 O 3 —ZrO 2 layer is compliant with JIS B0601- In the measurement based on 1994 (the following surface roughness shows the measured value based on all such standards), the surface roughness of Ra: 0.3 to 0.6 μm is shown. Even when a coated cutting tip in which the surface of the Al 2 O 3 —ZrO 2 layer was smoothed to a surface roughness of Ra: 0.3 to 0.6 μm by wet blasting, the cutting speed was 350 m / min. High-speed cutting that exceeds the limit cannot effectively suppress chipping at the cutting edge.
（ｂ）一方、図２に概略斜視図で示される通り、上記の従来被覆切削チップにおける硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の切刃稜線部を含むすくい面および逃げ面の全面に、
（ｂ−１）まず、下側層として、反応ガス組成を、体積％で、
ＴｉＣｌ4：０．２〜１０％、
ＣＯ2 ：０．１〜１０％、
Ａｒ ：５〜６０％、
Ｈ2 ：残り、
とし、かつ、
反応雰囲気温度：８００〜１１００℃、
反応雰囲気圧力：４〜７０ｋＰａ（３０〜５２５ｔｏｒｒ）、
とした条件で、０．１〜３μｍの平均層厚を有し、かつ、オージェ分光分析装置で測定して、Ｔｉに対する酸素の割合が原子比で１．２５〜１．９０、即ち、
組成式：ＴｉＯW 、
で表わした場合、
Ｗ：原子比で１．２５〜１．９０、
を満足する酸化チタン層を形成し、
（ｂ−２）ついで、上記酸化チタン層（下側層）の上に、上側層として、通常の条件、即ち、反応ガス組成を、体積％で、
ＴｉＣｌ4：０．２〜１０％、
Ｎ2 ：４〜６０％、
Ｈ2 ：残り、
とし、かつ、
反応雰囲気温度：８００〜１１００℃、
反応雰囲気圧力：４〜９０ｋＰａ（３０〜６７５ｔｏｒｒ）、
とした条件で、０．０５〜２μｍの平均層厚を有するＴｉＮ層を形成すると、
（ｂ−３）上記ＴｉＮ層（上側層）形成時に、上記下側層を構成する酸化チタン層の酸素が拡散してきて前記上側層（ＴｉＮ層）が、窒酸化チタン層で構成されるようになるが、この場合上記上側層（前記窒酸化チタン層）形成後の上記下側層である酸化チタン層は、厚さ方向中央部をオージェ分光分析装置で測定して、酸素の割合がＴｉに対する原子比で１．２〜１．７、即ち、
組成式：ＴｉＯＸ 、
で表わした場合、
Ｘ：原子比で１．２〜１．７、
を満足する酸化チタン層となり、
（ｂ−４）また、上記窒酸化チタン層で構成された上側層は、同じく厚さ方向中央部をオージェ分光分析装置で測定して、拡散酸素の割合が窒素（Ｎ）に対する原子比で０．０１〜０．４、即ち、
組成式：ＴｉＮ１−Ｙ（Ｏ）Ｙ、
で表わした場合（ただし、（Ｏ）は上側層の蒸着形成時における上記下側層である酸化チタン層からの拡散酸素を示す）、
Ｙ：原子比で０．０１〜０．４、
を満足する窒酸化チタン層となること。
(B) On the other hand, as shown in the schematic perspective view of FIG. 2, the rake face including the cutting edge ridge portion of the Al 2 O 3 —ZrO 2 layer constituting the upper layer of the hard coating layer in the conventional coated cutting tip and On the entire flank,
(B-1) First, as the lower layer, the reaction gas composition is in volume%,
TiCl 4 : 0.2 to 10%,
CO 2 : 0.1 to 10%,
Ar: 5 to 60%
H 2 : Remaining
And
Reaction atmosphere temperature: 800-1100 ° C.
Reaction atmosphere pressure: 4 to 70 kPa (30 to 525 torr),
And having an average layer thickness of 0.1 to 3 μm and a ratio of oxygen to Ti of 1.25 to 1.90 as measured by an Auger spectrometer,
Composition formula: TiO W ,
In the case of
W: 1.25 to 1.90 in atomic ratio,
Forming a titanium oxide layer that satisfies
(B-2) Next, on the titanium oxide layer (lower layer), as an upper layer, the normal conditions, that is, the reaction gas composition in volume%,
TiCl 4 : 0.2 to 10%,
N 2 : 4-60%,
H 2 : Remaining
And
Reaction atmosphere temperature: 800-1100 ° C.
Reaction atmosphere pressure: 4 to 90 kPa (30 to 675 torr),
When a TiN layer having an average layer thickness of 0.05 to 2 μm is formed under the conditions described above,
(B-3) When forming the TiN layer (upper layer), oxygen in the titanium oxide layer constituting the lower layer is diffused so that the upper layer (TiN layer) is composed of a titanium nitride oxide layer. In this case, the titanium oxide layer, which is the lower layer after the formation of the upper layer (the titanium oxynitride layer), is measured by an Auger spectroscopic analyzer at the center in the thickness direction. 1.2 to 1.7 in atomic ratio,
Composition formula: TiO x ,
In the case of
X: 1.2 to 1.7 in atomic ratio,
Titanium oxide layer that satisfies
(B-4) Further, the upper layer composed of the above titanium oxynitride layer was also measured at the center in the thickness direction with an Auger spectroscopic analyzer, and the proportion of diffused oxygen was 0 in terms of atomic ratio with respect to nitrogen (N). .01-0.4, i.e.
Composition formula: TiN 1-Y (O) Y ,
(Where, (O) represents diffused oxygen from the titanium oxide layer as the lower layer when the upper layer is deposited ),
Y: 0.01 to 0.4 in atomic ratio
Titanium nitride oxide layer that satisfies
（ｃ）上記窒酸化チタン層（上側層）および酸化チタン層（下側層）を蒸着形成した状態で、
上記（ａ）におけると同じくウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％のＡｌ2Ｏ3微粒を配合した研磨液を噴射すると、前記窒酸化チタン層および酸化チタン層は、前記Ａｌ2Ｏ3微粒によって粉砕微粒化し、窒酸化チタン微粒および酸化チタン微粒となって前記Ａｌ2Ｏ3微粒の共存下で研磨材として作用し、硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の表面を研磨することになり、この結果研磨後の前記Ａｌ２Ｏ３−ＺｒＯ２層の表面は、Ｒａ：０．２μｍ以下の表面粗さにまで平滑化されるようになり、この上部層であるＡｌ２Ｏ３−ＺｒＯ２層の表面がＲａ：０．２μｍ以下の表面粗さに平滑化した被覆切削チップを用いて、高速切削加工を行った場合、３５０ｍ／ｍｉｎ．を越える切削速度でも切刃部におけるチッピング発生が防止され、前記硬質被覆層は長期に亘ってすぐれた耐摩耗性を発揮するようになること。
(C) In a state where the titanium nitride oxide layer (upper layer) and the titanium oxide layer (lower layer) are formed by vapor deposition,
When a polishing liquid containing 15 to 60% by mass of Al 2 O 3 fine particles as a spraying abrasive in a ratio to the total amount of water is sprayed by wet blasting as in (a) above, the titanium nitride oxide The layer and the titanium oxide layer are pulverized and pulverized by the Al 2 O 3 fine particles, become titanium oxynitride fine particles and titanium oxide fine particles, and act as an abrasive in the presence of the Al 2 O 3 fine particles. will be polishing the surface of the Al 2 O 3 -ZrO 2 layer constituting the layer, the surface of the Al 2 O 3 -ZrO 2 layer after the results polishing, Ra: a surface roughness of not more than 0.2μm Using the coated cutting tip in which the surface of the upper layer Al 2 O 3 —ZrO 2 layer is smoothed to a surface roughness of Ra: 0.2 μm or less, high-speed cutting is performed. If done, 350m / Min. Chipping at the cutting edge is prevented even at a cutting speed exceeding 1, and the hard coating layer exhibits excellent wear resistance over a long period of time.
（ｄ）上記の通り、切削速度が３５０ｍ／ｍｉｎ．を越えた高速切削加工では、被覆切削チップの切刃部に懸かる負荷はきわめて高いものになるため、特にフライス切削の場合、工具本体への被覆切削チップの取り付けに際しては、きわめて高い締め付け力で取り付けが行なわれることになり、この結果被覆切削チップの工具取り付け孔周辺部の硬質被覆層に対する圧縮応力はきわめて高いものとなるので、特に上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層は、ビッカース硬さ（Ｈｖ）で約２４００の高硬度を有することと相俟って、これに割れが発生し易くなり、これが原因で硬質被覆層に剥離やチッピングが発生するようになるが、図１に概略斜視図で示される通り、前記ウエットブラストに際して、工具取り付け孔周辺部を研磨せず、この部分の研磨材層を残した状態にしておくと、上記の研磨材層を構成する窒酸化チタン層（上側層）および酸化チタン層（下側層）はいずれも前記Ａｌ２Ｏ３−ＺｒＯ２層に比して、相対的にきわめて低いＨｖ：約２０００の硬さをもつものであるため、工具本体への被覆切削チップの取り付けに際して、高い締め付け力の緩衝層として作用し、この結果前記Ａｌ２Ｏ３−ＺｒＯ２層に対する圧縮応力が著しく小さなものとなることから、剥離やチッピング発生の原因となる割れ発生が防止されるようになること。
以上（ａ）〜（ｄ）に示される研究結果を得たのである。
(D) As described above, the cutting speed is 350 m / min. In high-speed cutting processing exceeding 1, the load applied to the cutting edge of the coated cutting tip is extremely high. Therefore, especially in the case of milling, the coated cutting tip is attached to the tool body with a very high clamping force. As a result, the compressive stress on the hard coating layer around the tool mounting hole of the coated cutting tip becomes extremely high, and in particular, the Al 2 O 3 —ZrO 2 layer constituting the upper layer is made of Vickers. Combined with having a high hardness (Hv) of about 2400, it is easy for cracks to occur, which causes peeling and chipping on the hard coating layer. As shown in the schematic perspective view, during the wet blasting, the peripheral part of the tool attachment hole is not polished, and the abrasive layer of this part is left, Both oxynitride titanium layer constituting the serial abrasive layer (upper layer) and a titanium oxide layer (lower layer) is compared to the Al 2 O 3 -ZrO 2 layer, a relatively very low Hv: about Since it has a hardness of 2000, it acts as a buffer layer with a high clamping force when the coated cutting tip is attached to the tool body, and as a result, the compressive stress on the Al 2 O 3 —ZrO 2 layer is extremely small Therefore, the generation of cracks that cause peeling and chipping is prevented.
The research results shown in (a) to (d) above were obtained.
この発明は、上記の研究結果に基づいてなされたものであって、ＷＣ基超硬合金またはＴｉＣＮ基サーメットで構成され、かつ中心部に工具取り付け孔を有するチップ基体の切刃稜線部を含むすくい面および逃げ面の全面に、
（ａ−１）下部層として、ＴｉＣ層、ＴｉＮ層、ＴｉＣＮ層、ＴｉＣＯ層、およびＴｉＣＮＯ層のうちの１層または２層以上からなり、かつ３〜２０μｍの全体平均層厚を有するＴｉ化合物層、
（ａ−２）上部層として、１〜１５μｍの平均層厚を有し、化学蒸着した状態でＡｌ ２ Ｏ ３ とＺｒＯ ２ の２相混合酸化物組織を有し、かつ、前記ＺｒＯ ２ は、Ｚｒの含有割合に換算して、層中に含有するＡｌとＺｒの合量に占める割合（原子比）で０．０１〜０．２０であるＡｌ２Ｏ３−ＺｒＯ２層、
以上（ａ−１）および（ａ−２）で構成された硬質被覆層を化学蒸着形成してなる被覆切削チップの表面研磨方法にして、
（１）上記硬質被覆層の上部層であるＡｌ２Ｏ３−ＺｒＯ２層の全面に、
（ｂ−１）下側層として、０．１〜３μｍの平均層厚を有し、かつ、
組成式：ＴｉＯＸ 、
で表わした場合、厚さ方向中央部をオージェ分光分析装置で測定して、
Ｘ：原子比で１．２〜１．７、
を満足する酸化チタン層、
（ｂ−２）上側層として、０．０５〜２μｍの平均層厚を有し、かつ、
組成式：ＴｉＮ１−Ｙ（Ｏ）Ｙ、
で表わした場合（ただし、（Ｏ）は上側層の蒸着形成時における上記下側層である酸化チタン層からの拡散酸素を示す）、同じく厚さ方向中央部をオージェ分光分析装置で測定して、同じく原子比で、
Ｙ：原子比で０．０１〜０．４、
を満足する窒酸化チタン層、
以上（ｂ−１）および（ｂ−２）で構成された研磨材層を化学蒸着形成し、
（２）ついで、ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％のＡｌ2Ｏ3微粒を配合した研磨液を噴射し、
上記の研磨材層が噴射研磨材であるＡｌ 2 Ｏ 3 微粒の噴射により粉砕微粒化してなる粉砕化酸化チタン微粒（下側層）および粉砕化窒酸化チタン微粒（上側層）と、噴射研磨材としてのＡｌ2Ｏ3微粒の共存下で、上記工具取り付け孔周辺部の研磨材層を残して、上記硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の表面を研磨して、前記Ａｌ ２ Ｏ ３ −ＺｒＯ ２ 層の切刃稜線部を含むすくい面および逃げ面の表面粗さを準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定で、Ｒａ：０．２μｍ以下としてなる、硬質被覆層が高速切削加工ですぐれた耐チッピング性を発揮する被覆切削チップの表面研磨方法に特徴を有するものである。
The present invention has been made on the basis of the above research results, and includes a cutting edge ridge portion of a chip base made of a WC-based cemented carbide or TiCN-based cermet and having a tool mounting hole in the center. On the entire surface and flank,
(A-1) As a lower layer, a Ti compound layer composed of one or more of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer, and a TiCNO layer and having an overall average layer thickness of 3 to 20 μm ,
(A-2) As an upper layer, it has an average layer thickness of 1 to 15 μm, has a two-phase mixed oxide structure of Al 2 O 3 and ZrO 2 in a chemical vapor deposited state, and the ZrO 2 is Converted to the content ratio of Zr, an Al 2 O 3 —ZrO 2 layer having a ratio (atomic ratio) in the total amount of Al and Zr contained in the layer of 0.01 to 0.20,
In the surface polishing method of the coated cutting tip formed by chemical vapor deposition of the hard coating layer composed of (a-1) and (a-2) above,
( 1 ) On the entire surface of the Al 2 O 3 —ZrO 2 layer, which is the upper layer of the hard coating layer,
(B-1) The lower layer has an average layer thickness of 0.1 to 3 μm, and
Composition formula: TiO x ,
, Measure the central part in the thickness direction with an Auger spectrometer,
X: 1.2 to 1.7 in atomic ratio,
Satisfying titanium oxide layer,
(B-2) The upper layer has an average layer thickness of 0.05 to 2 μm, and
Composition formula: TiN 1-Y (O) Y ,
(However, (O) indicates the diffused oxygen from the titanium oxide layer, which is the lower layer when the upper layer is formed by vapor deposition ). Similarly, the central portion in the thickness direction is measured with an Auger spectrometer. , Also in atomic ratio,
Y: 0.01 to 0.4 in atomic ratio
Satisfying titanium oxynitride layer,
Abrasive material layer composed of (b-1) and (b-2) above is formed by chemical vapor deposition,
( 2 ) Next , in wet blasting, as a spraying abrasive, a polishing liquid containing 15 to 60% by mass of Al 2 O 3 fine particles in a proportion of the total amount with water is sprayed.
Abrasive titanium oxide fine particles (lower layer) and pulverized titanium oxynitride fine particles (upper layer) formed by pulverizing and atomizing the above-mentioned abrasive layer by spraying Al 2 O 3 fine particles, which are spray abrasives, and jet abrasives The surface of the Al 2 O 3 —ZrO 2 layer that constitutes the upper layer of the hard coating layer is polished in the presence of Al 2 O 3 fine particles, leaving the abrasive layer around the tool mounting hole. The surface roughness of the rake face and the flank face including the cutting edge ridge line portion of the Al 2 O 3 —ZrO 2 layer is measured based on JIS / B0601-1994, and Ra is 0.2 μm or less. The coating layer has a feature in the surface polishing method of a coated cutting tip that exhibits excellent chipping resistance in high-speed cutting.
以下に、この発明の被覆切削チップの表面研磨方法において、硬質被覆層および研磨材層、さらにウエットブラストで用いられる研磨液のＡｌ2Ｏ3微粒に関して、上記の通りに数値限定した理由を説明する。
（ａ）硬質被覆層
（ａ−１）下部層のＴｉ化合物層
Ｔｉ化合物層は、Ａｌ ２ Ｏ ３ −ＺｒＯ ２ 層の下部層として存在し、自身の具備するすぐれた高温強度によって硬質被覆層の高温強度向上に寄与するほか、チップ基体とＡｌ ２ Ｏ ３ −ＺｒＯ ２ 層のいずれにも強固に密着し、よって硬質被覆層のチップ基体に対する密着性を向上させる作用を有するが、その全体平均層厚が３μｍ未満では、前記作用を十分に発揮させることができず、一方その全体平均層厚が２０μｍを越えると、特に高熱発生を伴なう高速切削では熱塑性変形を起し易くなり、これが偏摩耗の原因となることから、その全体平均層厚を３〜２０μｍと定めた。
Hereinafter, in the surface polishing method of the coated cutting tip of the present invention, the reason why the hard coating layer, the abrasive layer, and the Al 2 O 3 fine particles of the polishing liquid used in wet blasting are numerically limited as described above will be described. .
(A) hard coating layer (a-1) Ti compound layer Ti compound layer of the lower layer is present as a lower layer of Al 2 O 3 -ZrO 2 layer, the hard coating layer by excellent high temperature strength which includes its own In addition to contributing to the improvement of high-temperature strength, it has a function of firmly adhering to both the chip base and the Al 2 O 3 —ZrO 2 layer , thereby improving the adhesion of the hard coating layer to the chip base. If the thickness is less than 3 μm, the above-mentioned effect cannot be sufficiently exerted. On the other hand, if the total average layer thickness exceeds 20 μm, thermoplastic deformation tends to occur particularly in high-speed cutting accompanied by high heat generation. Since it causes wear, the overall average layer thickness is determined to be 3 to 20 μm.
（ａ−２）上部層のＡｌ２Ｏ３−ＺｒＯ２層
Ａｌ２Ｏ３−ＺｒＯ２層からなる上部層は、そのＡｌ成分によって、すぐれた高温硬さと耐熱性を、また、そのＺｒ成分によって、すぐれた高温強度を備え、被覆切削チップの切削性能（耐チッピング性、耐摩耗性）向上に寄与するが、Ａｌ２Ｏ３−ＺｒＯ２層におけるＺｒＯ ２ の含有割合は、Ｚｒの含有割合に換算して、層中に含有するＡｌとＺｒの合量に占める割合（＝Ｚｒ／（Ａｌ＋Ｚｒ））で、０．０１〜０．２０但し、原子比）の範囲内のものとする。Ａｌ２Ｏ３−ＺｒＯ２層におけるＺｒＯ ２ の含有割合を示すこの値が０．０１未満であると、上部層の高温強度の向上の効果が少なく、一方、この値が０．２０を超えると、上部層におけるＡｌ ２ Ｏ ３ 量の相対的な減少により高温硬さ、耐熱性の低下が生じ、その結果として耐摩耗性劣化の傾向がみられるので、Ａｌ２Ｏ３−ＺｒＯ２層におけるＺｒＯ ２ の含有割合（原子比で換算したＺｒ／（Ａｌ＋Ｚｒ）の値）を、上記のとおり、０．０１〜０．２０の範囲内の値とする。
また、その平均層厚が１μｍ未満では、所望のすぐれた切削性能を長期に亘って発揮させることができず、一方その平均層厚が１５μｍを越えて厚くなりすぎると、チッピングが発生し易くなることから、その平均層厚を１〜１５μｍと定めた。
(A-2) an upper layer made of Al 2 O 3 -ZrO 2-layer Al 2 O 3 -ZrO 2 layers of upper layer by its Al component, an excellent high-temperature hardness and heat resistance and, by that Zr component Although it has excellent high-temperature strength and contributes to improving the cutting performance (chipping resistance, wear resistance) of the coated cutting tip, the content ratio of ZrO 2 in the Al 2 O 3 —ZrO 2 layer is equal to the content ratio of Zr. In terms of conversion, the ratio (= Zr / (Al + Zr)) in the total amount of Al and Zr contained in the layer is within the range of 0.01 to 0.20 (atomic ratio). When this value indicating the content ratio of ZrO 2 in the Al 2 O 3 —ZrO 2 layer is less than 0.01, the effect of improving the high-temperature strength of the upper layer is small, whereas when this value exceeds 0.20 Since the relative decrease in the amount of Al 2 O 3 in the upper layer causes a decrease in high-temperature hardness and heat resistance, and as a result, there is a tendency for wear resistance degradation, ZrO in the Al 2 O 3 —ZrO 2 layer The content ratio of 2 (value of Zr / (Al + Zr) converted by atomic ratio) is set to a value within the range of 0.01 to 0.20 as described above.
Further, if the average layer thickness is less than 1 μm, the desired excellent cutting performance cannot be exhibited over a long period of time. On the other hand, if the average layer thickness exceeds 15 μm, chipping is likely to occur. Therefore, the average layer thickness was determined to be 1 to 15 μm.
（ｂ）研磨材層
上側層を構成する窒酸化チタン層は、上記の通り、まず、酸素の割合をＮに対する原子比で１．２５〜１．９０（Ｗ値）とした酸化チタン層を形成し、ついで、前記酸化チタン層の上に通常の条件でＴｉＮ層を蒸着することにより形成されるものであり、したがって前記ＴｉＮ層形成時における前記酸化チタン層からの酸素の拡散が不可欠となるが、前記酸化チタン層のＷ値が１．２５未満であると、前記ＴｉＮ層への酸素の拡散反応が急激に低下し、上側層における拡散酸素の割合（Ｙ値）を原子比で０．０１以上にすることができず、一方同Ｗ値が１．９０を越えると、前記上側層における拡散酸素の割合（Ｙ値）が原子比で０．４０を越えて多くなってしまうことから、Ｗ値を１．２５〜１．９０と定めたものであり、この場合上側層形成後の下側層（酸化チタン層）における酸素の割合（Ｘ値）は原子比で１．２〜１．７の範囲内の値をとるようになる、言い換えれば上側層形成後の下側層のＸ値が１．２〜１．７を満足する場合に、前記上側層のＹ値は０．０１〜０．４０を満足するものとなる。
また、この場合、下側層のＸ値および上側層のＹ値をそれぞれ１．２〜１．７および０．０１〜０．４０と定めたのは、前記Ｘ値およびＹ値が前記の値をとった場合に、これら研磨材層のウエットブラスト時における粉砕微粒化が好適な状態で行なわれ、すぐれた研磨機能を十分に発揮することが多くの試験結果から得られ、これらの試験結果に基いて定めたものである。したがって、前記Ｘ値およびＹ値がそれぞれ１．２〜１．７および０．０１〜０．４０の範囲から外れると、前記研磨材層のウエットブラスト時における粉砕微粒化が満足に行なわれず、すぐれた研磨機能を期待することができない。
さらに、上側層および下側層の平均層厚を、それぞれ０．０５〜２μｍおよび０．１〜３μｍとしたのは、その平均層厚が０．０５μｍ未満および０．１μｍ未満では、ウエットブラスト時における下側層の粉砕化酸化チタン微粒、上側層の粉砕化窒酸化チタン微粒の割合が少な過ぎて、研磨機能を十分に発揮することができず、一方、その平均層厚がそれぞれ２μｍおよび３μｍを越えても、研磨機能が急激に低下するようになり、いずれの場合もＡｌ２Ｏ３−ＺｒＯ２層の表面をＲａ：０．２μｍ以下の表面粗さに研磨することができなくなるという理由にもとづくものである。
(B) Abrasive material layer As described above, the titanium oxynitride layer constituting the upper layer first forms a titanium oxide layer in which the oxygen ratio is 1.25 to 1.90 (W value) in terms of the atomic ratio to N. Then, it is formed by depositing a TiN layer on the titanium oxide layer under normal conditions. Therefore, diffusion of oxygen from the titanium oxide layer during the formation of the TiN layer is indispensable. When the W value of the titanium oxide layer is less than 1.25, the diffusion reaction of oxygen into the TiN layer is drastically reduced, and the ratio of diffused oxygen (Y value) in the upper layer is 0.01 by atomic ratio. On the other hand, if the same W value exceeds 1.90, the ratio of diffused oxygen (Y value) in the upper layer will increase beyond 0.40 in terms of atomic ratio. The value is defined as 1.25 to 1.90, In this case, the oxygen ratio (X value) in the lower layer (titanium oxide layer) after the upper layer formation takes an atomic ratio in the range of 1.2 to 1.7, in other words, the upper layer formation. When the X value of the later lower layer satisfies 1.2 to 1.7, the Y value of the upper layer satisfies 0.01 to 0.40.
In this case, the X value of the lower layer and the Y value of the upper layer are set to 1.2 to 1.7 and 0.01 to 0.40, respectively. It is obtained from many test results that these abrasive layers are pulverized and atomized in a suitable state at the time of wet blasting, and exhibit an excellent polishing function sufficiently. Based on this. Therefore, if the X value and Y value are out of the range of 1.2 to 1.7 and 0.01 to 0.40, respectively, the pulverization and atomization at the time of wet blasting of the abrasive layer is not satisfactorily performed, which is excellent. The polishing function cannot be expected.
Further, the average layer thicknesses of the upper layer and the lower layer were set to 0.05 to 2 μm and 0.1 to 3 μm, respectively, when the average layer thickness was less than 0.05 μm and less than 0.1 μm. The ratio of the pulverized titanium oxide fine particles in the lower layer and the fine pulverized titanium oxynitride fine particles in the upper layer is too small to perform the polishing function sufficiently, while the average layer thickness is 2 μm and 3 μm, respectively. The reason is that the polishing function is suddenly lowered even if the thickness exceeds 1, and in any case, the surface of the Al 2 O 3 —ZrO 2 layer cannot be polished to a surface roughness of Ra: 0.2 μm or less. It is based on.
（ｃ）研磨液のＡｌ2Ｏ3微粒の割合
研磨液のＡｌ2Ｏ3微粒には、ウエットブラスト時に研磨材層を構成する下側層の粉砕化酸化チタン微粒および上側層の粉砕化窒酸化チタン微粒と共存した状態で、Ａｌ２Ｏ３−ＺｒＯ２層の表面を研磨する作用があるが、その割合が水との合量に占める割合で１５質量％未満でも、また６０質量％を越えても研磨機能が急激に低下するようになることから、その割合を１５〜６０質量％と定めた。
(C) The Al 2 O 3 fine of Al 2 O 3 fine fraction polishing liquid of the polishing liquid, pulverization oxynitride of pulverized titanium oxide fine and the upper layer of the lower layer of the abrasive layer during wet blasting Although it acts to polish the surface of the Al 2 O 3 —ZrO 2 layer in the presence of titanium fine particles, the proportion of the total amount with water is less than 15% by mass or more than 60% by mass. However, since the polishing function is abruptly lowered, the ratio is determined to be 15 to 60% by mass.
この発明の方法で表面研磨された被覆切削チップは、硬質被覆層の上部層を構成するＡｌ ２ Ｏ ３ −ＺｒＯ ２ 層の切刃稜線部を含むすくい面および逃げ面が、Ｒａ：０．２μｍ以下の表面粗さに研磨され、さらに工具取り付け孔周辺部に存在する研磨材層が、工具本体への被覆切削チップの取り付けに際して、高速切削加工では不可欠の高い締め付け力の緩衝層として作用することから、前記Ａｌ ２ Ｏ ３ −ＺｒＯ ２ 層に対する圧縮応力が著しく小さなものとなり、この結果剥離やチッピング発生の原因となる割れ発生が防止されるようになることと相俟って、各種の鋼や鋳鉄などの切削加工を、切削速度が３５０ｍ／ｍｉｎ．を越える高速で行うのに用いた場合にも、すぐれた耐チッピング性を発揮し、使用寿命の一層の延命化を可能とするものである。 The coated cutting tip surface-polished by the method of the present invention has a rake face and a flank face including the cutting edge ridge line portion of the Al 2 O 3 —ZrO 2 layer constituting the upper layer of the hard coating layer, with Ra: 0.2 μm. The abrasive layer that is ground to the following surface roughness and that exists in the periphery of the tool mounting hole acts as a buffer layer with high clamping force, which is indispensable for high-speed cutting when attaching the coated cutting tip to the tool body. From the fact that the compressive stress on the Al 2 O 3 —ZrO 2 layer is remarkably small, and as a result, cracks that cause peeling and chipping are prevented, various steels and For cutting of cast iron and the like, the cutting speed is 350 m / min. Even when used for high-speed operation exceeding the above, excellent chipping resistance is exhibited, and the service life can be further extended.
つぎに、この発明の被覆切削チップの表面研磨方法を実施例により具体的に説明する。 Next, the method for polishing the surface of the coated cutting tip according to the present invention will be specifically described with reference to examples.
原料粉末として、いずれも１〜３μｍの平均粒径を有するＷＣ粉末、ＴｉＣ粉末、ＺｒＣ粉末、ＶＣ粉末、ＴａＣ粉末、ＮｂＣ粉末、Ｃｒ3Ｃ2粉末、ＴｉＮ粉末、ＴａＮ粉末、およびＣｏ粉末を用意し、これら原料粉末を、表１に示される配合組成に配合し、さらにワックスを加えてアセトン中で２４時間ボールミル混合し、減圧乾燥した後、９８ＭＰａの圧力で所定形状の圧粉体にプレス成形し、この圧粉体を５Ｐａの真空中、１３７０〜１４７０℃の範囲内の所定の温度に１時間保持の条件で真空焼結し、焼結後、切刃部にＲ：０．０７ｍｍのホーニング加工を施すことによりＩＳＯ・ＣＮＭＧ１２０４０８に規定するスローアウエイチップ形状をもったＷＣ基超硬合金製のチップ基体Ａ〜Ｆをそれぞれ製造した。 WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder, TaN powder, and Co powder all having an average particle diameter of 1 to 3 μm are prepared as raw material powders. These raw material powders were blended into the composition shown in Table 1, added with wax, ball milled in acetone for 24 hours, dried under reduced pressure, and pressed into a green compact with a predetermined shape at a pressure of 98 MPa. The green compact was vacuum sintered at a predetermined temperature in the range of 1370 to 1470 ° C. for 1 hour in a vacuum of 5 Pa. After sintering, the cutting edge portion was R: 0.07 mm honing By processing, chip bases A to F made of a WC-based cemented carbide having a throwaway tip shape defined in ISO · CNMG120408 were manufactured.
また、原料粉末として、いずれも０．５〜２μｍの平均粒径を有するＴｉＣＮ（質量比でＴｉＣ／ＴｉＮ＝５０／５０）粉末、Ｍｏ2Ｃ粉末、ＺｒＣ粉末、ＮｂＣ粉末、ＴａＣ粉末、ＷＣ粉末、Ｃｏ粉末、およびＮｉ粉末を用意し、これら原料粉末を、表２に示される配合組成に配合し、ボールミルで２４時間湿式混合し、乾燥した後、９８ＭＰａの圧力で圧粉体にプレス成形し、この圧粉体を１．３ｋＰａの窒素雰囲気中、温度：１５４０℃に１時間保持の条件で焼結し、焼結後、切刃部分にＲ：０．０７ｍｍのホーニング加工を施すことによりＩＳＯ規格・ＣＮＭＧ１２０４１２のチップ形状をもったＴｉＣＮ基サーメット製のチップ基体ａ〜ｆを形成した。 In addition, as raw material powders, TiCN (mass ratio TiC / TiN = 50/50) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder, all having an average particle diameter of 0.5 to 2 μm. Co powder and Ni powder are prepared, and these raw material powders are blended in the blending composition shown in Table 2, wet mixed by a ball mill for 24 hours, dried, and pressed into a compact at a pressure of 98 MPa. The green compact was sintered in a nitrogen atmosphere of 1.3 kPa at a temperature of 1540 ° C. for 1 hour, and after the sintering, the cutting edge portion was subjected to a honing process of R: 0.07 mm. TiCN base cermet chip bases a to f having a standard / CNMG12041 chip shape were formed.
ついで、これらのチップ基体Ａ〜Ｆおよびチップ基体ａ〜ｆのそれぞれを、通常の化学蒸着装置に装入し、
まず、表３（表３中のｌ−ＴｉＣＮは特開平６−８０１０号公報に記載される縦長成長結晶組織をもつＴｉＣＮ層の形成条件を示すものであり、これ以外は通常の粒状結晶組織の形成条件を示すものである）、および表４に示される条件にて、表７に示される目標層厚のＴｉ化合物層およびＡｌ２Ｏ３−ＺｒＯ２層を硬質被覆層の下部層および上部層として蒸着形成し（図３参照）、
ついで、研磨材層の下側層形成用酸化チタン層［ＴｉＯＷ（１）〜（６）のいずれか］を表５に示される条件で形成した後、上側層形成用窒化チタン層（ＴｉＮ層）を同じく表３に示される条件で、表７に示される目標層厚で蒸着形成して、表７に示される組成、すなわち厚さ方向中央部をオージェ分光分析装置で測定して、それぞれ表７に示されるＸ値およびＹ値の下側層および上側層からなる研磨材層を形成し（図２参照）、
引き続いて、上記の下側層および上側層からなる研磨材層形成の被覆切削チップに、表６に示されるブラスト条件で、かつ表７に示される組み合わせでウエットブラストを施して、工具取り付け孔周辺部に研磨材層を存在させた状態で、前記Ａｌ２Ｏ３−ＺｒＯ２層からなる上部層の切刃稜線部を含むすくい面および逃げ面を、同じく表７に示される表面粗さに研磨することにより本発明被覆切削チップ１〜１３をそれぞれ製造した（図１参照）。
Next, each of these chip bases A to F and chip bases a to f is charged into a normal chemical vapor deposition apparatus,
First, Table 3 (l-TiCN in Table 3 indicates the conditions for forming a TiCN layer having a vertically grown crystal structure described in JP-A No. 6-8010, and other than that, a normal granular crystal structure is shown. And the Ti compound layer and the Al 2 O 3 —ZrO 2 layer having the target layer thicknesses shown in Table 7 under the conditions shown in Table 4 and the lower and upper layers of the hard coating layer. As a vapor deposition (see FIG. 3),
Next, after forming the lower layer forming titanium oxide layer [any of TiO W (1) to (6)] under the conditions shown in Table 5, the upper layer forming titanium nitride layer (TiN layer) ) Under the same conditions as shown in Table 3, and with the target layer thickness shown in Table 7, the composition shown in Table 7, that is, the central portion in the thickness direction was measured with an Auger spectroscopic analyzer. Forming an abrasive layer composed of a lower layer and an upper layer of the X and Y values shown in FIG. 7 (see FIG. 2);
Subsequently, the coated cutting tip for forming the abrasive layer composed of the lower layer and the upper layer was subjected to wet blasting under the blasting conditions shown in Table 6 and in the combinations shown in Table 7, and the periphery of the tool mounting hole The rake face and flank face including the cutting edge ridge line part of the upper layer made of the Al 2 O 3 —ZrO 2 layer are polished to the surface roughness shown in Table 7 in the state where the abrasive layer is present in the part. By doing this, this invention coated cutting tip 1-13 was manufactured, respectively (refer FIG. 1).
また、比較の目的で、表８に示される通り、下側層および上側層からなる研磨材層の形成を行なわない以外は同一の条件で従来被覆切削チップ１〜１３をそれぞれ製造した。
この結果得られた従来被覆切削チップ１〜１３の硬質被覆層を構成するＡｌ２Ｏ３−ＺｒＯ２層のウエットブラスト後の表面粗さを表８に示した。
For comparison purposes, as shown in Table 8, conventionally coated cutting chips 1 to 13 were produced under the same conditions except that the abrasive layer composed of the lower layer and the upper layer was not formed.
Table 8 shows the surface roughness after wet blasting of the Al 2 O 3 —ZrO 2 layer constituting the hard coating layers of the conventional coated cutting chips 1 to 13 obtained as a result.
また、上記本発明被覆切削チップ１〜１３および従来被覆切削チップ１〜１３の硬質被覆層の構成層の厚さを走査型電子顕微鏡を用いて測定（縦断面測定）したところ、いずれも目標層厚と実質的に同じ平均層厚（５点測定の平均値）を示した。 Further, when the thicknesses of the constituent layers of the hard coating layer of the present invention-coated cutting chips 1 to 13 and the conventional coated cutting chips 1 to 13 were measured using a scanning electron microscope (longitudinal section measurement), both were target layers. The average layer thickness (average value of 5-point measurement) substantially the same as the thickness was shown.
つぎに、上記の本発明被覆切削チップ１〜１３および従来被覆切削チップ１〜１３の各種の被覆切削チップについて、いずれも工具鋼製バイトの先端部に固定治具にてネジ止めした状態で、
被削材：ＪＩＳ・ＦＣ２５０の丸棒、
切削速度： ６００ ｍ／ｍｉｎ、
切り込み： ２．０ ｍｍ、
送り： ０．３ ｍｍ／ｒｅｖ、
切削時間： １３ 分、
の条件（切削条件Ａという）での普通鋳鉄の乾式連続高速切削試験（通常の切削速度は２５０ｍ／ｍｉｎ）、
被削材：ＪＩＳ・Ｓ４５Ｃの長さ方向等間隔４本縦溝入り丸棒、
切削速度： ５００ ｍ／ｍｉｎ、
切り込み： ２．０ ｍｍ、
送り： ０．２５ ｍｍ／ｒｅｖ、
切削時間： ９ 分、
の条件（切削条件Ｂという）での炭素鋼の乾式断続高速切削試験（通常の切削速度は２００ｍ／ｍｉｎ）、さらに、
被削材：ＪＩＳ・ＳＣＭ４１５の丸棒、
切削速度： ５３０ ｍ／ｍｉｎ、
切り込み： １．５ ｍｍ、
送り： ０．３ ｍｍ／ｒｅｖ、
切削時間： １０ 分、
の条件（切削条件Ｃという）での合金鋼の乾式連続高速切削試験（通常の切削速度は２００ｍ／ｍｉｎ）を行い、いずれの切削試験でも切刃の逃げ面摩耗幅を測定した。この測定結果を表９に示した。
Next, for the various coated cutting chips of the present invention coated cutting chips 1 to 13 and the conventional coated cutting chips 1 to 13 described above, all of them are screwed to the tip of the tool steel tool with a fixing jig,
Work material: JIS / FC250 round bar,
Cutting speed: 600 m / min,
Cutting depth: 2.0 mm,
Feed: 0.3 mm / rev,
Cutting time: 13 minutes,
Dry continuous high-speed cutting test (normal cutting speed is 250 m / min) of normal cast iron under the following conditions (referred to as cutting condition A),
Work material: JIS · S45C lengthwise equal 4 round grooved round bars,
Cutting speed: 500 m / min,
Cutting depth: 2.0 mm,
Feed: 0.25 mm / rev,
Cutting time: 9 minutes,
Dry intermittent high speed cutting test (normal cutting speed is 200 m / min) of carbon steel under the above conditions (referred to as cutting conditions B),
Work material: JIS / SCM415 round bar,
Cutting speed: 530 m / min,
Cutting depth: 1.5 mm,
Feed: 0.3 mm / rev,
Cutting time: 10 minutes,
The dry continuous high-speed cutting test (normal cutting speed is 200 m / min) of the alloy steel under the above conditions (referred to as cutting condition C) was performed, and the flank wear width of the cutting edge was measured in any cutting test. The measurement results are shown in Table 9.
表７〜９に示される結果から、この発明の方法によって表面研磨された本発明被覆切削チップ１〜１３は、いずれも硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の切刃稜線部を含むすくい面および逃げ面が、Ｒａ：０．２μｍ以下の表面粗さに研磨され、さらに工具取り付け孔周辺部に存在する研磨材層が、工具本体への被覆切削チップの取り付けに際して、３５０ｍ／ｍｉｎを越える高速切削加工では不可欠の高い締め付け力の緩衝層として作用することから、剥離やチッピング発生の原因となる割れ発生が防止され、鋼および鋳鉄の高速切削加工で、すぐれた耐チッピング性を示し、長期に亘ってすぐれた切削性能を発揮するのに対して、硬質被覆層の上部層を構成するＡｌ２Ｏ３−ＺｒＯ２層の表面粗さが、Ｒａ：０．３〜０．６μｍを示す従来被覆切削チップ１〜１３においては、いずれも３５０ｍ／ｍｉｎを越える高速切削加工では、工具取り付けに高い締め付け力を必要とすることと相俟って、前記Ａｌ２Ｏ３−ＺｒＯ２層にチッピングが発生し、比較的短時間で使用寿命に至ることが明らかである。 From the results shown in Tables 7 to 9, the coated cutting chips 1 to 13 of the present invention, which were surface-polished by the method of the present invention, all cut the Al 2 O 3 —ZrO 2 layer constituting the upper layer of the hard coating layer. The rake face and flank face including the edge line are polished to a surface roughness of Ra: 0.2 μm or less, and the abrasive layer existing around the tool attachment hole is used to attach the coated cutting tip to the tool body. , It acts as a buffer layer with a high clamping force, which is indispensable for high-speed cutting exceeding 350 m / min. This prevents cracks that cause peeling and chipping, and provides excellent resistance to high-speed cutting of steel and cast iron. shows the chipping resistance, whereas exhibit excellent cutting performance over a long period of time, the surface roughness of the Al 2 O 3 -ZrO 2 layer constituting the upper layer of the hard coating layer, Ra: 0 In the conventional coated cutting chips 1-13 showing the 3～0.6Myuemu, in both high-speed cutting of over 350 meters / min, coupled with the fact that require high clamping force to the tool mounting, the Al 2 O It is clear that chipping occurs in the 3- ZrO 2 layer and the service life is reached in a relatively short time.
上述のように、この発明の方法によって表面研磨された被覆切削チップは、各種鋼や鋳鉄などの通常の条件での連続切削や断続切削は勿論のこと、特に切削加工を３５０ｍ／ｍｉｎを越えた高速で行う場合にもすぐれた耐チッピング性を示し、長期に亘ってすぐれた切削性能を発揮するものであるから、切削装置の高性能化並びに切削加工の省力化および省エネ化、さらに低コスト化に十分満足に対応できるものである。 As described above, the coated cutting tip surface-polished by the method of the present invention exceeds 350 m / min in particular, in addition to continuous cutting and intermittent cutting under normal conditions such as various steels and cast iron. Excellent chipping resistance even when performed at high speeds, and excellent cutting performance over a long period of time. Higher performance of cutting equipment, labor saving and energy saving of cutting, and cost reduction It is possible to cope with the above sufficiently.
Claims (1)
（ａ−１）下部層として、炭化チタン層、窒化チタン層、炭窒化チタン層、炭酸化チタン層、および炭窒酸化チタン層のうちの１層または２層以上からなり、かつ３〜２０μｍの全体平均層厚を有するＴｉ化合物層、
（ａ−２）上部層として、１〜１５μｍの平均層厚を有し、化学蒸着した状態で酸化アルミニウムと酸化ジルコニウムの２相混合酸化物組織を有し、かつ、前記酸化ジルコニウムは、Ｚｒの含有割合に換算して、層中に含有するＡｌとＺｒの合量に占める割合（原子比）で０．０１〜０．２０である、酸化アルミニウムと酸化ジルコニウムの２相混合酸化物層、
以上（ａ−１）および（ａ−２）で構成された硬質被覆層を化学蒸着形成してなる、表面被覆サーメット製切削スローアウエイチップの表面研磨方法にして、
（１）上記硬質被覆層の上部層である酸化アルミニウムと酸化ジルコニウムの２相混合酸化物層の全面に、
（ｂ−１）下側層として、０．１〜３μｍの平均層厚を有し、かつ、
組成式：ＴｉＯＸ 、
で表わした場合、厚さ方向中央部をオージェ分光分析装置で測定して、原子比で、
Ｘ：１．２〜１．７、
を満足する酸化チタン層、
（ｂ−２）上側層として、０．０５〜２μｍの平均層厚を有し、かつ、
組成式：ＴｉＮ１−Ｙ（Ｏ）Ｙ、
で表わした場合（ただし、（Ｏ）は上側層の蒸着形成時における上記下側層である酸化チタン層からの拡散酸素を示す）、同じく厚さ方向中央部をオージェ分光分析装置で測定して、同じく原子比で、
Ｙ：０．０１〜０．４、
を満足する窒酸化チタン層、
以上（ｂ−１）および（ｂ−２）で構成された研磨材層を化学蒸着形成し、
（２）ついで、ウエットブラストにて、噴射研磨材として、水との合量に占める割合で１５〜６０質量％の酸化アルミニウム微粒を配合した研磨液を噴射し、
上記の研磨材層が噴射研磨材である酸化アルミニウム微粒の噴射により粉砕微粒化してなる粉砕化酸化チタン微粒（下側層）および粉砕化窒酸化チタン微粒（上側層）と、噴射研磨材としての酸化アルミニウム微粒の共存下で、上記工具取り付け孔周辺部の研磨材層を残して、上記硬質被覆層の上部層を構成する酸化アルミニウムと酸化ジルコニウムの２相混合酸化物層の表面を研磨して、前記酸化アルミニウムと酸化ジルコニウムの２相混合酸化物層の切刃稜線部を含むすくい面および逃げ面の表面粗さを準拠規格ＪＩＳ・Ｂ０６０１−１９９４に基いた測定で、Ｒａ：０．２μｍ以下としたことを特徴とする、硬質被覆層が高速切削加工ですぐれた耐チッピング性を発揮する表面被覆サーメット製切削スローアウエイチップの表面研磨方法。 It is composed of a tungsten carbide base cemented carbide or a titanium carbonitride base cermet, and the entire rake face and flank face including the cutting edge ridge line part of the chip base having a tool attachment hole in the center part,
(A-1) The lower layer is composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carbonate layer, and a titanium carbonitride oxide layer, and has a thickness of 3 to 20 μm. A Ti compound layer having an overall average layer thickness,
(A-2) As an upper layer, it has an average layer thickness of 1 to 15 μm, has a two-phase mixed oxide structure of aluminum oxide and zirconium oxide in a chemical vapor deposited state, and the zirconium oxide is made of Zr A two-phase mixed oxide layer of aluminum oxide and zirconium oxide that is 0.01 to 0.20 in terms of the ratio (atomic ratio) to the total amount of Al and Zr contained in the layer, in terms of content ratio,
In the surface polishing method of the cutting throwaway tip made of surface-coated cermet, formed by chemical vapor deposition of the hard coating layer composed of (a-1) and (a-2) above,
( 1 ) On the entire surface of the two-phase mixed oxide layer of aluminum oxide and zirconium oxide that is the upper layer of the hard coating layer,
(B-1) The lower layer has an average layer thickness of 0.1 to 3 μm, and
Composition formula: TiO x ,
, The central part in the thickness direction is measured with an Auger spectrometer, and the atomic ratio is
X: 1.2 to 1.7,
Satisfying titanium oxide layer,
(B-2) The upper layer has an average layer thickness of 0.05 to 2 μm, and
Composition formula: TiN 1-Y (O) Y ,
(However, (O) indicates the diffused oxygen from the titanium oxide layer, which is the lower layer when the upper layer is formed by vapor deposition ). Similarly, the central portion in the thickness direction is measured with an Auger spectrometer. , Also in atomic ratio,
Y: 0.01 to 0.4
Satisfying titanium oxynitride layer,
Abrasive material layer composed of (b-1) and (b-2) above is formed by chemical vapor deposition,
( 2 ) Next , with wet blasting, as a spray abrasive, a polishing liquid containing 15 to 60% by mass of aluminum oxide fine particles in a proportion of the total amount with water is sprayed.
The above-mentioned abrasive material layer is pulverized titanium oxide fine particles (lower layer) and pulverized titanium oxynitride fine particles (upper layer) formed by pulverization and atomization by injection of aluminum oxide fine particles, which are spray abrasives . In the presence of aluminum oxide fine particles, the surface of the two-phase mixed oxide layer of aluminum oxide and zirconium oxide constituting the upper layer of the hard coating layer is polished, leaving the abrasive layer around the tool mounting hole. The surface roughness of the rake face and flank face including the cutting edge ridge line portion of the two-phase mixed oxide layer of aluminum oxide and zirconium oxide was measured based on JIS / B0601-1994, and Ra: 0.2 μm or less It characterized in that the the surface polished side of the surface-coated cermet cutting throw-away tip hard coating layer exhibits excellent chipping resistance in high-speed cutting .
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