WO2009070109A1 - Coated cemented carbide inserts for gear milling in cast low carbon steel parts - Google Patents

Coated cemented carbide inserts for gear milling in cast low carbon steel parts Download PDF

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Publication number
WO2009070109A1
WO2009070109A1 PCT/SE2008/051356 SE2008051356W WO2009070109A1 WO 2009070109 A1 WO2009070109 A1 WO 2009070109A1 SE 2008051356 W SE2008051356 W SE 2008051356W WO 2009070109 A1 WO2009070109 A1 WO 2009070109A1
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WO
WIPO (PCT)
Prior art keywords
coating
thickness
cemented carbide
sublayer
layer
Prior art date
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Ceased
Application number
PCT/SE2008/051356
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French (fr)
Inventor
Kenneth Westergren
Kenneth Lundberg
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Sandvik Intellectual Property AB
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Sandvik Intellectual Property AB
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Publication date
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Publication of WO2009070109A1 publication Critical patent/WO2009070109A1/en
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Ceased legal-status Critical Current

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Classifications

    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0641—Nitrides

Definitions

  • the present invention relates to a PVD-coated cutting tool insert particularly useful for roughing and finishing milling of gears in cast low carbon steel alloys parts.
  • Milling of gears is generally performed with a package of several disk shaped cutter bodies. Each cutter body is equipped with a large number of left and right hand inserts tangentially mounted. The shape of the inserts is designed according to the shape of the gears to be machined. First the roughing operation is performed and if nessesary a finishing operation is performed in order to obtain desired surface quality.
  • Fig.l shows a typical tangential insert used for gear milling.
  • the substrate comprises cemented carbide with a composition of 9-11 wt% Co, 10-14 wt-% TaC, 2-5 wt% NbC, 3-6 wt% TiC, and balance WC with an He-value of 12.8-15.2 kA/m and a hardness of 1425-1575 HV3.
  • the insert is provided with an aperiodic (Ti, Al)N multilayer consisting of a binary A/B/A/B/A/B structure with thin alternating sublayers A and B being repeated throughout the entire coating.
  • a sublayer A/B is here denoted a lamella. Due to the aperiodic nature of the coating, the thickness of each lamella varies but in average the lamella thickness is 30-300 nm, preferably 60-120 nm.
  • Sublayer A consists of Al x Tii_ x N, where x is 0.40-0.7, preferably 0.5-0.67.
  • Sublayer B consists of Ti y Ali_ y N, where y is 0.6-1, preferably 0.75-1.
  • the total thickness of coating is 2-6 ⁇ m on the edgelme.
  • the present invention also relates to a method of making a coated cutting tool insert consisting of a cemented carbide sub- strate and a coating.
  • a substrate as described above is made by conventional powder metallurgical technique milling, pressing and sintering.
  • this substrate is deposited a coating according to above using cathodic arc evaporation using two or three pairs of arc sources consisting of pure Ti and/or TiAl alloy (s), m an N 2 or mixed N 2 +Ar gas atmosphere.
  • arc sources consisting of pure Ti and/or TiAl alloy (s), m an N 2 or mixed N 2 +Ar gas atmosphere.
  • Example 1 A Cemented carbide milling inserts, special type, see Fig.l, and the composition 10 wt% Co, 12.1 wt-% TaC, 3.7 wt% NbC, 4.3 wt% TiC, and balance WC with a He-value of 14.1 kA/m and a hardness of 1500 HV3.
  • the multilayer was deposited from one pair of Ti 84 Al 16 -target and two pairs of Ti 33 Al 67 -targets with the inserts mounted on a three-fold rotating substrate table arranged in order to obtain the aperiodic structure.
  • the arc evaporation was performed in an N 2 -atmosphere .
  • the total coating thickness was 4 ⁇ m on the edge line.
  • the coating consisted of a binary A/B/A/B/A/B aperiodic multilayer, i.e. layers with a non-repetitive thickness, but with an average A+B layer thickness of 60-120 nm.
  • the insert was finally coated with a final outer layer of TiO . 84 AIO . I6 N to produce a bronze colour.
  • the uncoated substrate of A was coated using a target material consisting of Ti 33 Al 57 alloy by arc evaporation performed in an N2 gas atmosphere.
  • the resulting total coating thickness was 2.5 ⁇ m, and consisted of a homogeneous Al 0 62T10 3sN layer.
  • the top side (rake face) of the in- serts was subjected to intense wet blasting with a slurry consist ⁇ ing of AI2O3 grits and water removing the top TiN-layer on the rake face exposing a smooth CC-AI2O3.
  • Milling Cutter Diameter 216 mm, with six cutterbodies
  • Grade B (prior art) 122 segments
  • Grade C (reference) 138 segments

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physical Vapour Deposition (AREA)
  • Gear Processing (AREA)

Abstract

The present invention relates to a cutting insert for milling of cast low carbon steel alloys comprising a cemented carbide substrate and a coating. The cemented carbide has a composition of 9-11 wt% Co, 10-14 wt-% TaC, 2-5wt% NbC,3-6 wt% TiC,and balance WC with anHc-value of 12.8-15.2 kA/m and a hardness of 1425-1575 HV3. The coating consists of an aperiodic (Ti,Al)N multilayer consisting of a binary A/B/A/B/A/B structure with thin alternating sublayers A and B being repeated throughout the entire coating with a thickness of each A/B sequence of 30-300 nm, sublayer A consists of Al xTi 1-xN, where x is 0.40-0.7, sublayer B consists of Ti yAl 1-yN, where y is 0.6-1,with an average composition of the coating of Ti zAl 1-zN with z= 0.40-0.7 and an outermost Ti bAl 1-bN layer, b=0.8-0.9 of sufficient thickness to give a visible, homogenous bronze-coluored look thick whereby the total thickness of coating is 2-6mm on the edgeline.

Description

Coated cemented carbide inserts for gear milling in cast low carbon steel parts
The present invention relates to a PVD-coated cutting tool insert particularly useful for roughing and finishing milling of gears in cast low carbon steel alloys parts.
Milling of gears is generally performed with a package of several disk shaped cutter bodies. Each cutter body is equipped with a large number of left and right hand inserts tangentially mounted. The shape of the inserts is designed according to the shape of the gears to be machined. First the roughing operation is performed and if nessesary a finishing operation is performed in order to obtain desired surface quality.
It is an object of the present invention to provide a cutting tool insert particularly useful for milling of gears m cast low carbon steel alloys with increased tool life and better surface quality of the workpiece.
It has now surprisingly been found that a high gamma phase containing cemented carbide substrate combined with PVD-coating results m increased tool life and better surface quality of the workpiece in gear milling.
Fig.l shows a typical tangential insert used for gear milling.
The substrate comprises cemented carbide with a composition of 9-11 wt% Co, 10-14 wt-% TaC, 2-5 wt% NbC, 3-6 wt% TiC, and balance WC with an He-value of 12.8-15.2 kA/m and a hardness of 1425-1575 HV3.
The insert is provided with an aperiodic (Ti, Al)N multilayer consisting of a binary A/B/A/B/A/B structure with thin alternating sublayers A and B being repeated throughout the entire coating. One sequence of a sublayer A/B is here denoted a lamella. Due to the aperiodic nature of the coating, the thickness of each lamella varies but in average the lamella thickness is 30-300 nm, preferably 60-120 nm. Sublayer A consists of AlxTii_xN, where x is 0.40-0.7, preferably 0.5-0.67. Sublayer B consists of TiyAli_yN, where y is 0.6-1, preferably 0.75-1. The average composition of the coating as measured by e.g. WDS or EDS is TizAli_zN with z= 0.40-0.7, preferably 0.45-0.6. The coating consists of an outermost TibAli_bN layer, b=0.8-0.9, preferably 0.82-0.85, of sufficient thickness to give a visible, homogenous bronze-coluored look, preferably 0.1-1 μm thick. The total thickness of coating is 2-6 μm on the edgelme.
The present invention also relates to a method of making a coated cutting tool insert consisting of a cemented carbide sub- strate and a coating.
A substrate as described above is made by conventional powder metallurgical technique milling, pressing and sintering.
Onto this substrate is deposited a coating according to above using cathodic arc evaporation using two or three pairs of arc sources consisting of pure Ti and/or TiAl alloy (s), m an N2 or mixed N2+Ar gas atmosphere.
The invention also relates to the use of PVD-coated cutting tool inserts according to above for roughing and finishing gear milling with length between the tops of the teeth of 10-40 mm and a height of 5-25 mm at a cutting speed of 150-500 m/min and a feed of fz=0.10 to 0.85 mm per tooth and a depth of cut of 0.5 to 25 mm in cast low carbon steel.
Example 1 A. Cemented carbide milling inserts, special type, see Fig.l, and the composition 10 wt% Co, 12.1 wt-% TaC, 3.7 wt% NbC, 4.3 wt% TiC, and balance WC with a He-value of 14.1 kA/m and a hardness of 1500 HV3.
The multilayer was deposited from one pair of Ti84Al16-target and two pairs of Ti33Al67-targets with the inserts mounted on a three-fold rotating substrate table arranged in order to obtain the aperiodic structure. The arc evaporation was performed in an N2-atmosphere . The total coating thickness was 4 μm on the edge line. The coating consisted of a binary A/B/A/B/A/B aperiodic multilayer, i.e. layers with a non-repetitive thickness, but with an average A+B layer thickness of 60-120 nm. The insert was finally coated with a final outer layer of TiO .84AIO . I6N to produce a bronze colour.
B. The uncoated substrate of A. C. The substrate of A was coated using a target material consisting of Ti33Al57 alloy by arc evaporation performed in an N2 gas atmosphere. The resulting total coating thickness was 2.5 μm, and consisted of a homogeneous Al0 62T10 3sN layer.
D. The substrate in A was provided with the following coating: a first layer of 0.5 μm TiCxNy with a composition of about x=0.05 and y=0.95, a second layer of 1.7 μm columnar TiCxNy with a composition of about x=0.55 and y=0.45 by using the well-known MTCVD-technique, a third, bonding layer of 0.5 μm TiCxO2 with needle shaped grains and x=0.5, and z=0.5, a fourth layer consisting of 2.5 μm CC-AI2O3 and finally a top layer of about 0.3 μm TiN.
After the coating cycle the top side (rake face) of the in- serts was subjected to intense wet blasting with a slurry consist¬ ing of AI2O3 grits and water removing the top TiN-layer on the rake face exposing a smooth CC-AI2O3.
Example 2 Inserts from A, B, C and D were tested according to the following:
Operation: Milling of gear teeth
Work-piece: Elevator segments with length=l .5 m and width 80 mm. Height of teeth 12 mm and 20 mm distance between the tops of the teeth.
Material: Cast low carbon steel, hardness 220HB
Milling Cutter: Diameter 216 mm, with six cutterbodies
Total number of teeth: 8+8 right and left hand inserts in six cutter bodies, total 96 inserts Cutting speed: 163 m/min (rpm=240)
Feed rate: 250 mm/mm (fz=0.13)
Depth of cut: Radial Ae=3 mm axial Ap=10.5 mm
Insert-style: Tangential special inserts, eight edges per insert Note: Dry milling
Criteria for replacing inserts: work piece out of tolerance
Results :
Grade A: (invention) 166 segments
Grade B: (prior art) 122 segments Grade C: (reference) 138 segments
Grade D: (reference) 109 segments

Claims

Claims
1. Cutting insert for milling of cast iron and low carbon steel alloys comprising a cemented carbide substrate and a coating c h a r a c t e r i s e d in that the cemented carbide has a composition of 9-11 wt% Co, 10-14 wt-% TaC, 2-5 wt% NbC, 3-6 wt% TiC, and balance WC with He-value of 12.8-15.2 kA/m and a hardness of 1425-1575 HV3 and in that said coating consists of an aperiodic (Ti, Al) N multilayer consisting of a binary A/B/A/B/A/B structure with thin alternating sublayers A and B being repeated throughout the entire coating with a thickness of each A/B sequence of 30-300 nm, sublayer A consists of AlxTii XN, where x is 0.40-0.7, sublayer B consists of TiyAli-yN, where y is 0.6-1, with an average composition of the coating of TizAli_zN with z= 0.40-0.7, and an outermost Ti]3Al1-I3N layer, b=0.8-0.9, of sufficient thickness to give a visible, homogenous bronze-coluored look, whereby the total thickness of coating is 2-6 μm on the edgeline.
2. Cutting insert according to claim 1, c h a r a c t e r i s e d in that the thickness of each A/B sequence is 60-120 nm.
3. Cutting insert according to any one of claims 1-2, c h a r a c t e r i s e d in that for AlxTii_xN, x=0.5-0.67, for TIyAl1 yN, y= 0.75-1, for Ti2Al1 ZN, z=0.45-0.6 and for Ti13Al1 bN, b=0.82-0.85.
4. Cutting insert according to any one of claims 1-3, c h a r a c t e r i s e d in that the outermost TibAli-bN layer has a thickness of 0.1-1 μm.
5. Method of making a coated cutting tool insert consisting of a cemented carbide substrate and a coating c h a r a c t e r i s e d in providing using conventional powder metallurgical techniques milling, pressing and sintering a cemented carbide with the composition 9-11 wt% Co, 10-14 wt-% TaC, 2-5 wt% NbC, 3-6 wt% TiC, and balance WC with a He-value of 12.8- 15.2 kA/m and a hardness of 1425-1575 HV3 and depositing onto this substrate a coating using cathodic arc evaporation using two or three pairs of arc sources consisting of pure Ti and/or TiAl alloy(s), in an N2 or mixed N2+Ar gas atmosphere consisting of an aperiodic (Ti, Al)N multilayer consisting of a binary A/B/A/B/A/B structure with thin alternating sublayers A and B being repeated throughout the entire coating with a thickness of each A/B sequence of 30-300 nm, sublayer A consists of AlxTii-χN, where x is 0.40-0.7, sublayer B consists of TiyAli_yN, where y is 0.6-1, with an average composition of the coating of TizAlL_zN with z= 0.40-0.7, and an outermost TibAli_bN layer, b=0.8- 0.9, of sufficient thickness to give a visible, homogenous bronze- coluored look, whereby the total thickness of coating is 2-6 μm in the edgelme.
6. Method according to claim 5, c h a r a c t e r i s e d in that the thickness of each A/B sequence is 60-120 nm.
7. Method according to any one of claims 5-6, c h a r a c t e r i s e d in that for AlxTii_xN, x=0.5-0.67, for TIyAl1 yN, y= 0.75-1, for Ti2AIi 2N, z=0.45-0.6 and for TibAli bN, b=0.82-0.85.
8. Method according to any one of claims 5-7, c h a r a c t e r i s e d in that the outermost TiI3AIi-I3N layer has a thickness of 0.1-1 μm.
9. Use of the insert according to any one of claims 1-4 for gear milling with length between the tops of the teeth of 10-40 mm and a height of 5-25 mm at a cutting speed of 150-500 m/min and a feed of fz=0.10 to 0.85 mm per tooth and a depth of cut of 0.5 to 15 mm in cast low carbon steel.
PCT/SE2008/051356 2007-11-28 2008-11-26 Coated cemented carbide inserts for gear milling in cast low carbon steel parts Ceased WO2009070109A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0702620 2007-11-28
SE0702620-6 2007-11-28

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WO2009070109A1 true WO2009070109A1 (en) 2009-06-04

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1038989A2 (en) * 1999-03-26 2000-09-27 Sandvik Aktiebolag Coated milling insert
WO2001016388A1 (en) * 1999-09-01 2001-03-08 Sandvik Ab (Publ) Coated grooving or parting insert
WO2001018272A1 (en) * 1999-09-06 2001-03-15 Sandvik Ab (Publ) Coated cemented carbide insert
JP2002254229A (en) * 2001-02-27 2002-09-10 Mmc Kobelco Tool Kk Drill made of surface-coated cemented carbide and excellent in wear resistance in high speed cutting
WO2006080888A1 (en) * 2005-01-31 2006-08-03 Sandvik Intellectual Property Ab Cemented carbide insert for toughness demanding short hole drilling operations
EP1795628A1 (en) * 2005-12-08 2007-06-13 Sandvik Intellectual Property AB Insert for milling of steel
US20080299383A1 (en) * 2007-06-01 2008-12-04 Sandvik Intellectual Property Ab Fine grained cemented carbide cutting tool insert
US20080299366A1 (en) * 2007-06-01 2008-12-04 Sandvik Intellectual Property Ab Cemented carbide insert

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1038989A2 (en) * 1999-03-26 2000-09-27 Sandvik Aktiebolag Coated milling insert
WO2001016388A1 (en) * 1999-09-01 2001-03-08 Sandvik Ab (Publ) Coated grooving or parting insert
WO2001018272A1 (en) * 1999-09-06 2001-03-15 Sandvik Ab (Publ) Coated cemented carbide insert
JP2002254229A (en) * 2001-02-27 2002-09-10 Mmc Kobelco Tool Kk Drill made of surface-coated cemented carbide and excellent in wear resistance in high speed cutting
WO2006080888A1 (en) * 2005-01-31 2006-08-03 Sandvik Intellectual Property Ab Cemented carbide insert for toughness demanding short hole drilling operations
EP1795628A1 (en) * 2005-12-08 2007-06-13 Sandvik Intellectual Property AB Insert for milling of steel
US20080299383A1 (en) * 2007-06-01 2008-12-04 Sandvik Intellectual Property Ab Fine grained cemented carbide cutting tool insert
US20080299366A1 (en) * 2007-06-01 2008-12-04 Sandvik Intellectual Property Ab Cemented carbide insert

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