JP7249292B2 - コーティングされた切削工具 - Google Patents
コーティングされた切削工具 Download PDFInfo
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Description
本発明は、α-Al2O3の副層とTiCO、TiCNO、AlTiCO又はAlTiCNOの副層とが交互になったものからなるα-Al2O3多層を含むコーティングされた切削工具に関し、前記α-Al2O3多層は少なくとも5つのα-Al2O3の副層を含み、前記α-Al2O3多層の総厚さは1-15μmであり、かつα-Al2O3多層中の周期は50-900nmである。
金属切削産業において、コーティングされた切削工具は当該技術分野で周知である。CVDコーティングされた切削工具及びPVDコーティングされた切削工具は、コーティングされた切削工具のうちの2つの最も支配的なタイプである。これらのコーティングの利点は、コーティングされた切削工具の長い工具寿命を達成するために重要である化学的摩耗及び研摩摩耗に対する高い耐性である。
「切削工具」という略語は、本明細書において、切削工具インサート、エンドミル又はドリルを示すことを意図している。適用分野は、金属切削用途であり、例えば、旋削加工、フライス加工又は穿孔加工であり得る。
XRD分析
層のテクスチャ又は配向を調べるために、X線回折(XRD)を、PIXcel検出器を備えたPANalytical CubiX3回折計を使用して、逃げ面上で行った。コーティングされた切削工具をサンプルホルダー内に取り付けて、サンプルの逃げ面がサンプルホルダーの基準面に対して平行であること、及び逃げ面が適切な高さにあることを確認した。測定のために、Cu-Kα線を45kVの電圧及び40mAの電流で使用した。1/2度の散乱防止スリット及び1/4度の発散スリットを使用した。コーティングされた切削工具からの回折強度を、20°から140°までの2θの範囲で、すなわち10から70°までの入射角θの範囲にわたって測定した。データのバックグラウンドフィッティング、Cu-Kα2ストリッピング及びプロファイルフィッティングを含むデータ分析は、PANalytical社のX’Pert HighScore Plusソフトウェアを使用して行われた。次に、このプログラムからの出力(プロファイル適合曲線の積分ピーク面積)を使用して、強度比及び/又は関係に関して本発明のコーティングを定義した。
副層の突起を調べるために、STEM分析が、単色化、収差プローブ補正Titan 80-300 TEM/STEMで行われた。
式中、I(hkl)は(hkl)反射の測定強度(積分面積)であり、I0(hkl)はICDDのPDFカード番号42-1489に従った標準強度であり、nは反射の数であり、計算に使用される反射は、(1 1 1)、(2 0 0)、(2 2 0)、(3 1 1)、(3 3 1)、(4 2 0)、(4 2 2)及び(5 1 1)であり、TC(4 2 2)≧2、好ましくは≧3.5を示す。
超硬合金基材は、フライス加工、混合、噴霧乾燥、プレス、及び焼結などの従来のプロセスを利用して製造された。焼結基材は、10000個のハーフインチサイズの切削インサートを収容することができるイオン結合型(Ionbond Type)(530サイズ)のラジアルCVD反応器の中でCVDコーティングされた。超硬合金基材(インサート)のISO型形状はCNMG-120408-PMであった。サンプルのSingle A1、Multi A6、Multi A24、Multi A26、Multi A32、Multi A56、Multi A28u及びMulti A40uの超硬合金の組成は、7.2重量%のCo、2.9重量%のTaC、0.5重量%のNbC、1.9重量%のTiC、0.4重量%のTiN及び残部WCであった。サンプルMulti B38及びMulti B58の超硬合金の組成は、7.5重量%のCo、2.9重量%のTaC、0.5重量%のNbC、1.9重量%のTiC、0.4重量%のTiN及び残部WCであった。サンプルの概要を表1に示す。
表1-サンプルの概要
約0.4μmのTiNの最初の最も内側のコーティングが、400mbar及び885℃でのプロセスにおいてすべての基材上に堆積された。48.8体積%のH2、48.8体積%のN2、及び2.4体積%のTiCl4のガス混合物を使用した。
上記の方法のセクションにおいて開示されているように、XRD分析が行われた。強度データに対して薄膜補正は適用されなかった。サンプルのα-Al2O3に由来するピーク1 1 0、1 1 3、0 2 4、1 1 6、0 0 12及び0 1 14の強度が表3に示され、0 0 12の強度が100%に設定されるように値が正規化されている。サンプルMulti A28u及びSingle A1のXRDディフラクトグラムを、それぞれ図12及び13に示す。
表3-α-Al2O3に由来するXRD強度
ハリスの式は以下であり、
式中、I(hkl)は(hkl)反射の測定強度(積分面積)であり、I0(hkl)はICDDのPDFカード番号42-1489に従った標準強度であり、nは反射の数であり、計算に使用される反射は、(1 1 1)、(2 0 0)、(2 2 0)、(3 1 1)、(3 3 1)、(4 2 0)、(4 2 2)及び(5 1 1)である。
表4
副層の突起を調べるために、HAADFSTEM分析が、単色化、収差プローブ補正Titan 80-300 TEM/STEMで行われた。
摩耗試験の前に、コーティングされた切削工具のすくい面上にブラスト処理が実施された。使用されたブラスタースラリーは、水中20体積%のアルミナからなり、切削インサートのすくい面とブラスタースラリーの方向との間の角度は90度であった。ガンへのスラリーの圧力は、すべての摩耗試験サンプルについて1.8barであった。
サンプルは、ワークピース材料SS2541(700x180mmのバー)における乾式旋削試験切削において試験された。前記バーに直径178mmから直径60mmまでの面旋削加工が施された。次の切削データが使用された:
切削速度、Vc:200m/分
送り、fz:0.35mm/回転
切削深さ、ap:2mm
表5
サンプルは、ワークピース材料SS2541(700x180mmのバー)における乾燥状態での長手方向旋削において試験された。次の切削データが使用された:
切削速度、Vc:98又は110m/分
送り、fz:0.7mm/回転
切削深さ、ap:2mm
切削時間:30s
表6.
Claims (15)
- 基材とコーティングとを含むコーティングされた切削工具であって、コーティングが
α-Al2O3の副層とTiCO、TiCNO、AlTiCO又はAlTiCNOの副層とが交互になったものからなるα-Al2O3多層を含み、前記α-Al2O3多層が少なくとも5つのα-Al2O3の副層を含み、
前記α-Al2O3多層の総厚さが、1-15μmであり、
α-Al2O3多層中の周期が、50-900nmであり、
α-Al2O3多層が、20°-140°のθ-2θスキャンにわたってXRD回折を示し、0 0 12回折ピークの強度、I(0 0 12)と、1 1 3回折ピークの強度、I(1 1 3)、1 1 6回折ピークの強度、I(1 1 6)、及び0 2 4回折ピークの強度、I(0 2 4)との関係が、I(0 0 12)/I(1 1 3)>1、I(0 0 12)/I(1 1 6)>1、及びI(0 0 12)/I(0 2 4)>1であることを特徴とする、コーティングされた切削工具。 - 0 0 12回折ピークの強度、I(0 0 12)に対する、0 1 14回折ピークの強度、I(0 1 14)が、I(0 1 14)/I(0 0 12)<2である、請求項1に記載のコーティングされた切削工具。
- 1 1 0回折ピークの強度、I(1 1 0)と、1 1 3回折ピークの強度、I(1 1 3)、及び0 2 4回折ピークの強度、I(0 2 4)との関係が、I(1 1 0)>I(1 1 3)及びI(0 2 4)の各々である、請求項1又は2のいずれか一項に記載のコーティングされた切削工具。
- 0 0 12回折ピークの強度、I(0 0 12)と、1 1 0回折ピークの強度、I(1 1 0)との関係が、 I(0 0 12)>I(1 1 0)である、請求項1から3のいずれか一項に記載のコーティングされた切削工具。
- TiCO、TiCNO、AlTiCO又はAlTiCNOの副層が突起を含み、前記突起が結晶質である、請求項1から4のいずれか一項に記載のコーティングされた切削工具。
- 前記突起が少なくとも1つの双晶境界を含み、突起が(1 1 1)面を共有し、その<2 1 1>方向に延在している、請求項5に記載のコーティングされた切削工具。
- 前記突起の延在方向の長さが10-100nmである、請求項5又は6のいずれか一項に記載のコーティングされた切削工具。
- 基材の面法線に垂直な方向で測定される前記突起の高さが、多層の周期よりも小さい、請求項5から7のいずれか一項に記載のコーティングされた切削工具。
- 前記α-Al2O3副層の平均厚さが40-800nmである、請求項1から8のいずれか一項に記載のコーティングされた切削工具。
- 基材とα-Al2O3多層との間に位置し、α-Al2O3多層と直接接触する第1のα-Al2O3層をさらに含み、前記α-Al2O3層の厚さが<1μmである、請求項1から9のいずれか一項に記載のコーティングされた切削工具。
- コーティングされた切削工具が、基材とα-Al2O3多層との間に位置するTiC、TiN、TiAlN又はTiCNの少なくとも1つの層を含む、請求項1から10のいずれか一項に記載のコーティングされた切削工具。
- TiC、TiN、TiAlN又はTiCN層の厚さが2-15μmである、請求項11に記載のコーティングされた切削工具。
- コーティングの最外層がα-Al2O3層である、請求項1から12のいずれか一項に記載のコーティングされた切削工具。
- 基材が、超硬合金、サーメット、セラミック、高速度鋼又はcBNのものである、請求項1から13のいずれか一項に記載のコーティングされた切削工具。
- 基材が、3-14重量%のCo及び50重量%を超えるWCを含む超硬合金のものである、請求項1から14のいずれか一項に記載のコーティングされた切削工具。
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