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CN1073168C - 刀具的镶刃 - Google Patents

刀具的镶刃 Download PDF

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CN1073168C
CN1073168C CN97198792A CN97198792A CN1073168C CN 1073168 C CN1073168 C CN 1073168C CN 97198792 A CN97198792 A CN 97198792A CN 97198792 A CN97198792 A CN 97198792A CN 1073168 C CN1073168 C CN 1073168C
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cutting insert
substrate
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titanium
cobalt
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CN1233295A (zh
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乔治·P·格雷普
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Abstract

一种切削镶刃，它包括一个前倾面和一个侧面，在前倾面和侧面的交界处有一个切削刃口。该切削镶刃具有一个涂层和一个基底，其中，涂层粘附在基底上。基底是碳化钨基硬质合金，其中有一个非分层的钴富集区，它从靠近基底周边表面处开始向内延伸。主体基底具有大于C00并小于C02的孔隙度。

Description

刀具的镶刃
本发明涉及一种带有涂层的硬质合金切削镶刃，该切削镶刃具有一个基底，此基底的孔隙度(按照标题为“硬质合金中表观气孔度的标准测定方法”的ASTM Designation B 276-86(美国材料试验学会的规定B 276-86))大于CO0并小于或等于CO2，其中，具有一个不分层的，即，大体均匀的粘结剂富集区，该富集区由靠近基底的周边表面处开始并向内延伸。
在此之前，已存在Kennametal KC850带有涂层的切削镶刃(KC850是美国宾西法尼亚州Latrobe的Kennametal公司生产的切削镶刃的注册商标)，该切削镶刃具有一个孔隙度为CO3/CO6的基底，此基底具有一个表面粘结剂富集区。这种粘结剂的富集是一种分层式的粘结剂富集，它意味着粘结剂的富集形成了明显的金属粘结剂层。Nemeth等人的论文“高刃口强度的标号为KC850的肯纳硬质合金的显微结构特点和切削性能”(第十届Plansee研讨会会刊，Reutte,Tyrol,Austria,Metalwerke Plansee A.G.(1981).pp.613-627)对“Kennametal KC850带涂层的刀具(或镶刃)进行了描述。根据Smith等人的标题为“具有三层涂层的硬质合金烧结体”的美国专利No.4,035,541,“Kennametal KC850”带涂层的切削镶刃具有TiC-TiCN-TiN的三相涂层。
本发明是一种切削镶刃，它包括一个前倾面和一个侧面，在前倾面和侧面的交界处有一个切削刃口。该切削镶刃具有一个涂层和一个基底，其中，涂层粘附在基底上。基底是一种碳化钨基烧结硬质合金，它具有如下所述的体积成份，即约在3％至12％重量百分比之间的钴，高达约12％重量百分比的钽，高达约6％重量百分比的铌，高达约10％重量百分比的钛，余量为钨和碳。其中存在着一个从基底的周边表面附近开始并向内延伸的不分层的钴富集区。该不分层的富集区具有A孔隙度。整个基底具有大于CO0且小于或等于CO2的孔隙度。
下面是对构成本专利申请的一个部分的附图的简单说明：
图1是一个SPGN432型切削镶刃的一个特定实施例的等角视图；
图2是图1所示的切削镶刃沿2-2线的剖面图；
图3是SNG433型切削镶刃的一个特定实施例的等角视图；以及
图4是图3所示的切削镶刃沿4-4线的剖面图。
参照附图，图1示出了总的用标号10代表的本发明的可转换角度的切削镶刃的一个特定实施例。该切削镶刃10具有一个在前倾面14与侧面16的交界处的切削刃口12。尽管图1中所示的切削镶刃10是一种带有珩磨切削刃口的SPGN432型切削镶刃，但申请人的意图是，本发明包括其它类型的具有或不具有珩磨刃口的切削镶刃。
图2表示沿着图1的2-2切面截取的在切削镶刃10的切削刃口12处的剖面。总的由标号18表示的基底具有一个非粘结剂富集区20，即构成基底的中心部分(或主体部分)的区域，以及一个靠近基底的外周边界24和26的外部(或周边)粘结剂富集区22。外部粘结剂富集区22是一种非分层型的粘结剂富集区。换句话说，粘结剂富集区22在本质上通常是均匀的。这与分层的粘结剂富集区不同，在分层的粘结剂富集区中，粘结剂形成了一层位于另一层的顶部上的多个层，如Kobori等人在题为“在烧结硬质合金表面附近形成的粘结剂富集层”(粉末和粉末冶金，Vol.34,No.3,pp.129-133(April 1987))的文章中所讨论的那样。
在一个优选实施例中，基底18是一种碳化钨基硬质合金基底，它含有至少为70％重量百分比的碳化钨，更为优选的是，它含有至少占80％重量百分比的碳化钨。粘结剂最好为钴或钴合金，同时，最好其体积浓度为3％至12％重量百分比。更优选的钴的体积含量在约5％至约8％重量百分比之间。最优选的是，钴的体积含量在约5.6％至约7.5％重量百分比之间。
基底18还含有固溶体碳化物和/或碳氮化物的形成元素，例如钛，铪，锆，铌，钽和钒，在这些元素中最好选择钛，铌和钽，它们或者单独存在或者以相互结合的方式或者以与钨结合的方式存在。这些元素最好能以碳化物，氮化物和/或碳氮化物的形式加入到混合物中，更好的是以氮化物的形式，而最佳的是以碳化钽(铌)和氮化钛的形式加入到混合物中。这些元素的浓度最好在下述范围内：高达12％重量百分比的钽，高达10％重量百分比的钛，及高达4％重量百分比的铌。更为优选的是，钽含量和铌含量的总和在约3％至约7％重量百分比之间，而钛含量在约0.5％至约5％重量百分比之间。最优选的是钽和铌含量的总和在约5.0％至约5.9％重量百分比之间，钛含量在约1.7％至约2.3％重量百分比之间。
在基底18的主体区域20内，这些元素(即，钛，铪，锆，铌，钽和钒)至少在一定程度上而且最好是大部分地在基底内与碳化钨形成固溶体碳化物和/或固溶体碳氮化物。在富集区22中，这种固溶体碳化物和/或固溶体碳氮化物已全部或部分地被耗尽，从而碳化钨和钴构成粘结剂富集区22的主要组分。
在粘结剂富集区22内，粘结剂(例如，钴)含量应达到最大值，该最大值约在125％至300％之间。粘结剂富集的更为优选的范围是大约在主体内粘结剂含量的150％至300％之间。粘结剂富集的最为优选的范围是，它大约为基底内主体钴浓度的200％至300％。
粘结剂富集区22最好延伸到基底周边表面24和26。或者是，可在邻接这些外周边界(24,26)处存在着一个薄层，在该薄层中由于在烧结基底过程中的蒸发，钴含量已被降低，从而粘结剂(例如，钴)富集区22延伸到基底18的周边表面(24,26)附近。粘结剂富集区的厚度最好高达50微米(μm)。
粘附在基底18的外周边界24和26上的是由括号29表示的硬涂层，它最好具有利用化学汽相淀积(CVD)或者CVD与物理汽相淀积(PVD)的组合技术施加的一个或多个层。MTVD(中温CVD)技术可用于施加一个涂层，例如碳氮化钛层。这些层可包含一个基底层30，一个中间层32和一个外层34。尽管图2中所示的这些层具有不同的厚度，但应当理解，这仅是为了进行说明。每一层(30,32,34)的厚度依切削镶刃的特定用途而定。
基底层30被直接沉积在基底18的表面(24,26)上。基底层30的厚度最好在约3微米(μm)和约6μm之间变化。尽管基底层的组分也可以变化，但优选的组分可包括，例如，碳化钛，碳氮化钛及氮化钛。中间层32直接沉积到基底层30的表面上。中间层32的厚度在约2μm与约5μm之间变化。尽管中间层(一层或多层)的组分是可以变化的，但优选的组分可包括碳氮化钛，氮化钛，碳化钛，氧化铝，氮化钛铝及它们的组合物。外层34直接沉积在中间层32的表面上。外层34的厚度在约1.5μm和约4μm之间变化。虽然外层的组分是可以变化的，但其优选组分可包括氮化钛，碳氮化钛，氮化钛铝以及氧化铝。
尽管在上面的描述中提到了用于涂层的适当的选择物，但优选的涂覆方案是采用碳化钛作为基底层，碳氮化钛作为中间层，并用氮化钛作为外层。
Smith等人的美国专利No.4,035,541公开了一种可用于图2所示切削镶刃的三层涂层。此外，例如下述文献中所描述的那种方法，可通过CVD和PVD的结合实施所述的涂覆方案，这些文献是，Santhanam等人的美国专利No.5,250,367，其题目为“粘结剂富集的由CVD和PVD涂覆的切削镶刃”；Santhanam等人的美国专利No.5,266,388，其题目为“粘结剂富集的经涂覆的切削镶刃”。申请人在这里引用Smith等人的美国专利No.4,025,541,Santhanam等人的美国专利No.5,250,367及Santhanam等人的美国专利No.5,266,388作为参考文献。
如图2所示，对于一个用于铣削的切削镶刃，最好是粘结剂富集区22位于外周边界的下面，这些外周边界与切削镶刃10的前倾面14及侧面16平行。在其它应用中，例如车削，可以预期，富集区将只存在于前倾面之下，而从其它面上除去了(例如，通过研磨)富集区。关于这个问题，图3和图4中所示的一种是SNG 433型切削镶刃的切削镶刃40具有这样的显微结构，在这种结构中，只在前倾面的下面存在富集区。
参照图3和图4，切削镶刃40具有四个侧面42，它们与一个前倾面44及与前倾面44相对的另一个前倾面(未示出)相交，从而形成八个切削刃口48。切削镶刃40具有一个总的由标号49表示的基底，它具有位于前倾面处的外周边界52和位于侧面处的外周边界54。基底49具有一个主体部分50，它包括基底49的主要部分以及一个靠近前倾面处的外周边界52的粘结剂富集层56。在包括靠近外周边界54的体积在内的主体部分49中不存在粘结剂富集。
切削镶刃40的基底49与切削镶刃10具有基本上相同的组分。切削镶刃40的粘结剂富集的情况与切削镶刃10的也基本上相同。切削镶刃40的基本涂覆方案(如括号59所示)也与切削镶刃10基本相同。关于这个问题，切削镶刃40具有一个基底涂层60，一个中间涂层62和一个外涂层64。
现将利用下面的例子对本发明作进一步的描述，该例子仅用于说明的目的，而不是对本发明的范围的限制。现将结合对比例No.1至No.3对本发明的例子No.1进行说明。
对于本发明的例子和比较例而言，基底粉末含有约5.8％重量百分比的钴，约5.2％重量百分比的钽，约2.0％重量百分比的钛，余量为钨和碳。钛是以氮化钛的形式添加的。钽是以碳化钽的形式添加的。钨是以碳化钨的形式添加的，而钨和碳是以金属钨的形式和碳黑的形式添加的。混合物中加入不同程度的碳，如下面的表Ⅰ所示
                                 表Ⅰ
                            各例中的加碳量
    例子 比较例No.1 比较例No.2 比较例No.3 本发明例No.1
    加碳量(重量百分比)     5.92     5.98     6.01     5.95
在每一个例子中将5公斤(kg)混合料加到一个19.05厘米内径X22.86厘米的钢制球磨罐中，并加入21kg直径为0.953厘米的硬质合金球及庚烷，填满到罐的顶部。在环境温度下以每分钟52转(rmp)的速度转动混合物40小时。将每一批料的料浆干燥，加入石蜡作为短效粘结剂，并对粉末进行造粒以提供足够的流动性。将粒化的粉末压制成SNG433型切削镶刃坯料，并在真空中于1456℃的温度下烧结30分钟。然后令这些切削镶刃基底在炉内冷却。
此后，研磨前倾面并将切削镶刃坯料在真空中于1456℃的温度下再加热约60分钟，随后进行控制冷却，冷却速度为56℃/小时，直到1149℃。下面的表Ⅱ表示在再加热之后所得基底的性质。
                                   表Ⅱ
                       比较例和本发明例的组分和物理性质
性质/例子    比较例No.1     比较例No.2     比较例No.3 本发明例No.1  Kennametal标号KC850
磁饱和(高斯-cm3/g钴)     155     158     158     158     158
Hc(奥斯特)     146     142     148     149     160
硬度(洛氏A)     91.5     91.3     91.4     91.3     91.6
粘结剂富集深度(μm)     32     40     42     45     20
然后将切削镶刃坯料进行周边研磨和珩磨，使得所获得的基底在前倾面上有钴的富集，而侧面没有钴的富集。此后根据美国专利No.4,035,541对切削镶刃坯料进行三相涂覆。基底层为通过CVD施加的碳化钛，厚度为4.5微米(μm)。中间层为通过CVD施加的、厚度为3.5μm的碳氮化钛。顶层为通过CVD施加的、厚度为3.0μm的氮化钛。
按照下列试验程序对比较例和本发明例做车削性能试验：
工件材料：AISI 4340钢(300BHN)(300布氏硬度)
车削条件：
137.2表面米/分钟(smm)或者167.8表面米/分钟，进给量为0.0508厘米/转以及0.254厘米的切削深度(doc)。
冷却剂：TrimSol Regular(20％)
镶刃型号SNG-433，具有进行过半径珩磨(0.0076厘米)的预加工刃口。
镶刃寿命的判断标准：
最大侧面磨损=0.076厘米
均匀侧面磨损=0.038厘米
缺口=0.076厘米
月牙洼磨损(深度)=0.010厘米
刀尖磨损=0.076厘米
切口深度=0.076厘米
同时还按照以下程序对比较例和本发明例的车削性能进行了试验：
工件材料：AISI 1045钢(210BHN)
车削条件：
228.8smm
0.0508厘米/转
0.254厘米切削深度(doc)
冷却剂：TrimSol Regular(20％)
镶刃型号SNG-433型，并且进行过径向珩磨(0.0076厘米)以预加工刃口。
镶刃寿命的判断标准：
最大侧面磨损=0.076厘米
均匀侧面磨损=0.038厘米
缺口=0.076厘米
月牙洼磨损(深度)=0.010厘米
刀尖磨损=0.076厘米
切口深度=0.076厘米
根据下述的开槽棒(41L50钢)车削试验程序对比较例和本发明例进行冲击强度试验：
速度：106.8smm
切削深度=0.254厘米
进给量=起始进给量为0.038厘米/转，然后每经过100次冲击进给量增加0.0127厘米/转，直到经过800次冲击，这时的进给量已到0.127厘米/转，或者直到发生断裂，哪种情况先发生到哪种情况为止。
下面的表Ⅲ给出了比较例No.1至No.4和本发明例No.1的试验结果。
                                    表Ⅲ
               比较例No.1至No.3和本发明例No.1的镶刃寿命及
                                 刃口强度试验结果
例子/特性 孔隙度额定值 刃口强度(冲击强度) 1045钢228.8smm(分钟) 4340钢137.35smm(分钟) 4340钢167.8smm(分钟)
比较例No.1     CO0     635     13.7     24.1     10.6
比较例No.2     CO3     800     10.7     20.7     9.5
比较例No.3     CO5     800     5.6     17.6     7.1
“KennametalKC850”涂层切削镶刃  CO3/CO6     800     5.3     18.75     7.2
发明例No.1     CO2     800     13.1     24.1     10.5
表Ⅲ中的孔隙度额定值是指按照ASTM规定B276-86中标题为“硬质合金中表观气孔度的标准测试方法”的方法进行测定的。粘结剂富集的深度是通过利用放大倍数为1500X的金相显微镜对样品的断面进行光学检验而确定的。
刃口强度表示在经由上述升槽杆试验直到发生断裂或当试验在达到800次冲击而终止时的冲击次数。车削试验的结果反映了在上述试验过程中以分钟计算的切削镶刃的寿命。
表Ⅲ中的数据非常清楚地表明，本发明例No.1具有极佳的开槽棒刃口强度(800次冲击)。同时在车削1045和4340钢时也具有非常好的工具寿命。本发明例No.1的总体金属切削性能优于其它所有的例子(即，比较例No.1至No.3和“kennametal KC850”有涂层的切削镶刃)。
更具体地说，本发明例No.1的刃口强度相当于高碳的比较例No.2和No.3的刃口强度，并优于低碳的比较例No.1的刃口强度。本发明例No.1也具有与高碳合金“Kennametal KC850”有涂层的切削镶刃相当的刃口强度。
在具有优异的刃口强度的同时，本发明例No.1与其它高碳的例子相比也表现出优异的1045钢刀具寿命。本发明例No.1具有的刀具寿命为13.1分钟，与之相比，比较例No.2为10.7分钟，比较例No.3为5.6分钟，而“Kennametal KC850”有涂层的切削镶刃的寿命为5.3分钟。本发明例No.1的4340钢刀具寿命也优于其它(800次冲击)刃口强度的高碳例子(例如，比较例No.2,No.3以及“KennametalKC850”有涂层的切削镶刃)。尽管本发明例No.1的4340和1045钢刀具寿命仅相当于或稍低于低碳比较例No.1，但本发明例No.1具有优异的刃口强度，它可经受800次冲击，而比较例No.1仅经受得住635次冲击。
非常明显，本发明提供了一种具有改进性能的切削镶刃，其性能优于比较例No.1至No.3以及“Kennametal KC850”带涂层的切削镶刃。结合在上述的对钢的被中断的和连续的车削中所显示出来的冲击强度和耐磨性，这些改进的特性特别明显。
在本申请中所援引的所有专利和其它文献，在这里均作为参考文献。
通过对这里所公开的本发明的说明书的研究或者对本发明的实践，对熟悉本领域的人员来说，本发明的其它实施例是显而易见的。上面的说明及所举的例子仅用于说明的目的，本发明的真正范围和主旨由下面的权利要求书来表明。

Claims (28)

1．一种切削镶刃，包括：
一个前倾面和一个侧面，一个位于前倾面和侧面的交界处的切削刃口；
该切削镶刃具有一个涂层和一个基底，其中，涂层粘附在基底上；
基底是碳化钨基硬质合金，其具有如下所述的体积组分，即在3％至12％重量百分比之间的钴，高达12％重量百分比的钽，高达6％重量百分比的铌，高达10％重量百分比的钛，余量包括钨，氮和碳；
其特征为，钴的浓度在一个非分层的钴富集区内富集，该富集区从靠近基底的周边表面处开始向内延伸，富集区具有相当于主体基底内钴的125％至300％的最大钴浓度；以及
主体基底具有大于CO0并小于或等于CO2的孔隙度。
2．如权利要求1所述的切削镶刃，其特征为，基底具有如下的主体组分，即它包括在5.6％至7.5％重量百分比之间的钴，在5.0％至5.5％重量百分比之间的钽，在1.7％至2.3％重量百分比之间的钛，可高达0.4％重量百分比的铌，其余量包括钨，碳和氮。
3．如权利要求1所述的切削镶刃，其特征为，富集区含有相当于主体基底中的钴的150％至300％的最大钴含量。
4．如权利要求1所述的切削镶刃，其特征为，富集区含有相当于主体基底中的钴的200％至300％的最大钴含量。
5．如权利要求1所述的切削镶刃，其特征为，非分层的钴富集区从周边表面开始延伸的深度基本上在40微米和50微米之间。
6．如权利要求1所述的切削镶刃，其特征为，基底具有一个如下的主体组分，即含有5.8％重量百分比的钴，5.2％重量百分比的钽，2.0％重量百分比的钛，其余量包括钨和碳。
7．如权利要求1所述的切削镶刃，其特征为，基底是通过烧结原料粉末的固结块形成的。
8．如权利要求7所述的切削镶刃，其特征为，原料粉末包括氮化钛。
9．如权利要求7所述的切削镶刃，其特征为，原料粉末包括碳化钽。
10．如权利要求7所述的切削镶刃，其特征为，原料粉末包括碳化铌。
11．如权利要求7所述的切削镶刃，其特征为，原料粉末包括碳化钨。
12．如权利要求7所述的切削镶刃，其特征为，原料粉末包括碳。
13．如权利要求1所述的切削镶刃，其特征为，钴富集区延伸至基底的周边表面。
14．如权利要求1所述的切削镶刃，其特征为，涂层包括一个邻近基底表面的基底层，一在基底层上的中间层和一在中间层上的外层；基底层包括一种或多种从下述组中选出的材料，该材料组包括碳氮化钛和氮化钛；中间层包括一种或多种从下述组中选出的材料，该材料组包括碳氮化钛、氮化钛、碳化钛、氧化铝和氮化钛铝；外层包括一种或多种从下述组中选出的材料，该材料组包括氮化钛、碳氮化钛、氮化钛铝和氧化铝。
15．如权利要求1所述的切削镶刃，其特征为，所述涂层包括一层或多层，其中各层是通过物理汽相淀积、化学汽相淀积和中温化学汽相淀积之一或一种以上的方式施加的。
16．如权利要求1所述的切削镶刃，其特征为，所述基底具有如下所述的体积组分，即在5.6％至6.4％重量百分比之间的钴，在2.5％至3.3％重量百分比之间的钽，在1.5％至2.5％重量百分比之间的钛，高达1％重量百分比的铌，余量包括钨，氮和碳。
17．如权利要求16所述的切削镶刃，其特征为，涂层系统包括一个邻近基底的基底层，一邻近基底层的中间层和一邻近中间层的外层；基底层包括一种或多种从下述组中选出的材料，该材料组包括碳氮化钛和氮化钛；中间层包括一种或多种从下述组中选出的材料，该材料组包括碳氮化钛、氮化钛、碳化钛、氮化铝和氮化钛铝；外层包括一种或多种从下述组中选出的材料，所述材料组包括氮化钛、碳氮化钛、氮化钛铝和氧化铝。
18．如权利要求16所述的切削镶刃，其特征为，非分层的钴富集区延伸至深达50μm的深度。
19．如权利要求16所述的切削镶刃，其特征为，基底包括6.0％重量百分比的钴，2.9％重量百分比的钽，2.0％重量百分比的钛，0.6％重量百分比的铌，其余量包括钨、碳和氮。
20．如权利要求1所述的切削镶刃，其特征为，涂层包括多个层，其中第一层包括碳氮化钛，第二层包括氧化铝，第三层包括氮化钛。
21．如权利要求1所述的切削镶刃，其特征为，主体基底的孔隙度为CO4。
22．如权利要求1所述的切削镶刃，其特征为，涂层包括多层，其中各层中包括一个靠近基底的基底层，该基底层包括氮化钛；一个包括氮化钛的外层；以及至少一个位于基底层和外层之间的中间层。
23．如权利要求22所述的切削镶刃，其特征为，中间层包括通过中温化学汽相淀积施加的碳氮化钛。
24．如权利要求22所述的切削镶刃，其特征为，中间层包括碳氮化钛和碳化钛。
25．如权利要求22所述的切削镶刃，其特征为，中间层包括氧化铝。
26．如权利要求16所述的切削镶刃，其特征为，主体基底的孔隙度为CO2。
27．如权利要求16所述的切削镶刃，其特征为，涂层系统包括多个层，其中各层包括一个靠近基底的基底层，该基底层包括氮化钛；一个包括氮化钛的外层；以及至少一个位于基底层和外层之间的中间层；中间层从如下所述的组中选取，所述组包括通过中温化学汽相淀积施加的碳氮化钛或碳氮化钛和碳化钛或氧化铝。
28．如权利要求20所述的切削镶刃，其特征为，主体基底的孔隙度为CO2。
CN97198792A 1996-10-15 1997-07-18 刀具的镶刃 Expired - Fee Related CN1073168C (zh)

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EP0932705A1 (en) 1999-08-04
US5955186A (en) 1999-09-21
AU711761B2 (en) 1999-10-21
JP2000514371A (ja) 2000-10-31
WO1998016664A1 (en) 1998-04-23
JP3448304B2 (ja) 2003-09-22
DE69726445D1 (de) 2004-01-08
DE69726445T2 (de) 2004-11-11
AU4042697A (en) 1998-05-11
BR9711914A (pt) 1999-08-24
ES2135364T3 (es) 2004-07-01
CN1233295A (zh) 1999-10-27
ES2135364T1 (es) 1999-11-01
CA2266382A1 (en) 1998-04-23
KR100326638B1 (ko) 2002-03-04
ATE255171T1 (de) 2003-12-15
CA2266382C (en) 2004-02-24
DE932705T1 (de) 2000-04-06
KR20000049076A (ko) 2000-07-25
EP0932705B1 (en) 2003-11-26

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