JPWO2011111261A1 - 立方晶窒化硼素焼結体工具 - Google Patents
立方晶窒化硼素焼結体工具 Download PDFInfo
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- JPWO2011111261A1 JPWO2011111261A1 JP2012504276A JP2012504276A JPWO2011111261A1 JP WO2011111261 A1 JPWO2011111261 A1 JP WO2011111261A1 JP 2012504276 A JP2012504276 A JP 2012504276A JP 2012504276 A JP2012504276 A JP 2012504276A JP WO2011111261 A1 JPWO2011111261 A1 JP WO2011111261A1
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Abstract
Description
Y≦0.6×X+3(ただし式中、20≦X<88) ・・・(II)
Y≦5.8×X−455(ただし式中、88≦X≦98) ・・・(III)
本発明の立方晶窒化硼素焼結体工具は、少なくとも工具作用点に立方晶窒化硼素焼結体を用いたものであって、該立方晶窒化硼素焼結体中に含まれる立方晶窒化硼素の割合をX体積%とし、立方晶窒化硼素焼結体の熱伝導率をY(W/m・K)とすると、以下の式(II’)とを満たすことを特徴とする。
また、立方晶窒化硼素焼結体は、立方晶窒化硼素に加え、断熱相と、結合相とを含有し、該断熱相は、Al、Si、Ti、Zr、Mo、Ni、およびCrからなる群より選択される1種以上の元素と、N、C、O、およびBからなる群より選択される1種以上の元素とからなる第1化合物を1種以上含み、該第1化合物は、立方晶窒化硼素焼結体中に1質量%以上20質量%以下含まれ、かつ100nm未満の平均粒子径を有することが好ましい。上記の第1化合物は、50nm未満の平均粒子径を有することが好ましい。また、断熱相は、その一部として未焼結の領域を0.01体積%以上3体積%以下含むことが好ましい。
<立方晶窒化硼素焼結体工具>
本発明の立方晶窒化硼素焼結体工具は、少なくとも工具作用点にcBN焼結体を用いる構成を有する。具体的には、本発明のcBN焼結体工具は、工具シャンク部に防振耐熱板を介してcBN焼結体が固定されている構成を有していてもよいし、超硬合金からなる基材に接合層を介してcBN焼結体が固定されている構成を有していてもよい。このような構成を有する本発明のcBN焼結体工具は、鉄系焼結合金、難削鋳鉄、焼入鋼等の機械加工において特に有効に用いることができる他、これら以外の一般的な金属の各種加工においても好適に用いることができる。ここで、「工具作用点」とは、cBN焼結体工具の表面のうちの加工物と接触する部分を意味する。なお、工具シャンク部および防振耐熱板については後述する。
本発明のcBN焼結体は、立方晶窒化硼素に加え、断熱相と結合相とを含有することが好ましい。熱伝導率の高い立方晶窒化硼素間に断熱相の成分を配置することにより、cBN焼結体の熱伝導性を低下させることができ、以下の式(I)と、式(II)または式(III)のいずれか一方とを満たすようにすることができる。
20≦X≦98 ・・・(I)
Y≦0.6×X+3(ただし式中、20≦X<88) ・・・(II)
Y≦5.8×X−455(ただし式中、88≦X≦98) ・・・(III)
このようなcBN焼結体を用いたcBN焼結体工具を用いて切削加工または塑性加工すると、加工時に生じる摩擦熱およびせん断熱がcBN焼結体工具に伝導するよりも加工物に伝導する。これにより加工物が軟化しやすくなり、cBN焼結体工具の刃先にかかる負荷を低減し、以ってcBN焼結体工具に摩耗および欠損を発生しにくくすることができる。
かかる式(II’)を満たす立方晶窒化硼素焼結体は、cBN粒子の含有量と断熱相の含有量とのバランスが極めて良好であり、cBN焼結体の熱伝導率が低く、かつ高温での硬度が高いものである。このようにcBN焼結体の熱伝導率が低いことにより被削材に切削熱が流入されて被削材の硬度を低下させるとともに、cBN粒子の含有量が高いことによりcBN焼結体の硬度が高められる。これらの効果が相俟って極めて長寿命のcBN焼結体工具を作製することができる。
本発明において、立方晶窒化硼素はcBN焼結体中に20体積%以上98体積%以下含まれることを特徴とする。ここで、cBN焼結体中のcBNが20体積%未満の場合、耐摩耗性が不足し、98体積%を超えると、相対的に結合相が少なくなり接合強度が低下する。耐摩耗性と接合強度のバランスから、cBNの含有率は60体積%以上88体積%未満とすることがより好ましい。
本発明において、cBN焼結体に含まれる結合相(結合材とも呼ばれる)は、cBN粒子同士を結合する作用を示すものであって、cBN焼結体の結合相として知られる従来公知の組成の結合相をいずれも採用することができる。結合相に用いられる組成としては、Ti、W、Co、Zr、およびCrからなる群より選ばれる少なくとも1種の元素と、N、C、O、およびBからなる群より選択される1種以上の元素と、Alとの化合物であることが好ましく、Ti、W、Co、Zr、およびCrからなる群より選ばれる少なくとも1種の元素の炭化物、硼化物、炭窒化物、酸化物、またはこれらの相互固溶体の少なくとも一種とAlとの化合物であることがより好ましい。これにより鉄系焼結合金、および鋳鉄の機械加工で、特に良好な耐摩耗性を得ることができる。
本発明において、断熱相はcBN焼結体中に点在することにより、cBN焼結体の熱伝導率を低下させることができ、以って加工時に生じる熱がcBN焼結体工具に伝導しにくく加工物への伝導が促進される。このような断熱相は、焼結性に劣る材料からなり、具体的には、Al、Si、Ti、Zr、Mo、Ni、およびCrからなる群より選択される1種以上の元素と、N、C、O、およびBからなる群より選択される1種以上の元素とからなる第1化合物を1種以上含み、該第1化合物は、cBN焼結体中に1質量%以上20質量%以下含まれ、かつ100nm未満の平均粒子径を有することが好ましい。第1化合物が1質量%未満であると、立方晶窒化硼素焼結体の熱伝導率を低下させる効果が十分に得られず、加工物への熱の伝導が促進されない。また、第1化合物が20質量%を超えると、焼結が不十分となり、立方晶窒化硼素焼結体の硬度が低下するという問題がある。また、第1化合物の平均粒子径が100nm以上であると、立方晶窒化硼素焼結体の熱伝導率を下げる効果が小さく、本発明の効果を得ることができない。立方晶窒化硼素焼結体の熱伝導率を低下させるという観点からは、第1化合物の平均粒子径が50nm未満であることが好ましい。
本発明において、cBN焼結体が固定される工具シャンク部は、この種の工具シャンク部として知られる従来公知のものであればいずれのものであっても採用することができ、特に限定されない。このような工具シャンク部としては、たとえば超硬合金製またはステンレス製のものを好適に用いることができる。
本発明において、cBN焼結体と工具シャンク部との固定部分に防振耐熱板を介在させることが好ましい。防振耐熱板を介在させることにより、加工時にcBN焼結体に生じる振動が工具シャンク部に伝播するのを抑制することができる。すなわち、防振耐熱板を設けることにより、加工時に工具シャンク部にかかる振動の負荷を軽減することができる。
本発明に用いられるcBN焼結体は、cBN粒子と断熱相を構成する原料粉末と結合相を構成する原料粉末とを超高圧装置に導入した上で、これらの粉末を超高圧焼結することにより得ることができる。このように断熱相を構成する原料粉末を含めた上で、超高圧焼結することにより、cBN焼結体の熱伝導率を低下させることができる。ここで、超高圧焼結の条件として、超高圧焼結時の圧力は、低圧力であることが好ましく、より具体的には2GPa以上7GPa以下であることが好ましい。超高圧焼結時の温度は、1100℃以上1800℃以下であることが好ましく、超高圧焼結の処理に要する時間は5分以上30分以下であることが好ましい。
以下、実施例を挙げて本発明をより詳細に説明するが、本発明はこれらに限定されるものではない。
以下のようにして、cBN焼結体工具を作製した。まず、平均粒子径0.8μmのWC粉末と、平均粒子径0.9μmのCo粉末と、平均粒子径2μmのAl粉末とを質量比で、WC:Co:Al=35:55:10となるように混合した。そして、真空中で1100℃、40分間熱処理した化合物を、φ3mmの超硬合金製ボールを用いて粉砕し結合相を構成する原料粉末を得た。
実施例1のcBN焼結体工具に対し、被覆層の有無および組成、ならびに断熱相の組成が表1のように異なる他は、実施例1と同様の方法により実施例2〜3のcBN焼結体工具を作製した。たとえば、実施例2では、断熱相を構成する成分として、平均粒子径0.85μmのMo粉末と、平均粒子径0.7μmのNi粉末とを第1化合物の原料粉末に用い、cBN粒子を被覆する被覆層の組成をTiAlとしたことを除いては実施例1と同様のものとした。
実施例1のcBN焼結体工具に対し、cBNの割合が表1のように異なる他は実施例1と同様の方法により実施例4〜6のcBN焼結体工具を作製した。
実施例1のcBN焼結体工具に対し、被覆層を有さないcBN原料粉末を用いたこと、cBNの割合を98体積%としたこと、および結合相を構成する粉末の50質量%の粉末量の第1化合物を使用したことを除いては、実施例1と同様の方法により、本実施例のcBN焼結体工具を作製した。
以下のようにして、cBN焼結体工具を作製した。なお、実施例8〜13のcBN焼結体工具は、cBN焼結体のみからなる工具である。まず、平均粒子径1.2μmのTiC粉末と平均粒子径3μmのAl粉末とを質量比で、TiC:Al=90:10となるように混合し、真空中で1200℃、30分間熱処理した化合物を、φ3mmの超硬合金製ボールを用いて粉砕し結合相を構成する原料粉末を得た。
実施例8のcBN焼結体工具に対し、cBNの割合が表1のように異なる他は実施例8と同様の方法により本実施例のcBN焼結体工具を作製した。
実施例8のcBN焼結体工具に対し、被覆層を有さないcBN原料粉末を用いたこと、cBNの割合を75体積%としたこと、および焼結時の温度を1450℃に設定したことが異なる他は実施例8と同様の方法により本実施例のcBN焼結体工具を作製した。
実施例10のcBN焼結体工具に対し、焼結時の圧力を2.8GPaに設定したことが異なる他は、実施例10と同様の方法により本実施例のcBN焼結体工具を作製した。
実施例10のcBN焼結体工具に対し、超高圧焼結装置を用いる代わりに、放電プラズマ焼結(SPS:Spark Plasma Sintering)装置を用いることにより、cBN焼結体工具を作製した。具体的には、SPS装置内の温度を1450℃とし、焼結時の圧力を0.06GPaに調整した上で、cBN粉末と結合相を構成する原料粉末と断熱相を構成する第1化合物の原料粉末とを焼結することによりcBN焼結体を得た。なお、SPS装置を用いたcBN焼結体の作製方法を具体的に説明すると、cBN粉末と結合相を構成する原料粉末と断熱相を構成する第1化合物の原料粉末とを混合したものをグラファイト製焼結型に充填した上で、0.06GPaに加圧し、真空加熱条件で装置内の温度を1450℃として、30分以下の間、放電プラズマ焼結を行なうことにより行なった(たとえば特開2008−121046号公報の段落[0014]参照)。
実施例10のcBN焼結体工具に対し、超高圧焼結装置を用いる代わりに、ホットプレス装置を用いることにより、cBN焼結体工具を作製した。具体的には、ホットプレス装置内の温度を1450℃とし、焼結時の圧力を0.02GPaに調整した上で、cBN粉末と結合相を構成する原料粉末と断熱相を構成する第1化合物の原料粉末とを焼結することによりcBN焼結体を得た。
Y≦0.6×X+3(ただし式中、20≦X<88) ・・・(II)
Y≦5.8×X−455(ただし式中、88≦X≦98) ・・・(III)
<比較例1〜2>
比較例1〜2の立方晶窒化硼素焼結体工具は、実施例1の立方晶窒化硼素焼結体工具に対して、cBNの割合、および結合相の組成が表1のように異なり、かつ断熱相を含まないことを除いては実施例1と同様の方法により作製した。なお、このようにして作製された立方晶窒化硼素焼結体に対し、結合相を構成する成分の平均粒子径を測定したところ、いずれも100nm以上であった。
市販されているcBN焼結体(製品名:MB8025(三菱マテリアル株式会社製))を用いた。
市販されているcBN焼結体(製品名:BX480(株式会社タンガロイ製))を用いた。
実施例1〜7、および比較例1〜4について、工具型番がSNMA120430のcBN焼結体工具を作製し、以下の条件で切削試験を行なった。
被削材 :Ni基超耐熱合金インコネル718の外径加工
被削材硬度:Hv430
切削条件:切削速度 Vc=150m/min.
送り量 f=0.13mm/rev.
切り込み量 ap=0.2mm
クーラント エマルジョン20倍希釈
実施例8〜13、比較例1および3において、工具型番がCNGA120408のcBN焼結体工具を作製し、以下の条件で切削試験を行なった。
被削材 :0.8C−2.0Cu−残Fe(JPMA記号:SMF4040)
被削材硬度:78HRB
切削条件:切削速度 Vc=100m/min.
送り量 f=0.08mm/rev.
切り込み量 ap=0.2mm
切削液あり
実施例1〜3、および比較例1〜2において、工具形状がφ10の円筒形状のcBN焼結体工具を作製し、以下の条件で塑性試験を行なった。
加工物 :SUS304
加工物の硬度:Hv170
加工物の厚み:2mm
塑性条件:押しぬき荷重2.3GPa
実施例1〜3および比較例1〜2において、直径12.7mmの円柱の中央部に、ネジ高さが3mmのM4の左ネジ形状の突起物を形成したcBN焼結体工具の底面に対し、厚み2mmのジルコニア製の防振耐熱板をロウ付けした特殊工具を作製し、以下の条件で塑性試験を行なった。
被接合材:高張力鋼を2枚重ねしたもの
被接合材の引張強度:600MPa
被接合物の厚み:1mm
接合条件:回転数 2800rpm
加圧力 11000N
Claims (9)
- 少なくとも工具作用点に立方晶窒化硼素焼結体を用いた立方晶窒化硼素焼結体工具であって、
前記立方晶窒化硼素焼結体中に含まれる立方晶窒化硼素の割合をX体積%とし、前記立方晶窒化硼素焼結体の熱伝導率をY(W/m・K)とすると、以下の式(I)と、式(II)または式(III)のいずれか一方とを満たす、立方晶窒化硼素焼結体工具。
20≦X≦98 ・・・(I)
Y≦0.6×X+3(ただし式中、20≦X<88) ・・・(II)
Y≦5.8×X−455(ただし式中、88≦X≦98) ・・・(III) - 少なくとも工具作用点に立方晶窒化硼素焼結体を用いた立方晶窒化硼素焼結体工具であって、
前記立方晶窒化硼素焼結体中に含まれる立方晶窒化硼素の割合をX体積%とし、前記立方晶窒化硼素焼結体の熱伝導率をY(W/m・K)とすると、以下の式(II’)を満たす、立方晶窒化硼素焼結体工具。
Y≦0.5×X+1(ただし式中、60≦X<88) ・・・(II’) - 前記立方晶窒化硼素焼結体は、前記立方晶窒化硼素に加え、断熱相と、結合相とを含有し、
前記断熱相は、Al、Si、Ti、Zr、Mo、Ni、およびCrからなる群より選択される1種以上の元素と、N、C、O、およびBからなる群より選択される1種以上の元素とからなる第1化合物を1種以上含み、
前記第1化合物は、前記立方晶窒化硼素焼結体中に1質量%以上20質量%以下含まれ、かつ100nm未満の平均粒子径を有する、請求の範囲第1項に記載の立方晶窒化硼素焼結体工具。 - 前記第1化合物は、50nm未満の平均粒子径を有する、請求の範囲第3項に記載の立方晶窒化硼素焼結体工具。
- 前記断熱相は、その一部として未焼結の領域を0.01体積%以上3体積%以下含む、請求の範囲第3項に記載の立方晶窒化硼素焼結体工具。
- 前記第1化合物は、Al、Si、Ti、Zr、Mo、Ni、およびCrからなる群より選択される1種以上の元素の窒化物、炭化物、および炭窒化物に対し、酸素および硼素のいずれか一方もしくは両方が0.1質量%以上10質量%以下固溶した化合物である、請求の範囲第3項に記載の立方晶窒化硼素焼結体工具。
- 前記断熱相は、前記第1化合物に加え、Wおよび/またはReと、N、C、O、およびBからなる群より選択される1種以上の元素とからなる第2化合物を1種以上含み、
前記第2化合物は、前記立方晶窒化硼素焼結体中に0.1質量%以上2質量%以下含まれる、請求の範囲第3項に記載の立方晶窒化硼素焼結体工具。 - 前記立方晶窒化硼素は、平均粒子径が1μm以下の立方晶窒化硼素粒子からなる、請求の範囲第1項に記載の立方晶窒化硼素焼結体工具。
- 前記立方晶窒化硼素粒子は、その表面が被覆層に覆われており、
前記被覆層は、その平均層厚が5nm以上50nm以下である、請求の範囲第1項に記載の立方晶窒化硼素焼結体工具。
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