JP6102617B2 - Surface coated cutting tool with excellent chipping resistance - Google Patents
Surface coated cutting tool with excellent chipping resistance Download PDFInfo
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Description
本発明は、硬質被覆層がすぐれた耐摩耗性を備えた表面被覆切削工具に関し、さらに詳しくは、焼き入れ鋼などの高硬度鋼の高速切削加工に用いた場合においても、チッピングが発生しにくく、長期に亘ってすぐれた切削性能を示す表面被覆切削工具(以下、被覆工具という)に関する。 The present invention relates to a surface-coated cutting tool having a hard coating layer with excellent wear resistance. More specifically, even when used for high-speed cutting of hardened steel such as hardened steel, chipping hardly occurs. The present invention relates to a surface-coated cutting tool (hereinafter referred to as a coated tool) that exhibits excellent cutting performance over a long period of time.
一般に、被覆工具には、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インサート、被削材の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、さらに被削材の面削加工や溝加工、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、またインサートを着脱自在に取り付けてソリッドタイプのエンドミルと同様に切削加工を行うインサート式エンドミルなどが知られている。 In general, coated tools are used for turning and planing of work materials such as various types of steel and cast iron, inserts that can be used detachably attached to the tip of a cutting tool, drilling processing of work materials, etc. There are drills, miniature drills, solid type end mills used for chamfering, grooving, shoulder processing, etc. of the work material, etc. Also, inserts are detachably attached and cutting is performed in the same way as solid type end mills An insert type end mill is known.
本発明は、立方晶窒化硼素(以下、cBNで示す)を主成分として、これを超高圧、高温下にて焼結成形してなるcBN焼結体切削工具に関し、特に、合金鋼、軸受鋼等の焼入れ鋼からなる高硬度鋼の高速切削加工においても、チッピングや欠損の発生を抑制し得るとともに、すぐれた切削性能を長期の使用に亘って維持し得るcBN焼結体切削工具に関するものである。 The present invention relates to a cBN sintered body cutting tool comprising cubic boron nitride (hereinafter referred to as cBN) as a main component and sintered and formed at ultrahigh pressure and high temperature, and in particular, alloy steel and bearing steel. In high-speed cutting of hardened steel such as hardened steel, etc., it relates to a cBN sintered body cutting tool that can suppress the occurrence of chipping and chipping and can maintain excellent cutting performance over a long period of use. is there.
従来、高硬度鋼の切削工具としては、cBN焼結体を工具基体としたcBN焼結体切削工具等が知られており、工具寿命の向上を目的として種々の提案がなされている。
例えば、特許文献1には、公知の方法を用いて作製された超硬などの工具基体表面に該工具基体表面に対して垂直に伸びる柱状結晶を主体としこれが並んだ組織中に富Ti柱状結晶が分散している硬質被覆層を被覆することにより、耐摩耗性が高く、かつ高い耐欠損性を有する表面被覆工具が得られる旨、開示されている。
また、特許文献2には、cBN焼結体基材上に硬質皮膜を具え該硬質皮膜が立方晶型結晶構造を有して組成の異なる2種以上の化合物層を積層した薄膜積層構造を有することにより、硬質皮膜が剥がれるまでの寿命の長期化と焼結体基材の硬質粒子の脱落を抑制する複合高硬度材料が開示されている。
Conventionally, cBN sintered body cutting tools using a cBN sintered body as a tool base are known as cutting tools for high hardness steel, and various proposals have been made for the purpose of improving the tool life.
For example, Patent Document 1 discloses a Ti-rich columnar crystal in a structure mainly composed of columnar crystals extending perpendicularly to the surface of the tool substrate, such as cemented carbide, manufactured using a known method. It is disclosed that a surface-coated tool having high wear resistance and high fracture resistance can be obtained by coating a hard coating layer in which is dispersed.
Patent Document 2 has a thin film laminated structure in which a hard film is provided on a cBN sintered body and the hard film has a cubic crystal structure and two or more compound layers having different compositions are laminated. Thus, a composite high-hardness material that suppresses the extension of the life until the hard coating is peeled off and the falling of the hard particles of the sintered body base material is disclosed.
ところが、特許文献1に開示された発明は、硬質被覆層中に富Ti柱状結晶が分散させることで、高い耐摩耗性がと耐欠損性の両立を図っているが、富Ti柱状結晶は硬度が低いため、特に焼き入れ鋼の高速切削においては、長期に亘って十分な耐摩耗性が得られないという課題が指摘されていた。
また、特許文献2に開示された発明は、cBN焼結体基材上に硬質被覆層を具え該硬質被覆層が立方晶型結晶構造を有して組成の異なる2種以上の化合物層を積層した薄膜積層構造を有することにより、硬質被覆層と基材との耐チッピング性、耐欠損性を向上させているが、より高速切削においては、薄膜積層構造が自壊するという課題が指摘されていた。
However, the invention disclosed in Patent Document 1 achieves both high wear resistance and fracture resistance by dispersing Ti-rich columnar crystals in the hard coating layer. Therefore, a problem has been pointed out that sufficient wear resistance cannot be obtained over a long period of time, particularly in high-speed cutting of hardened steel.
Further, the invention disclosed in Patent Document 2 includes a hard coating layer on a cBN sintered body base material, and the hard coating layer has a cubic crystal structure and two or more compound layers having different compositions are laminated. Although the chipping resistance and chipping resistance between the hard coating layer and the substrate are improved by having the thin film laminated structure, the problem that the thin film laminated structure self-destructs has been pointed out in higher speed cutting. .
そこで、本発明が解決しようとする技術的課題、すなわち、本発明の目的は、高負荷な切削条件が要求される焼き入れ鋼などの高硬度鋼の高速切削加工に用いた場合においても、チッピングが発生しにくく、長期に亘ってすぐれた切削性能を維持するcBN焼結体切削工具を提供することにある。 Therefore, the technical problem to be solved by the present invention, that is, the object of the present invention is to perform chipping even when used for high-speed cutting of hardened steel such as hardened steel which requires high-load cutting conditions. It is an object of the present invention to provide a cBN sintered body cutting tool that is less likely to generate and maintains excellent cutting performance over a long period of time.
本発明者らは、前記課題を解決するため、cBN焼結体からなる工具基体上に被覆する硬質被覆層に着目し、鋭意研究したところ、次のような知見を得た。 In order to solve the above-mentioned problems, the present inventors paid attention to a hard coating layer coated on a tool substrate made of a cBN sintered body and conducted earnest research, and obtained the following knowledge.
(1)cBN焼結体をcBN粒子とTiの窒化物、炭化物、炭窒化物、硼化物およびAlの窒化物、酸化物からなる群から選ばれた少なくとも1種以上の粒子と不可避不純物とを含む結合相とから構成した場合、工具基体上に所定の組成のTiAlN層を形成した場合、結合相形成原料粒子中のTi成分あるいはAl成分がTiAlN層形成過程中にTiAlN層中に拡散することにより、焼結体とTiAlN層との界面で生じがちな応力差や熱伝導率差が緩和されるため、TiAlN層の密着性および耐剥離性が向上する。
(2)TiAlN層は、その構成成分であるTi成分によってすぐれた強度と靭性を確保することができ、Alは高温硬さと耐熱性を向上させ、AlとTiが共存含有した状態でさらに高温耐酸化性を向上させる作用がある。さらに、岩塩型結晶構造を有するため、高硬度でありcBN焼結体からなる工具基体上に形成することで耐摩耗性を向上させることができる。
(3)一方、TiAlSiN層は、前記TiAlN層にSi成分を含有させることで、一層耐熱性が向上する。酸化開始温度が高くて高温耐酸化性が高いため、特に切削時に高温となるような高速切削時の耐摩耗性が向上する。
(4)cBN焼結体からなる工具基体上に所定の組成のTiAlN層を成膜し、その上に所定の組成のTiAlSiN層を積層させることで、cBN粒子間の隙間に存在する結合相上から硬質被覆層内を貫いて成長する帯状微粒組織が形成できる。
(5)cBN焼結体中のcBN粒子の含有割合を調整することでcBN焼結体表面に露出するcBN粒子の高さの差を制御することが可能になり、この高さの差が表面に露出するcBN粒子間の隙間に存在する結合相上に成長する帯状微粒組織の成長方向を制御することが出来る。
(6)硬質被覆層をTiAlN層とTiAlSiNの積層構造とし、さらに、所定の帯状微粒組織を硬質被覆層内に貫くように所定の角度で傾斜させて成長させることで、硬質被覆層の表面に加わった外力が直接工具基体に加わることなく、帯状微粒組織によって緩和される。
(7)帯状微粒組織内は粒界が多いため、外力が働いた際、粒界すべり等によって応力が緩和し、工具基体へ加わる外力が緩和されるため、耐チッピング性が向上する。
(8)帯状微粒組織が所定の角度で傾斜しているため、硬質被覆層表面に対して垂直な方向および平行な方向のいずれの力に対しても力を分散させる効果があり、このことが、硬質被覆層の切削性能に対する異方性を減少する効果をもたらし、切削工具の使用上の自由度を向上させることが出来る。
(9)また、帯状微粒組織の成長方向と帯状微粒組織の存在割合および硬質被覆層の層厚を調整することにより、硬質被覆層表面から工具基体表面までを結ぶ垂線上に存在する帯状微粒組織の量を制御することが出来るため、(7)、(8)に記載の作用がより効果的に奏される。
(1) A cBN sintered body comprising cBN particles and at least one type of particles selected from the group consisting of nitrides, carbides, carbonitrides, borides, Al nitrides, and oxides of Ti and inevitable impurities. When the TiAlN layer having a predetermined composition is formed on the tool base, the Ti component or Al component in the binder phase forming raw material particles diffuses into the TiAlN layer during the TiAlN layer formation process. As a result, stress differences and thermal conductivity differences that tend to occur at the interface between the sintered body and the TiAlN layer are alleviated, so that the adhesion and peel resistance of the TiAlN layer are improved.
(2) The TiAlN layer can ensure excellent strength and toughness due to its constituent Ti component, and Al improves high temperature hardness and heat resistance, and in a state where Al and Ti coexist, further high temperature acid resistance There is an effect of improving the chemical properties. Furthermore, since it has a rock salt type crystal structure, it has high hardness and can be formed on a tool substrate made of a cBN sintered body, thereby improving the wear resistance.
(3) On the other hand, the heat resistance of the TiAlSiN layer is further improved by adding a Si component to the TiAlN layer. Since the oxidation start temperature is high and the high-temperature oxidation resistance is high, the wear resistance during high-speed cutting such as high temperature during cutting is improved.
(4) A TiAlN layer having a predetermined composition is formed on a tool base made of a cBN sintered body, and a TiAlSiN layer having a predetermined composition is laminated thereon, whereby a binder phase existing in a gap between cBN particles is formed. A band-like fine grain structure that grows through the hard coating layer can be formed.
(5) By adjusting the content ratio of cBN particles in the cBN sintered body, it becomes possible to control the difference in height of the cBN particles exposed on the surface of the cBN sintered body. It is possible to control the growth direction of the band-like fine grain structure that grows on the binder phase existing in the gaps between the cBN grains exposed to.
(6) The hard coating layer has a laminated structure of TiAlN layer and TiAlSiN, and is further grown on the surface of the hard coating layer by being inclined at a predetermined angle so as to penetrate a predetermined band-like fine grain structure into the hard coating layer. The applied external force is not directly applied to the tool base, but is relaxed by the band-like fine grain structure.
(7) Since there are many grain boundaries in the belt-like fine grain structure, when an external force is applied, the stress is relaxed due to the sliding of the grain boundary and the external force applied to the tool base is relaxed, so that the chipping resistance is improved.
(8) Since the band-like fine grain structure is inclined at a predetermined angle, there is an effect of dispersing the force with respect to any force in a direction perpendicular to or parallel to the surface of the hard coating layer. The effect of reducing the anisotropy of the hard coating layer on the cutting performance can be obtained, and the degree of freedom in using the cutting tool can be improved.
(9) Further, by adjusting the growth direction of the band-shaped fine structure, the existence ratio of the band-shaped fine structure, and the layer thickness of the hard coating layer, the band-shaped fine structure existing on the vertical line connecting the surface of the hard coating layer to the surface of the tool substrate. Therefore, the effects described in (7) and (8) are more effectively achieved.
前述の知見に基づき本発明者らは、幾多の実験および切削試験を重ねることによって、刃先に高負荷および高温が加わる高硬度鋼の高速切削に使用してもチッピングや欠損が発生しにくく切削寿命の長い切削工具を製造することに成功した。 Based on the above knowledge, the present inventors have conducted a number of experiments and cutting tests, and the cutting life is less likely to cause chipping and chipping even when used for high-speed cutting of high-hardness steel in which a high load and high temperature are applied to the cutting edge. Succeeded in producing long cutting tools.
本発明は、前記の研究結果に基づいてなされたものであって、
「(1) 少なくとも切削に使用する刃先が立方晶窒化硼素焼結体からなる工具基体上に硬質被覆層を有する表面被覆切削工具であって、
前記立方晶窒化硼素焼結体は立方晶窒化硼素粒子とTiの窒化物、炭化物、炭窒化物、硼化物およびAlの窒化物、酸化物からなる群から選ばれた少なくとも1種以上の粒子と不可避不純物とを含む結合相とからなり、
前記立方晶窒化硼素粒子は平均粒径が0.5〜4.0μmかつ立方晶窒化硼素焼結体全体に占める含有割合が40〜70体積%であり、
前記結合相を構成する粒子は平均粒径が1.0μm以下であり、
前記硬質被覆層は少なくとも工具基体直上の下部層Aとその上に形成された上部層Bとからなるとともに平均総層厚が1.0〜8.0μmであり、
前記下部層Aは組成式:Ti1−aAlaN(但し、aは原子比で0.3≦a≦0.7)の成分系からなり、
前記上部層Bは組成式:Ti1−x―yAlxSiyN(但し、x、yは原子比で0.3≦x≦0.7、0.01≦y≦0.1)の成分系からなり、
前記硬質被覆層中に工具基体表面に露出している結合相の一部から下部層Aおよび上部層Bを貫き該上部層B表面まで連続した帯状微粒組織が工具基体表面の法線に対して平均して30〜60°傾斜して存在しているとともに前記帯状微粒組織の工具基体表面に平行な方向の平均幅が0.3〜1.5μmかつ硬質被覆層全体に占める含有割合が5〜20体積%であることを特徴とする表面被覆切削工具。
(2) 前記硬質被覆層中の帯状微粒組織以外を構成する結晶粒の平均粒径が0.05μm以上1.0μm以下でありかつ前記帯状微粒組織を構成する結晶粒の平均粒径が0.05μm未満であることを特徴とする(1)に記載の表面被覆切削工具。」
に特徴を有するものである。
The present invention has been made based on the above research results,
“(1) A surface-coated cutting tool having a hard coating layer on a tool substrate in which at least the cutting edge used for cutting is made of a cubic boron nitride sintered body,
The cubic boron nitride sintered body includes cubic boron nitride particles and at least one kind of particles selected from the group consisting of Ti nitride, carbide, carbonitride, boride, Al nitride, and oxide. Consisting of a binder phase containing inevitable impurities,
The cubic boron nitride particles have an average particle size of 0.5 to 4.0 μm and a content ratio of 40 to 70% by volume in the entire cubic boron nitride sintered body,
The particles constituting the binder phase have an average particle size of 1.0 μm or less,
The hard coating layer comprises at least a lower layer A immediately above the tool base and an upper layer B formed thereon, and an average total layer thickness is 1.0 to 8.0 μm,
The lower layer A is composed of a component system having a composition formula: Ti 1-a Al a N (where a is an atomic ratio of 0.3 ≦ a ≦ 0.7),
The upper layer B has a composition formula: Ti 1-xy Al x Si y N (where x and y are atomic ratios of 0.3 ≦ x ≦ 0.7 and 0.01 ≦ y ≦ 0.1). Consists of component system
In the hard coating layer, a band-like fine grain structure extending from a part of the binder phase exposed on the surface of the tool base through the lower layer A and the upper layer B to the surface of the upper layer B has a normal to the surface of the tool base. The average width in the direction parallel to the surface of the tool base of the band-shaped fine grain structure is 0.3 to 1.5 μm and the content ratio of the entire hard coating layer is 5 to A surface-coated cutting tool characterized by being 20% by volume.
(2) The average grain size of the crystal grains other than the band-like fine grain structure in the hard coating layer is 0.05 μm or more and 1.0 μm or less, and the average grain diameter of the crystal grains constituting the band-like fine grain structure is 0.00. The surface-coated cutting tool according to (1), which is less than 05 μm. "
It has the characteristics.
ここで、本発明の構造について、より詳しく説明する。 Here, the structure of the present invention will be described in more detail.
(a)焼結体中のcBN粒子の平均粒径:
cBN焼結体中に、微細な硬質なcBN粒子が分散していることにより、工具使用中に工具基体表面のcBN粒子が脱落して生じる刃先の凹凸形状を起点とするチッピングの発生を抑制することができる。その理由は、たとえ、工具基体表面のcBN粒子が脱落したとしても、その粒子が所定の粒径以下の微細粒子であるためチッピングを誘発するような大きな凹凸形状とならないためである。
また、焼結体中の微細cBN粒子が、工具使用中に刃先に加わる応力により生じるcBN粒子と結合相との界面から進展するクラック、あるいはcBN粒子が割れて進展するクラックの伝搬を分散・緩消する役割を担うため、すぐれた耐欠損性を発揮することが出来る。
しかしながら、平均粒径が0.5μm未満になると、微細すぎて硬質粒子としてのcBN粒子の機能が十分に発揮できない。一方、4.0μmを超えると、本発明における硬質被覆層の層厚と比べてかなり大きな粒子となるため、工具基体表面に露出するcBN粒子によって形成される凹凸形状が大きくなり過ぎ、後述する帯状微粒組織の傾斜角度を所定の範囲に収めることが出来なくなる。
したがって、cBN粒子の平均粒径は、0.5〜4.0μmと定めた。
ここで、cBN粒子の平均粒径は、作製したcBN焼結体の断面組織を走査型電子顕微鏡(Scanning Electron Microscopy:SEM)にて観察して得られた二次電子画像内のcBN粒子の部分を画像処理にて抜き出し、画像解析によって各cBN粒子の最大長を求め、それを各cBN粒子の直径とし、1画像におけるcBN粒子の直径の平均値を求め、少なくとも3画像について求めた平均値の平均をcBNの平均粒径[μm]とした。画像処理に用いる観察領域は予備観察を行うことによって定めたが、cBN粒子の平均粒径が0.5〜4.0μmであることをかんがみ、15μm×15μm程度の視野領域とすることが望ましい。
(A) Average particle size of cBN particles in the sintered body:
By dispersing fine hard cBN particles in the cBN sintered body, the occurrence of chipping starting from the uneven shape of the cutting edge caused by cBN particles falling off the tool base surface during tool use is suppressed. be able to. The reason is that even if the cBN particles on the surface of the tool base fall off, the particles are fine particles having a predetermined particle size or less, and thus do not have a large uneven shape that induces chipping.
In addition, the fine cBN particles in the sintered body disperse / relieve the propagation of cracks that develop from the interface between the cBN particles and the binder phase caused by the stress applied to the blade edge during tool use, or the cracks that propagate when the cBN particles break up. Since it plays a role of erasing, it can exhibit excellent fracture resistance.
However, when the average particle size is less than 0.5 μm, the function of the cBN particles as the hard particles cannot be sufficiently exhibited because the particles are too fine. On the other hand, if the thickness exceeds 4.0 μm, the particles are considerably larger than the thickness of the hard coating layer in the present invention, so that the uneven shape formed by the cBN particles exposed on the surface of the tool base becomes too large. It becomes impossible to keep the inclination angle of the fine grain structure within a predetermined range.
Therefore, the average particle size of the cBN particles was determined to be 0.5 to 4.0 μm.
Here, the average particle size of the cBN particles is the portion of the cBN particles in the secondary electron image obtained by observing the cross-sectional structure of the produced cBN sintered body with a scanning electron microscope (SEM). Is extracted by image processing, the maximum length of each cBN particle is obtained by image analysis, and the diameter of each cBN particle is used as an average value of the diameters of cBN particles in one image, and the average value obtained for at least three images is obtained. The average was defined as the average particle size [μm] of cBN. The observation area used for the image processing is determined by performing preliminary observation. However, it is desirable that the viewing area is about 15 μm × 15 μm in view of the average particle size of the cBN particles being 0.5 to 4.0 μm.
(b)cBN焼結体中のcBN粒子の体積割合:
cBN焼結体に占めるcBN粒子の含有割合が40体積%未満では、焼結体中に硬質物質が少なく、cBN焼結体の硬度が低下するため、耐摩耗性が低下する。一方、70体積%を超えると、結合相が不足するため、焼結体中にクラックの起点となる空隙が生成し、耐欠損性が低下する。そのため、本発明が奏する効果をより一層発揮するためには、cBN焼結体に占めるcBN粒子の含有割合は、40〜70体積%の範囲とすることが好ましい。
ここで、cBN焼結体に占めるcBN粒子の含有割合(体積%)の測定方法は、cBN焼結体の断面組織をSEMによって観察して得られた二次電子画像内のcBN粒子の部分を画像処理によって抜き出し、画像解析によって観察領域におけるcBN焼結体の全体の面積に対するcBN粒子が占める面積を算出し、少なくとも3画像を処理し求めた値の平均値をcBN粒子の含有割合(体積%)とした。画像処理に用いる観察領域は、cBN粒子の平均粒径が0.5〜4.0μmであることをかんがみ、15μm×15μm程度の視野領域とすることが望ましい。
(B) Volume ratio of cBN particles in the cBN sintered body:
When the content ratio of the cBN particles in the cBN sintered body is less than 40% by volume, the hard body is less in the sintered body and the hardness of the cBN sintered body is lowered, so that the wear resistance is lowered. On the other hand, if it exceeds 70% by volume, since the binder phase is insufficient, voids serving as starting points of cracks are generated in the sintered body, and the fracture resistance is lowered. Therefore, in order to further exhibit the effect exhibited by the present invention, the content ratio of the cBN particles in the cBN sintered body is preferably in the range of 40 to 70% by volume.
Here, the measurement method of the content ratio (volume%) of the cBN particles in the cBN sintered body is that the cBN particle portion in the secondary electron image obtained by observing the cross-sectional structure of the cBN sintered body with the SEM is used. The area occupied by the cBN particles with respect to the entire area of the cBN sintered body in the observation region is calculated by image processing, and the average value of the values obtained by processing at least three images is calculated as the content ratio (volume%) of the cBN particles. ). The observation area used for image processing is preferably a visual field area of about 15 μm × 15 μm, considering that the average particle size of cBN particles is 0.5 to 4.0 μm.
(c)結合相を構成する粒子の平均粒径:
工具基体表面に露出したcBN焼結体中の結合相を構成する粒子は、硬質被覆層中に成長する帯状微粒組織の核となる。そのため、所望の帯状微粒組織を成長させるためには、その粒径を所定の値以下に調整する必要がある。本発明においては、幾多の実験結果から、
結合相を構成する粒子の平均粒径を1.0μm以下と定義した。結合相を構成する粒子の平均粒径が1.0μmを超えると、帯状微粒組織を構成する粒子の径が大きくなるため、好ましくない。
なお、その測定方法は、前述したcBN粒子の平均粒径の測定方法と同様の方法を用いた。
(C) Average particle diameter of particles constituting the binder phase:
The particles constituting the binder phase in the cBN sintered body exposed on the surface of the tool substrate become the core of a band-like fine grain structure that grows in the hard coating layer. Therefore, in order to grow a desired belt-like fine grain structure, it is necessary to adjust the grain size to a predetermined value or less. In the present invention, from a number of experimental results,
The average particle size of the particles constituting the binder phase was defined as 1.0 μm or less. When the average particle diameter of the particles constituting the binder phase exceeds 1.0 μm, the diameter of the particles constituting the band-shaped fine grain structure increases, which is not preferable.
In addition, the measuring method used the method similar to the measuring method of the average particle diameter of cBN particle | grains mentioned above.
(d)硬質被覆層の平均層層厚:
本発明の硬質被覆層は、硬質被覆層は少なくとも工具基体直上のTi1−aAlaNの成分系からなる下部層Aとその上に形成されたTi1−x―yAlxSiyNの成分系からなる上部層Bとからなる積層構造を有している。この硬質被覆層は、下部層AであるTiAlN層に含まれるTi成分によってすぐれた強度と靭性を確保し、Alが高温硬さと耐熱性を向上させると共にAlとTiが共存含有した状態でさらに高温耐酸化性を向上させる作用があるとともに岩塩型結晶構造を有するため、高硬度であり工具基体上に形成することで耐摩耗性を向上させることができる。
また、上部層BであるTiAlSiN層は、前記TiAlN層にSi成分を含有させることで、一層耐熱性が向上し、酸化開始温度が高くて高温耐酸化性が高いため、特に切削時に高温となるような高速切削時の耐摩耗性が向上する。
特に平均総層厚が1.0〜8.0μmのとき、その効果が際立って発揮される。その理由は、平均総層厚が1.0μm未満では、工具基体表面粗さに比べ硬質被覆層の層厚が薄いため、長期の使用に亘っての耐摩耗性を十分確保することができない。一方、その平均総層厚が8.0μmを越えると、硬質被覆層を構成する複合窒化物の結晶粒が粗大化し易くなり、チッピングを発生しやすくなる。したがって、その平均総層厚を1.0〜8.0μmと定めた。
ここで、硬質被覆層の平均総層厚は、SEMにて観察して得られた二次電子画像内の硬質被覆層の部分を画像処理にて抜き出し、画像解析によって画像内の5箇所について硬質被覆層の層厚を求め、その平均値を求め平均総層厚とした。画像処理に用いる観察領域として、期待する硬質被覆層の平均総層厚が1.0〜8.0μmであることをかんがみ、15μm×15μm程度の視野領域とすることが望ましい。
(D) Average layer thickness of the hard coating layer:
The hard coating layer of the present invention is composed of a lower layer A composed of a component system of Ti 1-a Al a N at least immediately above the tool base and Ti 1 -xy Al x Si y N formed thereon. It has the laminated structure which consists of the upper layer B which consists of these component systems. This hard coating layer ensures excellent strength and toughness by the Ti component contained in the TiAlN layer which is the lower layer A, Al improves the high-temperature hardness and heat resistance, and at the same time contains Al and Ti at a higher temperature. Since it has the effect of improving oxidation resistance and has a rock salt type crystal structure, it has high hardness and can be formed on a tool base to improve wear resistance.
In addition, the TiAlSiN layer as the upper layer B has a high heat resistance by adding a Si component to the TiAlN layer, and has a high oxidation start temperature and a high temperature oxidation resistance. The wear resistance during high-speed cutting is improved.
In particular, when the average total layer thickness is 1.0 to 8.0 μm, the effect is remarkably exhibited. The reason is that if the average total layer thickness is less than 1.0 μm, the hard coating layer is thinner than the surface roughness of the tool base, so that sufficient wear resistance over a long period of use cannot be ensured. On the other hand, when the average total layer thickness exceeds 8.0 μm, the crystal grains of the composite nitride constituting the hard coating layer are likely to be coarsened and chipping is likely to occur. Therefore, the average total layer thickness was determined to be 1.0 to 8.0 μm.
Here, the average total thickness of the hard coating layer is determined by extracting the portion of the hard coating layer in the secondary electron image obtained by observing with the SEM by image processing, and performing hard analysis at five locations in the image by image analysis. The layer thickness of the coating layer was determined, and the average value was determined as the average total layer thickness. Considering that the expected average total thickness of the hard coating layer is 1.0 to 8.0 μm as the observation region used for image processing, it is desirable that the viewing region be about 15 μm × 15 μm.
(e)硬質被覆層を構成する下部層A:
下部層Aは、AlのTiとAlの合量に占める含有割合a(但し、aは原子比)が、0.3≦a≦0.7を満足する。
Al成分の含有量が0.3未満では、Al成分を含有することによる高温硬さと耐熱性の向上が十分得られず、所望の性能が得られない。また、Al成分の含有量が0.7を超えると、TiAlN層が岩塩型結晶構造を維持できず、硬さが極端に低下するため、望ましくない。
(E) Lower layer A constituting the hard coating layer:
In the lower layer A, the content ratio a (where a is an atomic ratio) of the total amount of Ti and Al in Al satisfies 0.3 ≦ a ≦ 0.7.
When the content of the Al component is less than 0.3, the high temperature hardness and the heat resistance are not sufficiently improved by containing the Al component, and the desired performance cannot be obtained. On the other hand, when the content of the Al component exceeds 0.7, the TiAlN layer cannot maintain the rock salt type crystal structure and the hardness is extremely lowered, which is not desirable.
(f)硬質被覆層を構成する上部層B:
上部層Bは、AlおよびSiのTiとAlとSiの合量に占める含有割合x、y(但し、x、yはいずれも原子比)が、それぞれ、0.3≦x≦0.7、0.01≦z≦0.1を満足する。
この条件を満たすとき、上部層Bを構成するTi1−x―yAlxSiyN層は所望の耐酸化性および切削時に高温となるような高速切削時における高い耐摩耗性を発揮する。
一方、Al成分の含有量が0.3未満では、Al成分を含有することによる高温硬さと耐熱性の向上が十分得られず、所望の性能が得られない。また、Al成分の含有量が0.7を超えると、AlTiSiN層が岩塩型結晶構造を維持できず、硬さが極端に低下するため、望ましくない。Si成分が0.01未満では所望の耐摩耗性が発揮されず、0.1を超えると結晶格子の歪みが大きくなり、耐欠損性が低下するため望ましくない。
(F) Upper layer B constituting the hard coating layer:
In the upper layer B, the content ratios x and y (where x and y are atomic ratios) of the total amount of Ti and Al and Si in Al and Si are 0.3 ≦ x ≦ 0.7, respectively. 0.01 ≦ z ≦ 0.1 is satisfied.
When this condition is satisfied, the Ti 1-xy Al x Si y N layer constituting the upper layer B exhibits desired oxidation resistance and high wear resistance during high-speed cutting such that the temperature becomes high during cutting.
On the other hand, if the content of the Al component is less than 0.3, sufficient improvement in high temperature hardness and heat resistance due to the inclusion of the Al component cannot be obtained, and desired performance cannot be obtained. On the other hand, when the content of the Al component exceeds 0.7, the AlTiSiN layer cannot maintain the rock salt type crystal structure and the hardness is extremely lowered, which is not desirable. If the Si component is less than 0.01, the desired wear resistance is not exhibited. If it exceeds 0.1, the distortion of the crystal lattice increases and the fracture resistance decreases, which is not desirable.
(g)硬質被覆層を貫く帯状微粒組織の傾斜角、平均幅、含有割合:
下部層であるTiAlN層と上部層であるTiAlSiN層の積層構造として構成される硬質被覆層内に貫くように連続した帯状微粒組織を傾斜させて成長させることにより、硬質被覆層の表面に加わった外力が直接工具基体に加わることなく、帯状微粒組織によって緩和される。帯状微粒組織内は粒界が多いため、外力が働いた際、粒界すべり等によって応力が緩和し、工具基体へ加わる外力が緩和されるため、耐チッピング性が向上する。
しかしながら、その傾斜角が工具基体表面の法線に対して30°未満では、硬質被膜層に垂直な方向の外力に対して十分な緩和効果が得られない。一方、60°以上の場合、硬質被膜層に平行な方向の外力に対して緩和効果が得にくくなる上、傾きが大きいと周囲組織の粒の成長と競合しやすくなるため、帯状微粒組織の制御が困難となり、安定して所望の効果が得られない。したがって、硬質被覆層を貫く帯状微粒組織の傾斜角は工具基体表面の法線に対して平均して30〜60°と定めた。
また、帯状微粒組織の工具基体表面に平行な方向の平均幅が0.3μm未満であると微粒組織の幅が狭く前述した工具基体へ加わる外力を緩和する機能が十分に奏されない。一方、平均幅が1.5μmを超える場合、帯状微粒組織は粒界密度が高いため、粒界から徐々に硬質粒子が脱落する摩耗が進行しやすくなり、硬質被覆層全体としての耐摩耗性が低下する。
したがって、帯状微粒組織の工具基体表面に平行な方向の平均幅は0.3〜1.5μmと定めた。
さらに、帯状微粒組織の硬質被覆層全体に占める含有割合が5体積%未満であると前述した工具基体へ加わる外力を緩和する機能が十分に奏されず、一方、20体積%を超える帯状微粒組織は、その発現機構の関係上、形成することが困難であることに加え、硬質被覆層全体に占める微粒組織の割合が大きくなるため、硬質被覆層全体としての耐摩耗性が低下する。また、20体積%を超えても前述した効果のさらなる向上は確認されなかった。
したがって、帯状微粒組織の硬質被覆層全体に占める含有割合は5〜20体積%と定めた。
なお、硬質被覆層を貫く帯状微粒組織の平均幅、傾斜角および含有割合は、帯状微粒組織を楕円錘台形状として処理し、算出する。算出手法について以下に示す。まず全体の算出手順について述べ、その後、各手順の具体的な処理法を示す。
楕円錘台形状は、cBN焼結体に被覆した硬質被覆層について、工具基体表面の面方向に平行な断面の作製とSEMによる観察を繰り返し、SEMによる観察で得られた帯状微粒組織の工具基体表面の面方向に平行な断面画像から見積もる。ここで工具基体表面とは、基体の硬質被覆層と接する面の面方向に垂直な断面を直交するように2面切り出し、それぞれの断面における基体と硬質被覆層の界面粗さの基準線を通る面とする。このように定めた工具基体表面の面方向に平行な断面を、形成した硬質被覆層上に作製し、作製した断面の組織観察をSEMによって行い、帯状微粒組織の断面領域を定め、ここで定めた領域を楕円近似する。硬質被覆層表面および工具基体表面に対して硬質被覆層側にそれぞれ0.3μmの位置に工具基体表面の面方向に平行な断面を作製し、作製した断面における帯状微粒組織の断面である楕円形状を結ぶことで、帯状微粒組織を楕円錐台形状として見積もる。ここで、硬質被覆層表面とは形成した硬質被覆層の表面粗さの基準面とする。こうして見積もった楕円錘台形状について、工具基体表面の面方向に平行な断面を硬質被覆層の層厚方向に等間隔に5面抜き出し、工具基体表面の面方向に平行な断面における、帯状微粒組織の断面である楕円形状の長径の平均値をその帯状微粒組織の平均幅[μm]とし、楕円形状の中心点にて直線近似した線分方向と工具基体表面の法線がなす角をその帯状微粒組織の傾斜角[°]とする。さらに断面組織の観察領域に含まれるすべての帯状微粒組織の平均幅と傾斜角の平均値および、硬質被覆層全体に対する含有割合を算出した。
次に、各算出手順における具体的な処理法を示す。硬質被覆層上に作製した工具基体表面の面方向に平行な断面の組織観察において、帯状微粒組織の断面領域と周囲組織の境界は粒径が0.05μm以上の結晶粒と0.05μm未満の結晶粒の粒界とし、帯状微粒組織の断面領域とは、0.05μm未満の結晶粒が0.025平方μm以上集合した領域とする。帯状微粒組織の断面領域の楕円近似は、得られた帯状微粒組織の断面領域における最大長さを長径とし、得られた領域と同等な面積となるような楕円形状を定め、実施する。
また、各結晶粒の長径、短径は、結晶粒の形状を楕円近似した際の長径、短径とする。また、各結晶粒の長径を結晶粒の粒径と定義する。
基材表面に平行な断面組織の観察領域は、10μm×10μm程度の視野領域とすることが望ましい。
(G) Inclination angle, average width, and content ratio of the band-shaped fine grain structure penetrating the hard coating layer:
A continuous belt-like fine grain structure was grown so as to penetrate into the hard coating layer configured as a laminated structure of the TiAlN layer as the lower layer and the TiAlSiN layer as the upper layer, and added to the surface of the hard coating layer. External force is not directly applied to the tool base but is relaxed by the band-like fine grain structure. Since there are many grain boundaries in the band-like fine grain structure, when external force is applied, stress is relaxed by grain boundary sliding or the like, and external force applied to the tool base is relaxed, so that chipping resistance is improved.
However, if the inclination angle is less than 30 ° with respect to the normal line of the tool base surface, a sufficient relaxation effect cannot be obtained with respect to the external force in the direction perpendicular to the hard coating layer. On the other hand, when the angle is 60 ° or more, it is difficult to obtain a relaxation effect against an external force in a direction parallel to the hard coating layer, and a large inclination tends to compete with the growth of grains in the surrounding structure. Thus, the desired effect cannot be obtained stably. Therefore, the inclination angle of the band-like fine grain structure penetrating the hard coating layer was determined to be 30 to 60 ° on the average with respect to the normal line of the tool base surface.
Further, if the average width of the strip-like fine grain structure in the direction parallel to the surface of the tool base is less than 0.3 μm, the width of the fine grain structure is narrow and the function of relaxing the external force applied to the above-mentioned tool base is not sufficiently achieved. On the other hand, when the average width exceeds 1.5 μm, the band-like fine grain structure has a high grain boundary density, so that the hard particles gradually fall off from the grain boundaries, and the wear resistance of the entire hard coating layer is increased. descend.
Therefore, the average width in the direction parallel to the surface of the tool base of the strip-like fine grain structure was determined to be 0.3 to 1.5 μm.
Furthermore, if the content ratio of the belt-like fine grain structure in the entire hard coating layer is less than 5% by volume, the above-described function of reducing the external force applied to the tool base is not sufficiently achieved, while the belt-like fine grain structure exceeding 20% by volume. In addition to being difficult to form due to its manifestation mechanism, the proportion of the fine grain structure in the entire hard coating layer increases, so that the wear resistance of the entire hard coating layer decreases. Moreover, even if it exceeded 20 volume%, the further improvement of the effect mentioned above was not confirmed.
Therefore, the content ratio of the belt-like fine grain structure in the entire hard coating layer is determined to be 5 to 20% by volume.
The average width, inclination angle, and content ratio of the band-like fine grain structure penetrating the hard coating layer are calculated by processing the band-like fine grain structure as an elliptic frustum shape. The calculation method is shown below. First, the overall calculation procedure is described, and then a specific processing method for each procedure is shown.
The ellipsoidal frustum shape is a tool substrate having a strip-like fine grain structure obtained by observation with an SEM by repeatedly producing a cross section parallel to the surface direction of the tool substrate surface and observing with a SEM for a hard coating layer coated with a cBN sintered body Estimate from a cross-sectional image parallel to the surface direction of the surface. Here, the surface of the tool base is cut out in two planes so that the cross section perpendicular to the surface direction of the surface in contact with the hard coating layer of the base is orthogonal, and passes through the reference line of the interface roughness between the base and the hard coating layer in each cross section. A surface. A cross section parallel to the surface direction of the surface of the tool base thus determined is prepared on the formed hard coating layer, and the structure of the prepared cross section is observed by SEM, and the cross-sectional area of the band-shaped fine grain structure is determined and determined here. Approximate the region with an ellipse. A cross section parallel to the surface direction of the tool base surface is formed at a position of 0.3 μm on the hard coating layer side with respect to the hard coating layer surface and the tool base surface, respectively, and an elliptical shape that is a cross section of a band-like fine grain structure in the prepared cross section , The band-like fine grain structure is estimated as an elliptic frustum shape. Here, the hard coating layer surface is a reference surface for the surface roughness of the formed hard coating layer. With respect to the elliptic frustum shape estimated in this way, five cross sections parallel to the surface direction of the tool base surface are extracted at equal intervals in the layer thickness direction of the hard coating layer, and a band-like fine grain structure in a cross section parallel to the surface direction of the tool base surface The average value of the major axis of the elliptical shape, which is the cross section of the belt, is defined as the average width [μm] of the strip-shaped fine structure, and the angle between the line segment direction linearly approximated at the center point of the elliptical shape and the normal of the tool base surface is The inclination angle of the fine grain structure [°]. Furthermore, the average value of all the strip | belt-shaped fine grain structures contained in the observation area | region of a cross-sectional structure | tissue, the average value of an inclination angle, and the content rate with respect to the whole hard coating layer were computed.
Next, a specific processing method in each calculation procedure is shown. In the observation of the structure of the cross section parallel to the surface direction of the surface of the tool base produced on the hard coating layer, the boundary between the cross-sectional area of the band-shaped fine grain structure and the surrounding structure is a crystal grain having a grain size of 0.05 μm or more and less than 0.05 μm The grain boundary of the crystal grains, and the cross-sectional area of the band-like fine grain structure is an area where 0.025 square μm or more of crystal grains less than 0.05 μm are gathered. The elliptical approximation of the cross-sectional area of the band-shaped fine grain structure is carried out by defining an elliptical shape with the maximum length in the cross-sectional area of the obtained band-shaped fine grain structure as the major axis and an area equivalent to the obtained area.
The major axis and minor axis of each crystal grain are the major axis and minor axis when the crystal grain shape is approximated to an ellipse. The major axis of each crystal grain is defined as the grain size of the crystal grain.
The observation region of the cross-sectional structure parallel to the substrate surface is desirably a visual field region of about 10 μm × 10 μm.
(h)硬質被覆層全体の帯状微粒組織以外を構成する結晶粒の平均粒径と帯状微粒組織を構成する結晶粒の平均粒径:
帯状微粒組織を構成する結晶粒の平均粒径および硬質被覆層全体の帯状微粒組織以外を構成する結晶粒の平均粒径は、特に限定されるわけではないが、硬質被覆層の表面に加わった外力が帯状微粒組織に加わり帯状微粒組織内は粒界が多いため、粒界すべり等によって応力が緩和するという前述の帯状微粒組織の作用がより効果的に奏されるためには、帯状微粒組織を構成する結晶粒の平均粒径は、硬質被覆層全体の帯状微粒組織以外を構成する結晶粒の平均粒径より小さいことが望ましく、さらに、具体的には、硬質被覆層全体の帯状微粒組織以外を構成する結晶粒の平均粒径が0.05μmを超え1.0μm以下でありかつ帯状微粒組織を構成する結晶粒の平均粒径が0.05μm以下であることが好ましい。
(H) The average grain size of the crystal grains constituting the hard coating layer other than the strip-like fine grain structure and the average grain diameter of the crystal grains constituting the strip-like fine grain structure:
The average particle diameter of the crystal grains constituting the band-shaped fine grain structure and the average grain diameter of the crystal grains constituting the entire hard coating layer other than the band-shaped fine grain structure are not particularly limited, but are added to the surface of the hard coating layer. Since the external force is applied to the band-shaped fine structure and there are many grain boundaries in the band-shaped fine structure, the effect of the above-mentioned band-shaped fine structure that stress is relieved by grain boundary sliding is more effective. It is desirable that the average grain size of the crystal grains constituting is smaller than the average grain size of the crystal grains constituting other than the band-like fine grain structure of the entire hard coating layer, and more specifically, the band-like fine grain structure of the entire hard coating layer It is preferable that the average grain size of the crystal grains constituting other than the above is 0.05 μm or more and 1.0 μm or less, and the average grain diameter of the crystal grains constituting the band-like fine grain structure is 0.05 μm or less.
本発明の切削工具は、少なくとも切削に使用する刃先がcBN焼結体からなる工具基体上に硬質被覆層を有する表面被覆切削工具であって、cBN焼結体はcBN粒子とTiの窒化物、炭化物、炭窒化物、硼化物およびAlの窒化物、酸化物からなる群から選ばれた少なくとも1種以上の粒子と不可避不純物とを含む結合相とからなり、cBN粒子が所定の平均粒径、含有割合が40〜70体積%であり、結合相を構成する粒子が所定の平均粒径であり、硬質被覆層は少なくとも工具基体直上の所定の組成のTi1−aAlaN層からなる下部層Aとその上に形成された所定の組成のTi1−x―yAlxSiyN層からなる上部層Bとからなるとともに所定の平均総層厚を有し、硬質被覆層中に工具基体表面に露出している結合相の一部から下部層Aおよび上部層Bを貫き該上部層B表面まで連続した帯状微粒組織が工具基体表面の法線に対して所定の角度傾斜しており、かつ帯状微粒組織が措定の平均幅と所定の含有割合であることによって、高負荷な切削条件が要求される焼き入れ鋼などの高硬度鋼の高速切削加工に用いた場合においても、チッピングが発生しにくく、長期に亘ってすぐれた切削性能を維持するという効果を発揮するものである。 The cutting tool of the present invention is a surface-coated cutting tool having a hard coating layer on a tool base having a cutting edge made of at least a cBN sintered body for cutting, and the cBN sintered body is a nitride of cBN particles and Ti, It consists of a binder phase containing at least one kind of particles selected from the group consisting of carbides, carbonitrides, borides, Al nitrides, and oxides and inevitable impurities, and the cBN particles have a predetermined average particle size, The content ratio is 40 to 70% by volume, the particles constituting the binder phase have a predetermined average particle diameter, and the hard coating layer is a lower part composed of at least a Ti 1-a Al a N layer having a predetermined composition directly above the tool substrate. A layer A and an upper layer B made of a Ti 1-xy Al x Si y N layer of a predetermined composition formed thereon, and having a predetermined average total layer thickness, and a tool in the hard coating layer Of the binder phase exposed on the substrate surface. A band-like fine grain structure that extends from a part through the lower layer A and the upper layer B to the surface of the upper layer B is inclined at a predetermined angle with respect to the normal of the tool substrate surface, and the belt-like fine grain structure is an average width of the determination. And the specified content ratio, chipping hardly occurs even when used for high-speed cutting of hardened steel such as hardened steel, which requires high-load cutting conditions, and it was excellent over a long period of time. The effect of maintaining the cutting performance is exhibited.
つぎに、本発明の被覆工具を実施例により具体的に説明する。 Next, the coated tool of the present invention will be specifically described with reference to examples.
工具基体の形成工程:
原料粉末として、0.5〜4.0μmの平均粒径を有するcBN粒子を硬質相形成用原料粉末として用意するとともに、いずれも0.3〜0.9μmの範囲内の平均粒径を有するTiN粉末、TiC粉末、TiCN粉末、Al粉末、AlN粉末、Al2O3粉末を結合相形成用原料粉末として用意する。
これら中からいくつかの原料粉末とcBN粒子粉末の合量を100体積%としたときのcBN粒子粉末の含有割合が40〜70体積%となるように表1に示される配合比で配合する。
次いで、この原料粉末をボールミルで72時間湿式混合し、乾燥した後、油圧プレスにて成形圧1MPaで直径:50mm×厚さ:1.5mmの寸法にプレス成形し、ついでこの成形体を、圧力:1Pa以下の真空雰囲気中、1000℃で30分間保持して熱処理し、揮発成分および粉末表面への吸着成分を除去して予備焼結体を作製する。
この予備焼結体をワイヤー放電加工機で所定寸法に切断し、Co:5質量%、TaC:5質量%、WC:残りの組成およびISO規格CNGA120408のインサート形状をもったWC基超硬合金製インサート本体のろう付け部(コーナー部)に、質量%で、Cu:26%、Ti:5%、Ag:残りからなる組成を有するAg系ろう材を用いてろう付けし、上下面および外周研磨、ホーニング処理を施すことによりISO規格CNGA120408のインサート形状をもった本発明用の工具基体1〜6を製造する。
また、原料粉末としてのcBN粒子の平均粒径、cBN粒子粉末の含有割合の少なくとも片方を前述の範囲外とすることによって比較品用の工具基体7〜12を製造した。
その結果を表1に示す。
Tool substrate forming process:
As the raw material powder, cBN particles having an average particle diameter of 0.5 to 4.0 μm are prepared as a raw material powder for forming a hard phase, and TiN having an average particle diameter in the range of 0.3 to 0.9 μm. Powder, TiC powder, TiCN powder, Al powder, AlN powder, and Al 2 O 3 powder are prepared as binder phase forming raw material powders.
Among these, the blending ratio shown in Table 1 is blended so that the content of the cBN particle powder is 40 to 70% by volume when the total amount of some raw material powders and the cBN particle powder is 100% by volume.
Next, the raw material powder is wet mixed in a ball mill for 72 hours, dried, and then press-molded with a molding pressure of 1 MPa to a size of diameter: 50 mm × thickness: 1.5 mm with a hydraulic press. A pre-sintered body is produced by removing the volatile components and the components adsorbed on the powder surface by heat treatment by holding at 1000 ° C. for 30 minutes in a vacuum atmosphere of 1 Pa or less.
This pre-sintered body is cut into a predetermined size with a wire electric discharge machine, Co: 5 mass%, TaC: 5 mass%, WC: remaining composition and made of WC-base cemented carbide with ISO standard CNGA120408 insert shape The brazing part (corner part) of the insert body is brazed using an Ag-based brazing material having a composition of Cu: 26%, Ti: 5%, and Ag: the remainder, and polishing the upper and lower surfaces and outer circumference. The tool bases 1 to 6 for the present invention having the ISO standard CNGA120408 insert shape are manufactured by performing the honing process.
Moreover, tool bases 7 to 12 for comparative products were manufactured by setting at least one of the average particle size of the cBN particles as the raw material powder and the content ratio of the cBN particle powder out of the above range.
The results are shown in Table 1.
成形工程:
前述の工程によって作製した工具基体1〜6に対して、図2に示したようなアークイオンプレーティング装置を用いて、硬質被覆層を形成した。
(a)工具基体1〜6を、アセトン中で超音波洗浄し、乾燥した状態で、アークイオンプレーティング装置内の回転テーブル上の中心軸から半径方向に所定距離離れた位置に外周部にそって装着する。また、カソード電極(蒸発源)として、所定組成のTi−Al合金およびTi−Al−Si合金を配置する。
(b)まず、装置内を排気して10−2Pa以下の真空に保持しながら、ヒーターで装置内を500℃に加熱した後、2PaのArガス雰囲気に設定し、前記回転テーブル上で自転しながら回転する工具基体に−200Vの直流バイアス電圧を印加し、もって工具基体表面をアルゴンイオンによってボンバード洗浄する。
(c)次に、装置内に反応ガスとして窒素ガスを導入して2〜10Paの所定の反応雰囲気とすると共に、前記回転テーブル上で自転しながら回転する工具基体に−20〜100Vの所定の直流バイアス電圧を印加し、かつ、前記Ti−Al合金からなるカソード電極(蒸発源)とアノード電極との間に90〜150Aの所定の電流を流してアーク放電を発生させ、前記工具基体の表面に、表2に示される目標平均組成、目標平均層厚の(Ti,Al)N層を蒸着形成する。
(d)次いで、装置内に反応ガスとして窒素ガスを導入して同じく2〜10Paの所定の反応雰囲気とすると共に、前記回転テーブル上で自転しながら回転する工具基体に−20〜100Vの所定の直流バイアス電圧を印加し、かつ、前記Ti−Al−Si合金からなるカソード電極(蒸発源)とアノード電極との間に90〜150Aの所定の電流を流してアーク放電を発生させ、前記工具基体の表面に、表2に示される目標平均組成、目標平均層厚の(Ti,Al,Si)N層を蒸着形成する。
前述したような(a)〜(d)の工程を経て、本発明切削工具1〜6を製造する。
このとき、工具基体表面におけるcBN粒子の突き出し量を0.1〜0.5μmとすることが望ましい。ここでcBN粒子の突き出し量とは、工具基体表面を基準とし、その表面に露出したcBN粒子の、工具基体表面に垂直な方向の最大高さを意味している。
工具基体を作製する際、表面を研削することで硬さの小さい結合相が優先的に除去され、表面にcBN粒子が露出する。さらに、前記(b)のように成膜前にボンバード処理を実施することで表面に露出するcBN粒子の突き出し量を制御することができる。
帯状微粒組織は結合相上に形成されるため、結合相の周囲のcBNの突き出し量の差が大きいほど、帯状微粒組織は大きく傾いて成長する。したがって、基体表面のcBN粒子の突き出し量を制御することで帯状微粒組織の傾き角度を制御することができる。
また、cBN粒子の粒径、含有量および成膜時のパラメータによって帯状微粒組織の形成される量を制御することで、帯状微粒組織の平均幅および含有割合を所望の値に調整する。
Molding process:
A hard coating layer was formed on the tool bases 1 to 6 produced by the above-described process using an arc ion plating apparatus as shown in FIG.
(A) The tool bases 1 to 6 are ultrasonically cleaned in acetone and dried. Then, the tool bases 1 to 6 are arranged along the outer peripheral portion at a predetermined radial distance from the central axis on the rotary table in the arc ion plating apparatus. Install. In addition, as a cathode electrode (evaporation source), a Ti—Al alloy and a Ti—Al—Si alloy having a predetermined composition are disposed.
(B) First, the inside of the apparatus is evacuated and kept at a vacuum of 10 −2 Pa or less, the inside of the apparatus is heated to 500 ° C. with a heater, set to an Ar gas atmosphere of 2 Pa, and rotated on the rotary table. Then, a DC bias voltage of −200 V is applied to the rotating tool base, and the tool base surface is bombarded with argon ions.
(C) Next, nitrogen gas is introduced as a reaction gas into the apparatus to form a predetermined reaction atmosphere of 2 to 10 Pa, and a predetermined base of −20 to 100 V is applied to a tool base that rotates while rotating on the rotary table. A DC bias voltage is applied, and a predetermined current of 90 to 150 A is passed between the cathode electrode (evaporation source) made of the Ti—Al alloy and the anode electrode to generate arc discharge, and the surface of the tool base Then, a (Ti, Al) N layer having a target average composition and target average layer thickness shown in Table 2 is formed by vapor deposition.
(D) Next, nitrogen gas is introduced as a reaction gas into the apparatus to form a predetermined reaction atmosphere of 2 to 10 Pa, and a predetermined base of −20 to 100 V is applied to a tool base that rotates while rotating on the rotary table. A direct current bias voltage is applied, and a predetermined current of 90 to 150 A is passed between a cathode electrode (evaporation source) made of the Ti—Al—Si alloy and an anode electrode to generate arc discharge, and the tool base body A (Ti, Al, Si) N layer having a target average composition and a target average layer thickness shown in Table 2 is formed by vapor deposition on the surface.
The cutting tools 1 to 6 of the present invention are manufactured through the steps (a) to (d) as described above.
At this time, it is desirable that the protruding amount of the cBN particles on the surface of the tool base is 0.1 to 0.5 μm. Here, the protruding amount of cBN particles means the maximum height of the cBN particles exposed on the surface of the tool base surface in the direction perpendicular to the tool base surface.
When producing the tool base, the surface is ground to preferentially remove the binder phase having a low hardness, and the cBN particles are exposed on the surface. Furthermore, the protrusion amount of the cBN particles exposed on the surface can be controlled by performing the bombarding process before the film formation as in (b).
Since the band-like fine grain structure is formed on the binder phase, the band-like fine grain structure grows with a greater inclination as the difference in the protruding amount of cBN around the binder phase increases. Therefore, the inclination angle of the band-like fine grain structure can be controlled by controlling the protruding amount of the cBN particles on the substrate surface.
Further, the average width and content ratio of the band-like fine grain structure are adjusted to desired values by controlling the amount of the band-like fine grain structure formed according to the particle size and content of the cBN particles and the parameters during film formation.
比較のため、工具基体7〜12に対して、前述したような(a)〜(d)の工程を経て、比較品切削工具1〜6を製造した。その結果を表3に示す。 For comparison, comparative product cutting tools 1 to 6 were manufactured through the steps (a) to (d) described above for the tool bases 7 to 12. The results are shown in Table 3.
本発明切削工具1〜6、比較品切削工具1〜6のホーニング面を集束イオンビーム(Focused Ion Beam:FIB)を用いて断面加工し、刃先稜線に垂直な断面を形成し、断面組織をSEMにより観察し、二次電子画像を取得する。
観察領域は、15μm×15μm程度であって、cBN焼結体中のcBN粒子および硬質被覆層の全体が観察できる倍率とする。
この二次電子画像から前述したような方法を用いて、cBN粒子の平均粒径、硬質被覆層の平均層厚を測定した。
また、前述の断面加工とSEMによる断面組織観察を繰り返すことにより、二次元電子画像から帯状組織の三次元形状を見積もり、帯状微粒組織の平均幅と平均傾斜角および硬質被覆層全体に対する体積%を算出した。
The honing surfaces of the cutting tools 1 to 6 of the present invention and the comparative cutting tools 1 to 6 are cross-sectioned using a focused ion beam (FIB) to form a cross-section perpendicular to the edge line of the cutting edge, and the cross-sectional structure is SEM To obtain a secondary electron image.
The observation area is about 15 μm × 15 μm, and the magnification is such that the entire cBN particles and the hard coating layer in the cBN sintered body can be observed.
From the secondary electron image, the average particle diameter of cBN particles and the average layer thickness of the hard coating layer were measured using the method as described above.
In addition, by repeating the cross-sectional processing described above and observation of the cross-sectional structure by SEM, the three-dimensional shape of the band-like structure is estimated from the two-dimensional electronic image, and the average width and average inclination angle of the band-like fine-grained structure and Calculated.
図3にcBN焼結体中のcBN粒子の平均粒径、硬質被覆層の平均層厚の測定に使用したSEMの断面画像の模式図を示している。 FIG. 3 shows a schematic diagram of a cross-sectional image of the SEM used for measurement of the average particle size of cBN particles in the cBN sintered body and the average layer thickness of the hard coating layer.
その結果を、表2および表3に示す。 The results are shown in Table 2 and Table 3.
本発明切削工具1〜6および比較品切削工具1〜6について、
切削条件A:
被削材:クロム鋼鋼材SCr420の浸炭焼入れ材(HRC60)の丸棒、
切削速度:300m/min.、
切り込み:0.2mm、
送り:0.1mm、
の乾式連続切削、
切削条件B:
被削材:クロム鋼鋼材SCM415の浸炭焼入れ材(HRC60)の長さ方向等間隔4本縦溝入り丸棒、
切削速度:210m/min.、
切り込み:0.15mm、
送り:0.1mm、
の乾式断続切削、
という切削条件で、最大切削長を条件Aでは900m、条件Bでは1200mとし、切削長100m毎に刃先のチッピングと逃げ面摩耗量を評価した。
その結果を表4に示す。
About this invention cutting tools 1-6 and comparative product cutting tools 1-6,
Cutting condition A:
Work material: Round bar of carburized and quenched material (HRC60) of chrome steel steel SCr420,
Cutting speed: 300 m / min. ,
Cutting depth: 0.2mm,
Feed: 0.1mm,
Dry continuous cutting,
Cutting condition B:
Work material: Four longitudinally-grooved round bars at equal intervals in the longitudinal direction of the carburized and quenched material (HRC60) of chrome steel SCM415,
Cutting speed: 210 m / min. ,
Cutting depth: 0.15 mm,
Feed: 0.1mm,
Of dry interrupted cutting,
The maximum cutting length was 900 m for condition A and 1200 m for condition B, and the chipping of the cutting edge and the amount of flank wear were evaluated for each cutting length of 100 m.
The results are shown in Table 4.
さらに、本発明切削工具1〜6および比較品切削工具1〜6の硬質被覆層を構成するTiAlN層およびTiAlSiN層について、FIBを用いた薄片加工により、工具逃げ面から、工具基体および硬質被覆層を含む、幅100μm×高さ300μm×厚さ0.2μmの薄片を切り出し、該薄片のうち、硬質被覆層の厚み領域が全て含まれるよう設定された、幅が10μmであり、高さが硬質被覆層の層厚の2倍である視野を、透過型電子顕微鏡(Transmission Electron Microscope:TEM)(倍率は200000倍から1000000倍の範囲から適切な値に設定する)による断面観察を行い、硬質被覆層中の帯状微粒組織を構成する結晶粒の平均粒径および硬質被覆層を構成する帯状微粒組織以外の結晶粒の平均粒径を測定した。断面組織観察視野内のTiAlN層およびTiAlSiN層の領域のうち、TiAlN層およびTiAlSiN層の層厚×5μmの範囲における個々の結晶粒の長径と短径の平均値を、その結晶粒の粒径とし、TiAlN層およびTiAlSiN層の層厚×5μmの範囲における個々の結晶粒の粒径の平均値を、本発明切削工具1〜6および比較品切削工具1〜6の硬質被覆層の下部層であるTiAlN層および上部層であるTiAlSiN層を構成する結晶粒の平均粒径とした。その結果を表2および表3に示した。また同時に、TEMを用いてのエネルギー分散型X線分析法(Energy Dispersive X−ray Spectroscopy:EDS)により、本発明切削工具1〜6および比較品切削工具1〜6の硬質被覆層を構成するTiAlN層およびTiAlSiN層の組成を測定したところ、いずれも表2および表3に示した目標組成と実質的に同じ組成を示した。 Further, the TiAlN layer and the TiAlSiN layer constituting the hard coating layers of the cutting tools 1 to 6 of the present invention and the comparative cutting tools 1 to 6 are processed from the tool flank to the tool base and the hard coating layer by thin piece processing using FIB. A thin piece having a width of 100 μm, a height of 300 μm, and a thickness of 0.2 μm was cut out, and the width of the thin piece was set so as to include the entire thickness region of the hard coating layer. The field of view, which is twice the thickness of the coating layer, is observed with a transmission electron microscope (Transmission Electron Microscope: TEM) (magnification is set to an appropriate value from the range of 200000 to 1000000), and hard coating is performed. The average grain size of the grains constituting the band-like fine grain structure in the layer and the crystals other than the band-like fine grain structure constituting the hard coating layer The average particle size of the grains was measured. Of the TiAlN layer and TiAlSiN layer within the cross-sectional structure observation field, the average value of the major axis and minor axis of each crystal grain in the range of the thickness of the TiAlN layer and the TiAlSiN layer × 5 μm is defined as the grain size of the crystal grain. The average value of the grain sizes of the individual crystal grains in the range of the thickness of the TiAlN layer and the TiAlSiN layer × 5 μm is the lower layer of the hard coating layer of the cutting tools 1 to 6 of the present invention and the comparative cutting tools 1 to 6 The average grain size of the crystal grains constituting the TiAlN layer and the TiAlSiN layer as the upper layer was used. The results are shown in Tables 2 and 3. At the same time, TiAlN constituting the hard coating layer of the cutting tools 1 to 6 of the present invention and the comparative cutting tools 1 to 6 by energy dispersive X-ray spectroscopy (EDS) using TEM. When the compositions of the layer and the TiAlSiN layer were measured, both showed substantially the same compositions as the target compositions shown in Tables 2 and 3.
また、本発明切削工具1〜6および比較品切削工具1〜6の硬質被覆層の層厚を、SEM(倍率は5000倍から200000倍の範囲から適切な値に設定する)を用いて測定し、観察視野内の5点の層厚を測って平均して平均層厚を求めたところ、いずれも表2および表3に示される目標層厚と実質的に同じ平均層厚を示した。 Moreover, the layer thickness of the hard coating layer of this invention cutting tool 1-6 and comparative product cutting tool 1-6 is measured using SEM (a magnification is set to an appropriate value from the range of 5000 times to 200000 times). When the average layer thickness was determined by measuring and averaging the five layer thicknesses in the observation field, the average layer thickness was substantially the same as the target layer thickness shown in Tables 2 and 3.
表2および表4に示される結果から、本発明切削工具は、硬質被覆層中に工具基体表面に露出している結合相の一部から下部層および上部層を貫き該上部層表面まで連続した帯状微粒組織が工具基体表面の法線に対して所定の角度傾斜しており、かつ帯状微粒組織が所定の平均幅と所定の含有割合であることによって、高負荷な切削条件が要求される焼き入れ鋼などの高硬度鋼の高速切削加工に用いた場合においても、チッピングが発生しにくく、長期に亘ってすぐれた切削性能を維持することが明らかである。 From the results shown in Tables 2 and 4, the cutting tool of the present invention was continuous from a part of the binder phase exposed on the surface of the tool base in the hard coating layer through the lower layer and the upper layer to the surface of the upper layer. The band-like fine grain structure is inclined at a predetermined angle with respect to the normal of the tool substrate surface, and the band-like fine grain structure has a predetermined average width and a predetermined content ratio, so that a high load cutting condition is required. Even when used for high-speed cutting of high hardness steel such as steel inserts, it is clear that chipping hardly occurs and excellent cutting performance is maintained over a long period of time.
一方、表3および表4に示される結果から、比較品切削工具は、硬質被覆層中に所定の帯状微粒組織を有していないために、硬質被覆層全体として、耐欠損性、耐摩耗性の面で劣り、剥離、欠損、チッピングを発生し、比較的短時間で使用寿命に至ることが明らかである。 On the other hand, from the results shown in Tables 3 and 4, since the comparative cutting tool does not have a predetermined band-like fine grain structure in the hard coating layer, the hard coating layer as a whole has fracture resistance and wear resistance. It is clear that it is inferior in terms of surface area, causes peeling, chipping and chipping, and reaches the service life in a relatively short time.
本発明の表面被覆切削工具は、各種の鋼などの通常の切削条件での切削加工は勿論のこと、特に高熱発生を伴うとともに、切刃部に対して大きな負荷がかかる合金鋼、ステンレス鋼などの高速断続旋削加工においても、すぐれた耐欠損性および耐摩耗性を発揮し、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。
The surface-coated cutting tool of the present invention is not only for cutting under normal cutting conditions such as various steels, but also alloy steel, stainless steel, etc. that are accompanied by high heat generation and a heavy load on the cutting edge part. Even in high-speed intermittent turning, it exhibits excellent chipping resistance and wear resistance and exhibits excellent cutting performance over a long period of time. And it can cope with energy saving and cost reduction sufficiently satisfactorily.
Claims (2)
前記立方晶窒化硼素焼結体は立方晶窒化硼素粒子とTiの窒化物、炭化物、炭窒化物、硼化物およびAlの窒化物、酸化物からなる群から選ばれた少なくとも1種以上の粒子と不可避不純物とを含む結合相とからなり、
前記立方晶窒化硼素粒子は平均粒径が0.5〜4.0μmかつ立方晶窒化硼素焼結体全体に占める含有割合が40〜70体積%であり、
前記結合相を構成する粒子は平均粒径が1.0μm以下であり、
前記硬質被覆層は少なくとも工具基体直上の下部層Aとその上に形成された上部層Bとからなるとともに平均総層厚が1.0〜8.0μmであり、
前記下部層Aは組成式:Ti1−aAlaN(但し、aは原子比で0.3≦a≦0.7)の成分系からなり、
前記上部層Bは組成式:Ti1−x―yAlxSiyN(但し、x、yは原子比で0.3≦x≦0.7、0.01≦y≦0.1)の成分系からなり、
前記硬質被覆層中に工具基体表面に露出している結合相の一部から下部層Aおよび上部層Bを貫き該上部層B表面まで連続した帯状微粒組織が工具基体表面の法線に対して平均して30〜60°傾斜して存在しているとともに前記帯状微粒組織の工具基体表面に平行な方向の平均幅が0.3〜1.5μmかつ硬質被覆層全体に占める含有割合が5〜20体積%であることを特徴とする表面被覆切削工具。 A surface-coated cutting tool having a hard coating layer on a tool substrate, at least a cutting edge of which is used for cutting is a cubic boron nitride sintered body,
The cubic boron nitride sintered body includes cubic boron nitride particles and at least one kind of particles selected from the group consisting of Ti nitride, carbide, carbonitride, boride, Al nitride, and oxide. Consisting of a binder phase containing inevitable impurities,
The cubic boron nitride particles have an average particle size of 0.5 to 4.0 μm and a content ratio of 40 to 70% by volume in the entire cubic boron nitride sintered body,
The particles constituting the binder phase have an average particle size of 1.0 μm or less,
The hard coating layer comprises at least a lower layer A immediately above the tool base and an upper layer B formed thereon, and an average total layer thickness is 1.0 to 8.0 μm,
The lower layer A is composed of a component system having a composition formula: Ti 1-a Al a N (where a is an atomic ratio of 0.3 ≦ a ≦ 0.7),
The upper layer B has a composition formula: Ti 1-xy Al x Si y N (where x and y are atomic ratios of 0.3 ≦ x ≦ 0.7 and 0.01 ≦ y ≦ 0.1). Consists of component system
In the hard coating layer, a band-like fine grain structure extending from a part of the binder phase exposed on the surface of the tool base through the lower layer A and the upper layer B to the surface of the upper layer B has a normal to the surface of the tool base. The average width in the direction parallel to the surface of the tool base of the band-shaped fine grain structure is 0.3 to 1.5 μm and the content ratio of the entire hard coating layer is 5 to A surface-coated cutting tool characterized by being 20% by volume.
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