TWI537405B - 切削工具 - Google Patents

切削工具 Download PDF

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Publication number
TWI537405B
TWI537405B TW097116758A TW97116758A TWI537405B TW I537405 B TWI537405 B TW I537405B TW 097116758 A TW097116758 A TW 097116758A TW 97116758 A TW97116758 A TW 97116758A TW I537405 B TWI537405 B TW I537405B
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Taiwan
Prior art keywords
cutting tool
layer
tool
coating
oxide
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TW097116758A
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TW200902734A (en
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丹尼斯昆頓
克里斯丁維拉布
侏根雷姆
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歐瑞康貿易特魯貝屈股份有限公司
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Publication of TW200902734A publication Critical patent/TW200902734A/zh
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B5/00—Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • C—CHEMISTRY; METALLURGY
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/044—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
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    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/048—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material with layers graded in composition or physical properties
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    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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    • C23C28/347—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with layers adapted for cutting tools or wear applications
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/24983—Hardness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Physical Vapour Deposition (AREA)
  • Chemical Vapour Deposition (AREA)
  • Drilling Tools (AREA)

Description

切削工具
本發明係關於一種塗膜尖銳刃口的切削工具，其係由包含至少一硬化材料及一接合劑材料在溫度及壓力下燒結成的燒結體所製成。切削工具包括，例如銑削工具(銑具)，車削工具，轉位插件，切齒工具，滾齒刀，柄式工具，螺紋工具，攻牙工具。
就過去及目前的粉末冶金燒結技術，燒結的碳化物切削工具已經被使用在未塗膜及在CVD(化學氣相沈積)及PVD(物理氣相沈積)已塗膜情況。包含MT-CVD(中溫CVD)塗膜製程的CVD塗膜製程需要高溫及化學反應性強烈的製程環境，溫度通常對HT-CVD(高溫CVD)為950℃以上，對MT-CVD為介於800℃與900℃之間。除了其他之外，此會造成習知的缺點，如橫向破壞強度(TRS)的降低及切削工具之低刃口強度及無法避免的塗膜之熱裂。
對MT-CVD缺點的更詳細觀察，將舉燒結的碳化物之塗膜為例說明如下：
(a)如前面所述，基板之TRS之降低可能係由於塗膜之前表面的狀態係由正確研磨過程所引起之有利的殘留壓縮應力之一；此狀態卻由高溫釋放此有利的殘留壓縮應力而改變。故，無關於塗膜，高溫退火在碳化物基板上有此效應。然而，例如即使基板不適當地研磨時，若受到過當的研磨而留下殘留抗拉應力或甚至某些表面龜裂，高 溫處理並無實質有利效果。
(b)塗膜工具之TRS的進一步降低，係起源於從高的CVD溫度冷卻下來時在塗膜與基板之間熱膨脹之不匹配所導致的熱龜裂之存在。龜裂通過塗膜之厚度，且因而在某些切削狀況下引起疲勞失效。
(c)在WC-Co硬金屬之情況，鈷會朝向約850℃或以上之溫度的表面擴散亦為周知，此亦與CVD過程中之除碳及ε相形成有關。此ε相例如可在TiC或TiCN CVD第1層之初期形成時基板的外部區域之除碳而形成，此TiC或TiCN CVD第1層通常係CVD Al2O3塗層之下層。此ε相區域形成高度多孔性之變脆層，再度造成微龜裂開始處及塗膜脫層傾向。至少HT-CVD之此缺點已被藉由在850℃塗佈一第1之TiCN層的MT-CVD所克服，藉此而減少ε相之形成。
故，過去已經採取不同的對策以消除此不利的效應。美國專利US 4,610,931號提案使用具有在靠近周邊表面富含黏結劑的燒結之碳化物體。在US 5,266,388及US5,250,367中，在殘留壓縮應力狀態下之PVD塗膜之後在殘留拉伸應力之狀態下進行的一CVD塗膜之施加，已經被提案用於上述富含黏結劑之工具。
不論燒結之碳化物已經被使用而顯示上述CVD塗膜過程之缺點之事實，其它具有燒結體之基板亦周知有相同或至少相似的問題。陶金(cermet)亦有Co,Ni，(及其他如Mo,Al...之其他金屬)黏結劑，且進行類似於燒結之碳化物 的燒結過程。TiCN系陶金，例如目前並不再樂於進行CVD塗膜，因為此等基板與塗膜氣體族族更具反應性，而在介面造成一不需要的反應層。超硬的CBN工具使用與碳化物及陶金不同的高溫高壓燒結技術。但是，其等亦有如Co,Ni....，之金屬黏結劑趨向於在CVD塗膜過程時引起高溫反應。此等基板有時以TiN、TiAlN、CrAlN或其他塗膜系統進行PVD塗膜，大部分用於在刃口處的磨損指示。然而，此塗膜僅能對由最進步技術之車削機器形成的高切削速度造成的高溫及高的氧化應力給予有限的保護。
固態Al2O3,Al2O3,-TiC系或加入玻璃相作為黏結劑的Al2O3-Si3N4(SiAlON)系之陶瓷工具材料係代表另一工具形態：電性絕緣且因而使用傳統PVD亦難以塗膜之工具。此等材料為已進行燒結的熱等靜壓(HIP：hot isostatic pressing)，與較低壓燒結碳化物相反。此等陶瓷嵌件再次並不進行CVD塗膜，因為高溫可造成Si3N4基板之軟化，或由於非結晶玻璃狀的黏結劑相變成結晶狀而使其失去某些韌性。然而未塗膜材料可使其等之黏結劑相與工件材料之間在金屬切削時相互作用，因而易受到坑狀磨損，故僅限制此工具使用於有限的利基應用。
故，隨同工具韌性或幾何形狀之特殊需要的高度要求，PVD塗膜在許多操作部分地或甚至完全取代CVD塗膜。此種工具之例，為使用在間斷的切削應用，如銑削或尤其是尖銳刃口螺紋及攻牙工具。但是，由於著名的熱化學抗性及熱硬性，氧化性CVD-塗膜，如α-及γ-晶體構造的Al2O3， 或包括此塗膜之厚的多層體仍然廣泛地被使用，尤其對粗-中度車削，在所有種類材料之分離及開槽應用及幾乎專門對鑄鐵的車削。一直到最近由於對電性絕緣材料及尤其對氧化性塗膜之主要製程限制，此塗膜無法由PVD製程生產。
熟於此技術者當知，所有上述的問題傾向於且聚焦在變成更尖銳具更小刃口半徑的刃口上。故，為了避免CVD塗膜工具刃口碎裂或破斷，必須對刃口及工具刀尖考慮額外之幾何形狀限制，例如對燒結碳化物之刃口係限制在40μm之最小半徑。另外，通常使用其他對策如施加倒角、淋水、刮除器或其他特殊幾何形狀至間隙側部、傾斜面或刃口之兩面，但是往往加入另外很複雜而難以處理的生產步驟至製造燒結工具基底。
因而，本發明之一目的在提供一種單層或多層PVD塗膜具尖銳刃口之切削工具，其同時顯示令人滿意的抗磨損及抗熱化學性及抗刃口碎裂。切削工具包括一燒結體，其由燒結碳化物、CBN、陶金或陶瓷材料製成具有刃口半徑為Re之刃口，一側面(flank)及一傾斜面(rake face)及包含一PVD塗膜的一單層或多層塗膜，其包括至少一氧化性PVD層覆蓋在燒結體之至少部分表面。
在一實施例中，刃口半徑Re係小於40μm，較佳為小於或等於30μm。表面被覆蓋的部分包括燒結體之尖銳刃口的至少某些部分。須提及，若在工具磨利之後，不再施以 任何後處理如搪磨、鈍化等，在燒結工具上可製成刃口半徑Re等於或甚至小於20μm。同時，此等工具可使用氧化性PVD塗膜進行有利的塗膜，因為塗膜製程並無任何有害的影響，且不致發生刃口之弱化。
塗膜無熱裂且不含任何鹵化物或其他由CVD製程氣體衍生的污染物。除此之外，塗膜或至少氧化性PVD層可免於惰性元素如He、Ar、Kr等。此可由在一純反應氣體環境中的真空電弧沈積而達成。作為多層塗膜之一例，一黏合層及/或硬質防磨損層之沈積，可在一氮氣環境中啟動，由一製程步驟跟隨，此製程步驟之特徵為在跟隨氮氣流的斜降或關閉之後成長氧氣流，對氧化性塗膜產生一陡率。在陰極電弧標靶的表面區域上施加一小的垂直磁場，對例如由電弧製程在純氧氣環境下形成的高度絕緣標靶表面有利。如何執行此塗膜過程之詳細指示可在申請案WO 2006-099758,WO 2006-099760,WO 2006-099754及CH 1166/03中發現，其等謹在此援用參考而作為實際說明書之一部分。
氧化物層宜加入一電性絕緣氧化物，其包括選自週期表之IV,V,VI族的過渡金屬之族及Al,Si,Fe,Co,Ni,Y,La的至少一個元素。(AlCr)2O3及Al2O3係此材料之兩個重要的例子。此等氧化物之晶體構造可變化且可包括一立方或六角形晶格，如阿爾發(α)、貝他(β)、伽瑪(γ)、代爾他(δ)相或尖晶石構造。例如，包括不同氧化物之薄膜的氧化物層可被塗佈到工具。不論多層塗膜可能包括區的上述 元素之氮化物、碳氮化物、氧氮化物、硼化物等之事實，且在不同元素或化學計量成分之界定層之間具有尖銳或梯度過渡，必須提及，抵抗高溫及/或高氧化性應力的最佳保護，僅能藉由包括至少一層含有純氧化物的塗膜而確保。
剛玉式(corundum type)構造，例如可為Al2O3,(AlCr)2O3及(AlV)2O3或通常為(Mel1-x Me2x)2O3，其中0.2≦x≦0.98且Me1及Me2為選自包含Al,Cr,Fe,Li,Mg,Mn,Nb,Ti,Sb和V的群組之不同元素，為氧化物層之較佳實施例，因而形成一熱穩定性狀態。如何製作此剛玉式單或多層構造的詳細說明，可在CH 01614/06之申請案中獲得，其在此被援用作為參考。
在本發明之一實施例中，塗膜包括一直接位於本體表面上之黏著層，及/或至少一硬質磨耗保護層位於本體與氧化物層之間，或位於二或多個連續氧化物層之間，及/或在塗膜層之頂部上的。此黏著層及其內的磨耗保護層較佳包括選自元素週期表之IV,V,VI族的過渡金屬之族及Al,Si,Fe,Co,Ni,Y,La的至少一個元素。磨耗保護層之化合物更包括N,C,O,B或其混合物，其中N,C及CN為較佳。此磨耗保護層之例子為TiN,TiC,CrN,CrC,TiAlN,CrAlN,TiCrAlN及TiCN,CrCN,TiAlCN,CrAlCN,TiCrAlCN。
黏著層之化合物可包括N,C,O或其混合物，其中N及O為較佳。此黏著層之例子為TiN,CrN,TiAlN,CrAlN,TiCrAlN，或TiON,CrON,TiAlON,CrAlON,TiCrAlON。黏著層之厚度宜為0.1與1.5μm之間。若黏著層包括一直 接位於本體表面上的薄金屬層時，金屬層之厚度必須在10與200nm之間以達到工具與塗膜之最佳結合。此一金屬中間層之例子為Ti,Cr,TiAl或CrAl。全部體塗膜厚度為在2與30μm之間，且由於塗膜過程之經濟因素，大多在3至10μm之間。但是，必須提及，原則上工具甚至可設置較厚的塗膜，若在某些應用上有需要的話，例如其可能為鑄鐵之高速車削。
本發明之另一實施例，可包含一磨耗保護層，其包含至少一成分隔離薄膜，此薄膜包括一具有培養如Si或B之晶體構造之相分離之特定元素的相當高濃度之相，及一具有此一特定元素的相當低濃度之相。在一實施例中，具有特定元素的相當高濃度之相，構成一非晶或為微晶相。此薄膜宜為一包括Cr與Si、或Ti與Si之結合物的氮化物或碳氮化物。
所有的層可依照實際需求而沈積具有尖銳或梯度的層至層之過渡區域，以形成顯示一個別或一梯度層構造的塗膜。若此等構造可用在特定應用中諸層之厚度可為數微米小至數奈米。
與包括氧化性CVD層的切削工具不同，此PVD塗膜工具不需要富含黏結劑的基板，以減少CVD製程對燒結體之TRS(橫向破壞強度)之負面效應。在壓縮應力的狀態下，以PVD製程及塗佈塗膜或某層之可能性，尤其上述之磨耗保護層之低處理溫度，已證明在抗龜裂之傳播及刃口碎裂的風險為有用的對策。故，在大多數的實際切削應用已不再 使用富含黏結劑的基板，此對碳化物工具生產係明顯的簡化。
但是，在某些切削情況下，例如若切削參數必須延伸使得更高的進給力被施加且甚至較宜有一更高的TRS，甚至PVD塗膜之富含碳化物等級可能有用。
由於此PVD塗膜的硬金屬等級之潛在較高的TRS，不僅可生產具有很小刃口半徑的切削工具，而且可生產具有較小鼻部半徑或尖角的切削工具，以供特別細的工具加工之應用。作為一例子，與具有共同鼻部半徑最小0.2mm(0.008in)至2.4mm(0.094mm)的習知燒結碳化物嵌件比較，甚至如0.15,0.10,0.05及0.10mm之半徑可被塗佈且在通常微細車削情況下測試而無過早的尖端碎裂之跡象。
由於PVD過程之固有「幾何」性質，另一塗膜特徵可僅藉使用所界定的夾具系統而賦予簡單幾何形狀之如嵌件的燒結體，藉此使本體之某個區域暴露於來自電弧或濺鍍源之「直接」之離子及/或中性流(在下文中將被稱為粒子流)，然而其他區域則實質上僅受到掠過或間接射入之撞擊。在本文中，「直接」意即由一電弧源發射的粒子之主要部分或大部分，以約90±15°撞擊到表面。故，在此區域的層成長係比暴露於實質上「間接」的粒子流之區域上的成長更快。此效應可被用來在一次PVD塗膜過程中塗佈變化厚度的塗膜；此與CVD過程完全不同而與由於不同的基板/來源定位引起的幾何效應無關，提供一均勻的塗膜厚度。
例如，使用三重旋轉心軸將與8mm間隔物交錯的中心開 挖之孔13x13x5mm之嵌件固定，在RSC型之商業歐瑞康(Oerlikon)塗膜單元中約500mm之基板轉台的全部個長度上、或商業上可利用之歐瑞康BAI 1200塗膜單元中約900mm之長度上，嵌件之側面厚度(dFlank)與傾斜面厚度(dRake)之約為2±0.5之比率可被調全部。在側面之中間及在傾斜面上從界定鼻部之尖角(point angle)的刃口(cutting edge)算起2mm距離連接嵌件之兩對向鼻部的二分線，進行厚度測定。此具有商值QR/F=dRake/dFlank<1之嵌件(其中dFlank係在傾斜面上之全部塗膜厚度，且dRake係在側面上之全部塗膜厚度對銑削工具尤其方便，蓋，由於在銑削操作期間之衝擊應力可從在側面上之較高的PVD塗膜厚度獲益之故。此效應被具有高殘留應力的PVD塗膜所強化，而殘留應力可被製程參數如基板偏壓、總壓力等所控制。
與銑削相反，由於通過的碎片造成高的磨損及熱化學磨損，車削操作的磨損抵抗係藉由在傾斜面上一較高的塗膜厚度而獲得。故，在此情況下，商值QR/F=dRake/dFlank>1。至於嵌件，此一塗膜分佈可藉由將傾斜面暴露到電弧或濺鍍源之直接粒子流的夾具而製成。兩重旋轉磁性夾具，例如可被用來將燒結碳化物嵌件之傾斜面直接暴露到電弧或濺鍍源。此磁性夾具在刃口上造成額外的厚度補強，其可被製程參數，如基板偏壓所影響，且可被用於改善工具性能。對非磁性切板，可依需求而使用夾鉗或勾夾具。又，對車削工具，包括由TiN,TiC或TiCN,TiAlN或TiAlCN,AlCrN或AlCrCN製成而位在本體與氧化物層之間的一防 止磨損層之塗膜設計，被證明尤其有效。
依本發明之切削工具可應用到各種不同工件材料，如所有類型之金屬，如非鐵金屬但是尤其是鐵金屬，鑄鐵等。銑削或車削此等材料的特殊工具可依上述方式最適化。此使得PVD塗膜變成為最新的CVD塗膜之可怕對手，即使至目前未接觸CVD領域，尤其是如鋼及鑄鐵的粗化及高速光製之車削操作亦然。
在許多切削操作中，具有作為塗膜系統之最外層的一氧化物層被證明係最佳方案。此尤其針對齒輪切削工具、滾齒刀或不同型式之柄式工具，包括可分度柄式工具。
下面的各例子係用來證明具有某些特殊工具及塗膜的本發明之有利效果，但是無論如何均非以這些例子來限制本發明的範圍。須提及者，已執行許多試驗來與習知的應用比較，其中PVD塗膜工具被了解長久以來，例如在不同類型之金屬材料中之攻螺紋及鑽孔、非鐵材料之乾及濕式銑削、及在鋼及超合金之某種銑削及車削應用係勝過CVD塗膜。對此種鋼之銑削，已被應用至低或中速高度至100m/min但自0.2至0.4mm/齒的高進刀速率。在大部分之情形，依本發明之工具在性能上係匹敵於習知的TiCN或TiAlN系的PVD塗膜工具或甚至更佳。但是，本發明之一個焦點係取代CVD塗膜在高熱化學及/或消耗性磨損方面的應用，如鐵、鋼及硬化材料的高速銑削，及鋼、鐵如鑄鐵、超合金及硬化材料之車削。
下列例子之PVD塗膜係藉由一陰極電弧製程而沈積；沈 積溫度在對比較的TiCN塗膜之500℃與對氧化物層之550℃之間。對氧化物PVD塗膜，基板偏壓已被施加脈衝且具有垂直磁場分量為3至50高斯及實質較小的水平分量的小的垂直磁場已被施加。對試驗25,28,35,37，一額外的脈衝信號已被重疊到Al0.6Cr0.4(Al0.6V0.4)之電弧源。此種或類似的可應用之氧化物塗膜製程可在援用作為參考的WO 2006-099758及其他前面提到的文件中發現。在基板與一頂部氧化物層之間的TiN及TiCN中間層之層厚係在0.5至1.5μm之間。比較的CVD塗膜係以MT-CVD及沈積溫度850℃而被沈積。
例A)合金鋼AISI 4140(DIN 1.7225)之銑削
工具：可分度面銑削，一個嵌件z=1
工具直徑：d=98mm
切削速度：vc=152m/min
進刀速率：fz=0.25mm/齒
切削深度：dc=2.5mm
嵌件類型：肯納金屬SEHW 1204 AFTN，12wt%Co；對PVD塗膜為倒角尖銳刃口，對CVD塗膜為倒角且搪磨到很小的40μm半徑。
例B)合金鋼AISI 4140(DIN 1.7225)之銑削
工具：可分度面銑削，一個嵌件z=1
工具直徑：d=98mm
切削速度：vc=213m/min
進刀速率：fz=0.18mm/齒
切削深度：dc=2.5mm
製程：順銑，無冷卻劑
嵌件類型：肯納金屬SEHW 1204 AFTN，12wt%Co；
刃口準備看例A
例C)合金鋼AISI 4140(DIN 1.7225)之銑削
工具：可分度面銑削，一個嵌件z=1
工具直徑：d=98mm
切削速度：vc=260m/min
進刀速率：fz=0.20mm/齒
切削深度：dc=3.125mm；
製程：順銑
嵌件類型：肯納金屬SEHW 1204 AFTN，試驗13,15,17,19富含Co 6.0wt%碳化物級，10.4
wt%立方碳化物。
試驗14,16,18,20，未富含Co 6.0wt%碳化物級，10.4wt%立方碳化物。
刃口準備看例A
例C，試驗14清楚地顯示CVD製程對未富含碳化物級之有害影響，此乃由於上述製程的效應。另一方面，富含Co表面區域的有利影響顯示在PVD塗膜上僅有限效果。包括氧化物層之PVD塗膜之優點明顯地在例A及B中顯示。
例D)不銹鋼AISI 430F(DIN 1.4104)之車削
切削速度：vc=200m/min
進刀速率：fz=0.20mm/齒
切削深度：dc=1.0mm；
製程：外徑之連續車削
嵌件類型：燒結級，ISO VNMG 160408A11，對PVD塗膜為尖銳刃口，在CVD塗膜之前倒角且搪磨到很小的60μm半徑。
除了塗層類型及材料之影響之外，可看出具氧化物PVD塗膜之層厚的明顯之有利影響。然而，即使最薄的氧化物PVD塗膜亦顯示比試驗22之厚的MT-CVD-塗膜之較佳性能。
例E)灰鑄鐵之車削
切削速度：vc=550m/min
進刀速率：fz=0.65mm/齒
切削深度：dc=5.0mm；
製程：外徑之連續車削
嵌件類型：陶瓷Al2O3-TiC 20%，ISO RNGN 120400T，對PVD塗膜為尖銳刃口，在CVD塗膜之前被倒角且搪磨到很小的50μm半徑。
例F)鍛鋼AISI 4137H(DIN 1.7225)之車削
切削速度：vc=100m/min
進刀速率：fz=0.80mm/齒
切削深度：dc=5-15mm；
製程：外徑之連續車削
嵌件類型：燒結碳化物，6%未富含，ISO TNMG 330924，對PVD塗膜為尖銳刃口，在CVD塗膜之前為倒角且搪磨到很小的50μm半徑。
由例A至F可證明，氧化物塗膜可藉由PVD塗膜製程而施加到尖銳刃口上。因為可導致較低的切削力，降低工具尖端溫度到較細的工件表面磨光度及工具壽命之改進，故一尖銳的刃口是所希望的。

Claims (29)

  1. 一種切削工具，包括：- 一燒結碳化物、CBN、陶金或陶瓷材料的燒結體，具有刃口半徑Re之刃口及側面及傾斜面；及- 一單層或多層PVD塗膜，覆蓋在燒結體之表面的至少一部分且包括至少一層藉由陰極電弧製程沉積且由本質上純氧化物所構成的氧化物層，其中該刃口半徑Re係小於或等於30μm。
  2. 如申請專利範圍第1項之切削工具，其中PVD塗膜係免於熱龜裂。
  3. 如申請專利範圍第1項之切削工具，其中PVD塗膜係不含鹵化物。
  4. 如申請專利範圍第1項之切削工具，其中氧化物層包括電性絕緣氧化物，該電性絕緣氧化物包括選自週期表之IV,V,VI族的過渡金屬之族，Al,Si,Fe,Ni,Co,Y及La的群組之至少一個元素。
  5. 如申請專利範圍第4項之切削工具，其中氧化物層包括立方或六角形之晶體構造。
  6. 如申請專利範圍第4或5項之切削工具，其中氧化物層包括(AlCr)2O3化合物。
  7. 如申請專利範圍第1或2項之切削工具，其中氧化物層包括一剛玉式構造。
  8. 如申請專利範圍第7項之切削工具，其中剛玉式構造係剛玉或一多數氧化物，具有下列組成：(Me11-x Me2x)2O3，其中0.2≦x≦0.98，且Me1及Me2為由Al,Cr,Fe,Li,Mg,Mn,Nb,Ti,Sb和V所組成的群組中選出，且Me1及Me2為不同的元素。
  9. 如申請專利範圍第8項之切削工具，其中剛玉式構造係(Al1-xCrx)2O3或(Al1-xVx)2O3，其中0.2≦x≦0.98。
  10. 如申請專利範圍第1項之切削工具，其中氧化物層包括不同氧化物之薄膜。
  11. 如申請專利範圍第10項之切削工具，其中PVD塗膜包括：- 黏著層，直接位於燒結體表面上及/或- 至少一個硬質磨耗保護層，位於燒結體與氧化物層之間，或位於二或多個連續氧化物層之間，及/或在PVD塗膜層之最外部，其中該黏著層及硬質磨耗保護層各包括選自週期表之IV,V,VI族的過渡金屬之族，Al,Si,Fe,Ni,Co,Y及La的群組之至少一個元素。
  12. 如申請專利範圍第11項之切削工具，其中硬質磨耗保護層之化合物係包括N,C,O,B或其混合物。
  13. 如申請專利範圍第11項之切削工具，其中硬質磨耗保護層之化合物係包括N,C,CN或其混合物。
  14. 如申請專利範圍第11或12項之切削工具，其中至少一 個硬質磨耗保護層包含至少一個成分隔離薄膜。
  15. 如申請專利範圍第11項之切削工具，其中黏著層之化合物係包括N,C,O或其混合物。
  16. 如申請專利範圍第11項之切削工具，其中黏著層之化合物係包括N,O或其混合物。
  17. 如申請專利範圍第11項之切削工具，其中黏著層具有0.1至1.5μm之厚度。
  18. 如申請專利範圍第11項之切削工具，其中黏著層包括一薄金屬層，該薄金屬層直接位於燒結體之表面上。
  19. 如申請專利範圍第1項之切削工具，其中全部塗膜厚度為在2與30μm之間。
  20. 如申請專利範圍第19項之切削工具，其中全部塗膜厚度為在3至10μm之間。
  21. 如申請專利範圍第1項之切削工具，其中燒結體為非富含黏結劑(binder-enriched)。
  22. 如申請專利範圍第1項之切削工具，其中燒結體為富含黏結劑。
  23. 如申請專利範圍第1項之切削工具，其中側面之塗膜厚度係與傾斜面之塗膜厚度不同。
  24. 如申請專利範圍第23項之切削工具，其中切削工具係銑削工具，且適用QR/F=dRake/dFlank<1，其中dRake係在傾斜面上之全部塗膜厚度，且dFlank 係在側面上之全部塗膜厚度。
  25. 如申請專利範圍第23項之切削工具，其中切削工具係車削工具，且適用QR/F=dRake/dFlank>1，其中dRake係在傾斜面上之全部塗膜厚度，且dFlank係在側面上之全部塗膜厚度。
  26. 如申請專利範圍第1項之切削工具，其中切削工具包括可分度之嵌件。
  27. 如申請專利範圍第1項之切削工具，其中切削工具係供下列工作材料之至少一種的工具：金屬、非鐵金屬、鐵金屬、鑄鐵。
  28. 如申請專利範圍第11項之切削工具，其中切削工具係一齒輪切削工具、或一滾齒刀或一柄式工具，具有氧化物層作為塗膜系統之最外層。
  29. 如申請專利範圍第28項之切削工具，其中硬質磨耗保護層係TiN,TiC,TiCN,TiAlN,TiAlCN,AlCrN或AlCrCN類型的層，且位於燒結體與氧化物層之間。
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ES2672002T3 (es) 2018-06-12
US20080286608A1 (en) 2008-11-20
CN101720365A (zh) 2010-06-02
BRPI0811874A2 (pt) 2014-11-18
CN101720365B (zh) 2013-03-06
CA2685003A1 (en) 2008-11-20
TW200902734A (en) 2009-01-16
US8129040B2 (en) 2012-03-06
PL2152936T3 (pl) 2018-09-28
RU2009146546A (ru) 2011-06-27
BRPI0811874B1 (pt) 2018-09-18
KR20100025522A (ko) 2010-03-09
WO2008138789A2 (en) 2008-11-20
TR201809804T4 (tr) 2018-07-23
WO2008138789A3 (en) 2009-12-17
EP2152936A2 (en) 2010-02-17
RU2466828C2 (ru) 2012-11-20
CA2685003C (en) 2015-11-17
US20120021137A1 (en) 2012-01-26
US8152971B2 (en) 2012-04-10
JP2010526680A (ja) 2010-08-05
EP2152936B1 (en) 2018-04-18

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