JP2006088229A - Small-diameter coated tool and method of coating the same - Google Patents
Small-diameter coated tool and method of coating the same Download PDFInfo
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- Milling, Broaching, Filing, Reaming, And Others (AREA)
- Physical Vapour Deposition (AREA)
- Drilling Tools (AREA)
Abstract
Description
本発明は、金属材料、プラスチック材料、各種セラミックス等の加工に使用される被覆小径工具に関する。 The present invention relates to a coated small-diameter tool used for processing metal materials, plastic materials, various ceramics and the like.
モノ作りの低コスト化に伴い、加工時間の短縮、被加工物の高硬度化、高精度加工等が要望されている。特に近年ではこれらの要求に加えて、被加工物の小型化による微細加工が特に重要視されており、切削工具の小径化が著しく進んでいる。これらの要求に伴い、切削工具にはより過酷な切削環境が強いられている。例えば、被加工物の高硬度化や高速加工による工具の摩耗増大、また工具摩耗による加工精度低下等があげられる。特に工具径1mm未満の小径工具においては、これらの現象が顕著であり、現状では安定した加工が行われているとは言い難い。これらの課題に対して、以下の特許文献1から5が開示されている。
特許文献1は、(TiAl)(CN)系の硬質皮膜を被覆した被覆工具が開示され、該硬質皮膜の残留圧縮応力を8GPa以下とすることが記載されている。
特許文献2は、プリント基板における多層積層板の穴あけ加工において、先端切刃の摩耗を抑制するために、工具の表面に物理蒸着法により(TiAl)N系多層膜を被覆する表面被覆超硬合金製ミニチュアドリルが開示されている。
特許文献3は、耐摩耗性や耐折損性を改善するために、基体である超硬合金表面に硬質炭素膜を被覆した、刃径が0.30〜0.50mmであるプリント基板穿孔用ドリルが開示されている。
特許文献4は、プリント回路基板加工用工具に(TiSi)(CN)層を被覆することにより、耐欠損性及び耐久性を高めた表面被覆切削工具が開示されている。
特許文献5は、超硬合金と実質的に同じ組成を有する超微粒組織を有するスパッタ蒸着皮膜で構成された表面被覆層を1〜10μmの平均厚さで形成してなる、超微粒組織の表面被覆層がすぐれた密着性を有する表面被覆超硬合金製ミニチュアドリルとすることにより、表面被覆材の密着性を高いものとし、耐摩耗性の一段の向上をもたらす提案が開示されている。
しかし、上記の何れの特許文献にも、被覆小径工具における皮膜の残留圧縮応力と耐折損性との関係に言及したものは無い。
With the cost reduction of manufacturing, there is a demand for shortening the processing time, increasing the hardness of the workpiece, and high-precision processing. In particular, in recent years, in addition to these requirements, fine machining by miniaturizing the workpiece has been especially emphasized, and the diameter of cutting tools has been remarkably reduced. With these requirements, cutting tools are forced to have a more severe cutting environment. For example, there is an increase in tool wear due to high hardness of the workpiece, high-speed machining, and a reduction in machining accuracy due to tool wear. In particular, in a small-diameter tool having a tool diameter of less than 1 mm, these phenomena are remarkable, and it is difficult to say that stable machining is currently performed. The following Patent Documents 1 to 5 are disclosed for these problems.
Patent Document 1 discloses a coated tool coated with a (TiAl) (CN) -based hard film, and describes that the residual compressive stress of the hard film is 8 GPa or less.
Patent Document 2 discloses a surface-coated cemented carbide that coats a (TiAl) N-based multilayer film on the surface of a tool by physical vapor deposition in order to suppress wear of the tip cutting edge in drilling a multilayer laminate on a printed circuit board. A miniature drill made is disclosed.
However, none of the above patent documents mentions the relationship between the residual compressive stress of the coating and the breakage resistance of the coated small-diameter tool.
本発明は、小径の回転工具の基体表面に適切な硬質皮膜を被覆することによって以下の課題を解決することを目的とした。その第1の課題は、刃部直径Dμmが、5≦D≦800の場合と、従来の1mm以上の場合とではその形状に適した被覆技術が必要となるからである。小径工具用の硬質皮膜とし性能改善に寄与しする皮膜を提供することである。即ち、小径工具の切削加工において最も重要となる折損寿命の向上と、硬質皮膜の酸化を抑制し耐摩耗性を改善させることである。第2の課題は、小径工具の、特に折損等生じやすい、首部からクランプするためのシャンク部との段差部の強度を向上させ、折損を防止する事である。 An object of the present invention is to solve the following problems by coating an appropriate hard film on the surface of a base of a rotary tool having a small diameter. The first problem is that a coating technique suitable for the shape is required when the blade diameter Dμm is 5 ≦ D ≦ 800 and when the blade diameter is 1 mm or more. It is to provide a film that contributes to performance improvement as a hard film for small diameter tools. That is, the improvement of the breakage life, which is the most important in the cutting of small diameter tools, and the improvement of wear resistance by suppressing the oxidation of the hard coating. The second problem is to improve the strength of the stepped portion of the small diameter tool, which is particularly likely to be broken, and the shank portion for clamping from the neck portion, thereby preventing breakage.
本出願の第1の発明は、硬質皮膜を被覆した被覆小径工具において、該小径工具の刃部の直径Dμmは、5≦D≦800、該硬質皮膜はスパッタリング法により被覆され、該硬質皮膜の少なくとも1層の残留圧縮応力TはGPaで、2≦T≦8、であることを特徴とする被覆小径工具である。
第2の発明は、硬質皮膜を被覆した被覆小径工具において、該被覆小径工具は、該刃部と、該刃部に連なりこれよりも外径が大きい首部と、該首部に連なりこれよりも外径が大きく工具をクランプするためのシャンク部とからなる段差付き円筒形状を有し、該刃部の直径Dμmは、5≦D≦800であり、該硬質皮膜の少なくとも1層の残留圧縮応力TはGPaで、2≦T≦8、該刃部・首部の少なくとも1部に該硬質皮膜が被覆されていることを特徴とする被覆小径工具である。ここで、該刃部1は刃溝が形成された部位を指し、首部2は該刃部1とは直径が異なり、実質的に切削加工に関与はしない部位を指し、シャンク部3は工具をクランプする部位を指す。上記の構成を採用することにより、優れた耐折損性を有し、耐摩耗性にも優れる硬質皮膜被覆小径工具を提供することが可能となる。
The first invention of the present application is a coated small-diameter tool coated with a hard coating, wherein the diameter D μm of the blade portion of the small-diameter tool is 5 ≦ D ≦ 800, the hard coating is coated by a sputtering method, The residual compressive stress T of at least one layer is GPa, and 2 ≦ T ≦ 8.
According to a second aspect of the present invention, there is provided a coated small-diameter tool coated with a hard coating, wherein the coated small-diameter tool is connected to the blade portion, the neck portion connected to the blade portion and having a larger outer diameter, and connected to the neck portion. It has a cylindrical shape with a step having a large diameter and a shank portion for clamping a tool, the diameter Dμm of the blade portion is 5 ≦ D ≦ 800, and the residual compressive stress T of at least one layer of the hard coating Is a small-diameter coated tool characterized in that 2 ≦ T ≦ 8 and at least one part of the blade / neck is coated with the hard coating. Here, the blade portion 1 indicates a portion where a blade groove is formed, the neck portion 2 has a diameter different from that of the blade portion 1 and substantially does not participate in cutting, and the
該硬質皮膜は、金属元素のみの原子比率でSi含有量が10原子%未満の結晶粒子と、Si含有量が10原子%以上の非晶質相が存在するように構成することが好ましい。該硬質皮膜は、Ti、Cr、Al、Zr、Nbから選ばれる少なくとも1種以上の元素を含有すること、硬質皮膜の最表面から膜厚方向に500nm以内の領域には、C、O、B、Cl、S、P、Sの何れか1種以上の元素が皮膜全体の3原子%以上含有することも好ましい。該硬質皮膜は、少なくともSiを含有し、X線光電子分光分析により、少なくともSi−N、Si−O及び金属Siの結合エネルギーを有し、Si−Nに相当する結合エネルギーの強度をI(Si−N)、Si−Oに相当する結合エネルギーの強度をI(Si−O)及び金属Siに相当する結合エネルギーの強度をI(Si)とした時、I(Si−N)>I(Si)、I(Si−N)>I(Si−O)を満足し、I(Si−N)の比率が52%以上、85%以下であること、
本発明の被覆小径工具は回転工具であり、エンドミル、ドリル、リーマ、ルーターのいずれかに適用されることが好適であり、優れた切削性能を得ることができる。加えて、本発明の硬質皮膜はスパッタリング法とアーク放電式イオンプレーティング法とを組み合わせて被覆する方法を採用することが好ましい。
The hard coating is preferably configured such that there are crystal particles having an Si content of less than 10 atomic% and an amorphous phase having an Si content of 10 atomic% or more in an atomic ratio of only the metal element. The hard coating contains at least one element selected from Ti, Cr, Al, Zr, and Nb, and C, O, B in a region within 500 nm from the outermost surface of the hard coating in the film thickness direction. It is also preferable that at least one element selected from the group consisting of Cl, S, P, and S contains 3 atomic% or more of the entire film. The hard coating contains at least Si, and has a binding energy of at least Si—N, Si—O, and metallic Si by X-ray photoelectron spectroscopy, and the strength of the binding energy corresponding to Si—N is I (Si -N), when the bond energy intensity corresponding to Si-O is I (Si-O) and the bond energy intensity corresponding to metal Si is I (Si), I (Si-N)> I (Si ), I (Si—N)> I (Si—O), and the ratio of I (Si—N) is 52% or more and 85% or less,
The coated small-diameter tool of the present invention is a rotary tool, and is preferably applied to any of an end mill, a drill, a reamer, and a router, and can obtain excellent cutting performance. In addition, it is preferable to employ a method in which the hard coating of the present invention is coated by a combination of a sputtering method and an arc discharge ion plating method.
本発明の硬質皮膜被覆小径工具は、耐折損性が重要視される小径工具に最適な硬質皮膜を被覆し、またそれに適した工具形状等を検討することにより、優れた耐折損性を有しながら耐摩耗性に優れる被覆小径工具を提供することができた。これにより、切削加工における生産性向上並びにコスト低減に極めて有効な工具を提供できる。 The hard coating coated small diameter tool of the present invention has excellent fracture resistance by coating a hard coating optimal for small diameter tools where breakage resistance is regarded as important, and studying suitable tool shapes and the like. However, a coated small diameter tool having excellent wear resistance could be provided. As a result, it is possible to provide a tool that is extremely effective in improving productivity and reducing costs in cutting.
本発明の第1の発明のD値μmは、5≦D≦800であり、硬質皮膜はスパッタリング法により被覆され、該硬質皮膜の少なくとも1層の残留圧縮応力TはGPaで、2≦T≦8、であることを特徴とする被覆小径工具である。D値は、スパッタリング法による被覆手段を採用した場合、硬質皮膜を被覆する前工程であるイオンクリーニング工程において、Dが5μm未満になると、基体がイオンボンバードにより消滅する可能性があるからである。一方、800μmを超えて大きいと、本発明の耐折損性の効果が顕著に認められなかったことによる。
残留圧縮応力TはGPaで、2≦T≦8、に限定する。T値が2≦T≦8の範囲として得られる硬質皮膜は、特に硬質皮膜表面の平滑性に優れ、高硬度を有するため耐摩耗性に優れる。更に、T値を限定した理由は、上記範囲を有する場合、工具そのものの強度が向上し、小径工具では特に重要となる切削過程における曲げやたわみに対する強度や抵抗を高め、耐折損性を著しく向上させることができるからである。更に好ましいT値の範囲は、2.5GPa以上、4.5GPaである。工具に被覆した場合、残留圧縮応力の確認方法は、硬質皮膜組成、結晶構造、組織構造、皮膜硬度、刃先先端の硬質皮膜状態、微小部薄膜X線回折における(200)の半価幅測定等から総合的に判断することができる。例えば、微小部薄膜X線回折による(200)面の半価幅が2θで1度以上であり、且つ組成が断定できれば残留圧縮応力が推定される。しかし、最終的にその単1層を被覆し、被覆前後の薄板の曲率から算出することが好ましい。硬質皮膜の残留圧縮応力は、硬質皮膜内の少なくとも1層の残留圧縮応力である。上記により第1の課題である、小径工具用の硬質皮膜とし性能改善に寄与しする皮膜を提供することができる。
The D value μm of the first invention of the present invention is 5 ≦ D ≦ 800, the hard film is coated by a sputtering method, the residual compressive stress T of at least one layer of the hard film is GPa, and 2 ≦ T ≦ 8 is a coated small-diameter tool. This is because the D value may be eliminated by ion bombardment when the D value is less than 5 μm in the ion cleaning process, which is a previous process for coating the hard film, when a coating means by sputtering is employed. On the other hand, if it exceeds 800 μm, the effect of breakage resistance of the present invention is not remarkably recognized.
The residual compressive stress T is GPa and is limited to 2 ≦ T ≦ 8. A hard film obtained with a T value in the range of 2 ≦ T ≦ 8 is particularly excellent in the smoothness of the surface of the hard film, and has high hardness, and thus is excellent in wear resistance. Furthermore, the reason for limiting the T value is that if it has the above range, the strength of the tool itself is improved, and the strength and resistance to bending and deflection in the cutting process, which is particularly important for small-diameter tools, are increased, and the fracture resistance is remarkably improved. It is because it can be made. A more preferable T value range is 2.5 GPa or more and 4.5 GPa. When the tool is coated, the residual compressive stress can be confirmed by a hard film composition, a crystal structure, a structure structure, a film hardness, a hard film state at the tip of the blade, a (200) half-value width measurement in micro thin film X-ray diffraction, etc. Can be judged comprehensively. For example, if the half width of the (200) plane by micro thin film X-ray diffraction is 1 ° or more at 2θ and the composition can be determined, the residual compressive stress is estimated. However, it is preferable to finally cover the single layer and calculate from the curvature of the thin plate before and after the coating. The residual compressive stress of the hard coating is a residual compressive stress of at least one layer in the hard coating. By the above, the hard coating for small diameter tools which is the 1st subject can be provided, and the coating which contributes to performance improvement can be provided.
本発明の第2の発明は、段差付き円筒形状を有し、その段差部の少なくとも1部に該硬質皮膜が被覆するように構成することである。図1に本発明に係る被覆小径工具の1例である概略図を示す。1が刃部であり、3が工具をクランプするシャンク部であり、2が実質的に切削加工に関与しない直径が異なる少なくとも1つ以上の首部を有する該首部であり、本発明の好ましい硬質皮膜の被覆部位としては、首部2の領域の少なくとも1部に該硬質皮膜を被覆することを意味する。実質的に切削加工に関与しない直径が異なる少なくとも1つ以上の首部2を複数設けることにより、刃部の耐折損性が向上する。首部2の領域も刃部1と同様に、残留圧縮応力を有した該硬質皮膜を被覆することにより、強度が向上し、耐折損性を大幅に向上させることができ好ましい。更に、図1中には示していないが、直径が異なる少なくとも1つ以上の首部の繋ぎ部に、微小な曲率を形成させると、更に耐折損性を改善することができ好ましい。 A second aspect of the present invention is to have a cylindrical shape with a step, and to be configured such that at least one part of the step portion is covered with the hard coating. FIG. 1 is a schematic view showing an example of a coated small diameter tool according to the present invention. 1 is a blade part, 3 is a shank part for clamping a tool, 2 is the neck part having at least one or more neck parts having different diameters that are not substantially involved in cutting, and a preferable hard coating of the present invention As the coating portion, it means that at least a part of the region of the neck 2 is coated with the hard coating. By providing a plurality of at least one or more neck portions 2 having different diameters that are not substantially involved in cutting, the breakage resistance of the blade portion is improved. Similarly to the blade portion 1, the region of the neck portion 2 is preferably coated with the hard film having a residual compressive stress, whereby the strength is improved and the breakage resistance is greatly improved. Further, although not shown in FIG. 1, it is preferable to form a minute curvature at a connecting portion of at least one neck having different diameters, since the breakage resistance can be further improved.
刃部直径Dμmが5≦D≦800となる小径工具形状には、被覆技術としてスパッタリング法を採用して、硬質皮膜表面における凹凸の発生を低減させることが必要である。これにより、摩擦抵抗を低減し工具精度の長期維持を計ることができる。例えばTiN、(TiAl)N及び(TiSi)N系硬質皮膜の成膜においては、スパッタリング法を採用することにより、硬質皮膜構成元素を蒸発イオン化させ、工具基体表面に被覆することができる。しかも、成膜中のプラズマ密度の適正化によって小径工具の刃部近傍での硬質皮膜表面の凹凸を低減させ、摩擦抵抗の低減や工具精度の向上に寄与し、性能改善に有効である。スパッタリング法では、蒸着源の構造、成膜中の電力、ガス圧力等の選択によりプラズマ密度の適正化し、イオン化されない皮膜元素が金属粒子として基体表面に付着するのを回避するのに有利である。 It is necessary to reduce the occurrence of unevenness on the surface of the hard coating by employing a sputtering method as a coating technique for a small-diameter tool shape having a blade diameter D μm of 5 ≦ D ≦ 800. Thereby, friction resistance can be reduced and long-term maintenance of tool accuracy can be measured. For example, in the formation of TiN, (TiAl) N, and (TiSi) N-based hard coatings, the hard coating constituent elements can be evaporated and ionized and coated on the tool base surface by employing a sputtering method. In addition, by optimizing the plasma density during film formation, unevenness on the surface of the hard coating near the blade portion of the small-diameter tool is reduced, contributing to reduction of frictional resistance and improvement of tool accuracy, which is effective for performance improvement. The sputtering method is advantageous in optimizing the plasma density by selecting the structure of the vapor deposition source, the power during film formation, the gas pressure, etc., and avoiding the non-ionized film elements from adhering to the substrate surface as metal particles.
本発明の該硬質皮膜は少なくともSiを含有し、X線光電子分光分析により、少なくともSi−N、Si−O及び金属Siの結合エネルギーが確認され、そのSi2pスペクトルのうち、Si−Nに相当する結合エネルギーの強度をI(Si−N)、Si−Oに相当する結合エネルギーの強度をI(Si−O)及び金属Siに相当する結合エネルギーの強度をI(Si)とした時、I(Si−N)>I(Si)、I(Si−N)>I(Si−O)を満足し、更にI(Si−N)の比率が52%以上、85%以下に制御することが好ましい。これは該硬質皮膜内にSiが含有し、更に上記関係を満足させることによって、極めて平滑で高硬度な硬質皮膜が得られ、耐摩耗性と耐折損性のバランスが最適であるからである。更に、該硬質皮膜をスパッタリング法により被覆すると、アーク放電式イオンプレーティング法(以下、AIP法と言う。)に比べ、硬質皮膜の結晶粒子が更に微細化され、表面平滑性が改善する。また、これらにより硬質皮膜の強度が向上し、耐折損性と皮膜硬度との向上による耐摩耗性の改善に有効に作用する。上記により折損寿命の向上に寄与しする皮膜を提供することができる。 The hard coating of the present invention contains at least Si, and at least the binding energy of Si—N, Si—O and metal Si is confirmed by X-ray photoelectron spectroscopy, and corresponds to Si—N in the Si 2p spectrum. When the bond energy strength is I (Si—N), the bond energy strength corresponding to Si—O is I (Si—O), and the bond energy strength corresponding to metal Si is I (Si), I (Si) Si—N)> I (Si), I (Si—N)> I (Si—O) is satisfied, and the ratio of I (Si—N) is preferably controlled to 52% or more and 85% or less. . This is because Si is contained in the hard coating, and by satisfying the above relationship, a very smooth and high hardness hard coating can be obtained, and the balance between wear resistance and breakage resistance is optimal. Further, when the hard film is coated by a sputtering method, crystal grains of the hard film are further refined and surface smoothness is improved as compared with an arc discharge ion plating method (hereinafter referred to as AIP method). Moreover, the strength of the hard coating is improved by these, and it effectively acts on the improvement of the wear resistance by improving the breakage resistance and the coating hardness. The film which contributes to the improvement of breakage life by the above can be provided.
本発明におけるX線光電子分光分析による、I(Si−N)、I(Si)、I(Si−O)の算出方法並びに被覆条件との関係について述べる。被覆基体は鏡面加工したCo含有量13.5重量%の微粒超硬合金を用いた。X線光電子分光分析は、PHI社製1600S型X線光電子分光分析装置を用い、X線源はMgKαを用い400Wとし、分析領域を直径0.4mmの円内部を分析した。分析前に、十分にアセトンにより脱脂洗浄を行い、更に分析部の硬質皮膜表面に付着した汚染物質等を除去するために5分間Arイオンガンを用いてエッチングした後、全体のスペクトルを測定し、更に30秒間エッチングした後、Si2pに相当するスペクトルを測定した。ArイオンガンによるエッチングレートはSiO2換算で1.9nm/分であった。全体に占めるI(Si−N)の強度比は被覆条件並びに硬質皮膜組成によって決定される。被覆条件に関して検討した結果、I(Si−N)の比率が52%以上、85%以下になる好ましい被覆条件としては、反応圧が0.2〜2.0Pa、バイアス電圧は−50〜−500V、被覆温度が350〜500度であった。 The relationship between the calculation method of I (Si—N), I (Si), and I (Si—O) by the X-ray photoelectron spectroscopy in the present invention and the coating conditions will be described. The coated substrate was a mirror-finished fine-grain cemented carbide with a Co content of 13.5% by weight. The X-ray photoelectron spectroscopic analysis was carried out using a 1600S type X-ray photoelectron spectroscopic analyzer manufactured by PHI, the X-ray source was set to 400 W using MgKα, and the inside of a circle having a diameter of 0.4 mm was analyzed. Before analysis, thoroughly degrease and wash with acetone, and further etch using an Ar ion gun for 5 minutes to remove contaminants attached to the hard coating surface of the analysis unit, and then measure the entire spectrum, After etching for 30 seconds, a spectrum corresponding to Si2p was measured. The etching rate by Ar ion gun was 1.9 nm / min in terms of SiO2. The intensity ratio of I (Si—N) in the whole is determined by the coating conditions and the hard film composition. As a result of examination on coating conditions, preferable coating conditions in which the ratio of I (Si—N) is 52% or more and 85% or less include a reaction pressure of 0.2 to 2.0 Pa and a bias voltage of −50 to −500 V. The coating temperature was 350 to 500 degrees.
本発明における好ましい被覆小径工具を得るために、該硬質皮膜内に、金属元素のみの原子比率でSi含有量が10原子%未満の結晶粒子とSi含有量が10原子%以上の非晶質相を存在させることが好ましい。その理由としては、上記組織構造を有する硬質皮膜内の結晶粒径がナノオーダーまで微細化され、極めて平滑な硬質皮膜表面を形成するからである。またSi含有量が異なる結晶粒子または非晶質相を分散させることによって、容易に残留圧縮応力を向上させることができ、その制御に有効である。ここで、上記組織構造の確認は、透過型電子顕微鏡により、試料厚さが粒子サイズ程度の領域で観察を行い、夫々の領域に対応した数ナノメートルオーダーをエネルギー分散型分析による定量分析、電子線回折像撮影により結晶構造を確認した。電子線回折像の撮影にはカメラ長を50cm、ビーム径を2〜5nmにて分析を行った。
本発明の硬質皮膜は、Siに加えて、Ti、Cr、Al、Zr、Nbの少なくとも1種以上を含有し、スパッタリング法により被覆される場合、該硬質皮膜の残留圧縮応力の制御並びに硬質皮膜表面の平滑性に有効であり好ましい。
本発明の硬質皮膜の最表面から500nm以内のC、O、B、Cl、S、P、Sの何れか1種以上が硬質皮膜全体の3原子%以上含有する場合、耐摩耗性に優れ、切削抵抗が減少し、耐折損性を向上させることができる。この場合の各種元素の添加方法は、反応ガスとしての添加、スパッタリングターゲットである固体蒸発材料から添加する手法、もしくは硬質皮膜の被覆終了後、イオン注入装置により硬質皮膜表面に添加することも可能である。
本発明の該被覆小径工具としては、回転工具のなかでも、特にエンドミル、ドリル、リーマ、ルーターのいずれかで使用した場合、切削性能改善が顕著であり好適である。
本発明の硬質皮膜の被覆方法には、物理蒸着法のスパッタリング法による被覆手段を採用することが重要であるが、基体との密着強度が十分ではない場合、AIP法と併用することにより、スパッタリング法による硬質皮膜の密着強度を補強することができる。この場合は、基体表面からの膜厚を200nm以内、より好ましくは100nm以内に制限することが必要である。AIP法による硬質皮膜の膜厚が増加するに従い、本発明の効果が低減する傾向にあるためである。また異特性の元素を添加する手段として、スパッタリング法とAIP法を同時に用いることも可能であり、本発明皮膜を被覆することができる。この場合AIP法による被覆時間が増加するに従い、耐折損性が低下する傾向にあるので注意を要する。AIP法とスパッタリング法を併用する場合、同時に行う方法と逐次的に行う被覆方法が可能である。上記の様に、小径工具に適した硬質皮膜被覆技術を提供することができる。以下、本発明を実施例に基づいて説明する。
In order to obtain a preferable coated small-diameter tool in the present invention, in the hard coating, crystal grains having an Si content of less than 10 atomic% and an amorphous phase having an Si content of 10 atomic% or more in an atomic ratio of only the metal element Is preferably present. The reason for this is that the crystal grain size in the hard film having the above-described structure is refined to the nano order to form an extremely smooth hard film surface. Further, by dispersing crystal grains or amorphous phases having different Si contents, it is possible to easily improve the residual compressive stress, which is effective for the control. Here, the above-mentioned structure is confirmed with a transmission electron microscope in a region where the sample thickness is about the particle size, and several nanometer order corresponding to each region is quantitatively analyzed by energy dispersive analysis. The crystal structure was confirmed by taking a line diffraction image. For taking an electron diffraction image, analysis was performed with a camera length of 50 cm and a beam diameter of 2 to 5 nm.
When the hard coating of the present invention contains at least one of Ti, Cr, Al, Zr, and Nb in addition to Si and is coated by a sputtering method, the control of the residual compressive stress of the hard coating and the hard coating It is effective and preferable for surface smoothness.
When any one or more of C, O, B, Cl, S, P, S within 500 nm from the outermost surface of the hard coating of the present invention contains 3 atomic% or more of the entire hard coating, the wear resistance is excellent. Cutting resistance is reduced and breakage resistance can be improved. In this case, various elements can be added as a reactive gas, a method of adding from a solid evaporation material as a sputtering target, or after the coating of the hard film is completed, it can be added to the surface of the hard film by an ion implantation apparatus. is there.
The coated small-diameter tool of the present invention is suitable for use in any of rotating tools, particularly an end mill, a drill, a reamer, or a router, because the cutting performance is significantly improved.
In the coating method of the hard coating of the present invention, it is important to employ a coating means by a physical vapor deposition sputtering method, but when the adhesion strength with the substrate is not sufficient, by using together with the AIP method, sputtering is performed. The adhesion strength of the hard coating by the method can be reinforced. In this case, it is necessary to limit the film thickness from the substrate surface to within 200 nm, more preferably within 100 nm. This is because the effect of the present invention tends to decrease as the thickness of the hard film by the AIP method increases. Further, as a means for adding elements having different characteristics, the sputtering method and the AIP method can be used simultaneously, and the coating of the present invention can be coated. In this case, care should be taken because the breakage resistance tends to decrease as the coating time by the AIP method increases. When the AIP method and the sputtering method are used in combination, a simultaneous method and a sequential coating method are possible. As described above, it is possible to provide a hard film coating technique suitable for a small-diameter tool. Hereinafter, the present invention will be described based on examples.
基体材料としてCo含有量が7重量パーセント、WC平均粒径が0.2μm〜0.6μm、丸棒形状の超硬合金を使用し、図1に示す形状に刃部1、首部2、シャンク部3を加工した。シャンク部の直径は4mmとした。図2は、刃部1のA−A断面形状を示し、逃げ面4とすくい面5との交わる切れ刃稜線からなり、刃部直径は40μm、ねじれ角30度からなる2枚刃スクエアエンドミルに加工した。刃部から首部への繋ぎ部、首部における径違いの段差となる夫々の繋ぎ部、更に首部からシャンク部への繋ぎ部は、応力集中による折損を抑制するために、微小なアール形状を形成した。
次に、上記で作製した2枚刃スクエアエンドミルの基体を脱脂洗浄して、スパッタリング法による真空容器内に配置した。被覆基体は温度500度となるように加熱・排気を行い、Arガスを真空容器内に導入した。真空容器内のプラズマによりArイオンを形成し、基体に印加した負バイアス電圧により、被覆基体のクリーニング処理を行った。この時のクリーニング源として、金属イオンを用いることも可能である。Arと反応ガスである窒素とを真空容器内に導入しながら、ターゲット材をイオン化し、負に印加したバイアス電圧により、基体表面に硬質皮膜を1μm被覆した。特に指定がない限り上記に示す製法で被覆小径工具を作成し、各種硬質皮膜を被覆した。硬質皮膜の被覆領域等も含めて被覆条件を表1に記載する。
As a base material, a Co content of 7 weight percent, a WC average particle size of 0.2 μm to 0.6 μm, a round bar-shaped cemented carbide is used, and the shape shown in FIG. 1 is a blade part 1, a neck part 2, and a shank part. 3 was processed. The diameter of the shank part was 4 mm. FIG. 2 shows an AA cross-sectional shape of the blade portion 1, which is composed of a cutting edge ridge line intersecting the
Next, the base of the two-blade square end mill produced as described above was degreased and cleaned and placed in a vacuum container formed by sputtering. The coated substrate was heated and evacuated to a temperature of 500 degrees, and Ar gas was introduced into the vacuum vessel. Ar ions were formed by plasma in a vacuum vessel, and the coated substrate was cleaned by a negative bias voltage applied to the substrate. It is also possible to use metal ions as the cleaning source at this time. The target material was ionized while introducing Ar and reactive gas nitrogen into the vacuum vessel, and the substrate was coated with 1 μm of a hard film by a negatively applied bias voltage. Unless otherwise specified, coated small-diameter tools were prepared by the manufacturing method described above, and various hard coatings were coated. The coating conditions including the coating region of the hard coating are shown in Table 1.
表1に示す様に各種作製した本発明例、比較例、従来例により、切削試験を実施した。折損寿命の評価は同一試料を3本切削加工し、切削長さの平均値として表1の折損寿命に併記した。また、折損寿命に関しては小数点以下を切り捨てて記載した。切削条件を以下に示す。
(切削条件)
工具:2枚刃エンドミル
切削方法:側面仕上げ切削加工
被削材:マルテンサイト系ステンレス鋼、硬さ:HRC53
切り込み:軸方向:4μm、径方向:1μm
切削速度:5m/min
送り:1μm/刃
切削油:なし
As shown in Table 1, cutting tests were carried out according to various examples of the present invention, comparative examples, and conventional examples. The evaluation of the breakage life was performed by cutting three identical samples and writing the breakage life in Table 1 as an average value of the cutting length. In addition, the broken life is shown by rounding down the decimal point. The cutting conditions are shown below.
(Cutting conditions)
Tool: 2-flute end mill Cutting method: Side finish cutting Work material: Martensitic stainless steel, Hardness: HRC53
Cutting depth: axial direction: 4 μm, radial direction: 1 μm
Cutting speed: 5 m / min
Feed: 1 μm / blade Cutting oil: None
表1内の表現方法において、被覆手段の欄のSPはスパッタリング法、AIPはアーク放電式イオンプレーティング法を示す。AIP→SPは、AIPによる硬質皮膜を200nm以下で被覆し、その後SPによって硬質皮膜を被覆したことを示す。ここで、AIPによる硬質皮膜を200nm以下とした理由は、200nmを超えて厚く被覆した場合には、硬質皮膜内もしくは表面に金属粒子が付着し、摩擦抵抗が大きくなり、折損寿命を低下させたためである。AIP+SPは、硬質皮膜の1部をAIPとSPを同時に稼動させ被覆したことを示す。
X線光電子分光分析により算出したSi含有皮膜のI(Si−N)の強度比も併記した。Si含有皮膜の組織構造は、Si含有量が結晶質層で10原子%未満、非晶質相で10原子%以上含有した層を含む場合、ナノ組織と記載した。図3に本測定により得られた本発明例1のSi2pに相当するスペクトル測定結果を示す。図3のピーク分離については、Si−N成分のピーク位置を101.2±0.2eV、Si−O成分のピーク位置を103.3±0.2eV、Siの金属成分のピーク位置を99.3±0.2eVとして、ピークフィッティング法によって行った。図3から夫々の面積強度は、I(Si−N)=1098、I(Si)=184、I(Si−O)=265であり、全体に占めるI(Si−N)の強度比率は71%となった。
In the expression method in Table 1, SP in the column of coating means indicates a sputtering method, and AIP indicates an arc discharge ion plating method. AIP → SP indicates that a hard film by AIP was coated at 200 nm or less, and then the hard film was coated by SP. Here, the reason why the hard film by AIP was set to 200 nm or less was that when it was thickly coated exceeding 200 nm, metal particles adhered to or on the surface of the hard film, resulting in increased frictional resistance and reduced breakage life. It is. AIP + SP indicates that a part of the hard coating was coated by operating AIP and SP simultaneously.
The intensity ratio of I (Si—N) of the Si-containing coating calculated by X-ray photoelectron spectroscopy was also shown. The structure of the Si-containing coating was described as a nanostructure when the Si content included a layer containing less than 10 atomic% in the crystalline layer and 10 atomic% or more in the amorphous phase. FIG. 3 shows a spectrum measurement result corresponding to Si2p of Invention Example 1 obtained by this measurement. 3, the Si—N component peak position is 101.2 ± 0.2 eV, the Si—O component peak position is 103.3 ± 0.2 eV, and the Si metal component peak position is 99. ± 9. The peak fitting method was performed at 3 ± 0.2 eV. From FIG. 3, the area strengths are I (Si—N) = 1098, I (Si) = 184, I (Si—O) = 265, and the intensity ratio of I (Si—N) in the whole is 71. %.
表1に示す本発明例1から23は、比較例24から27、従来例28から32と比較して安定した折損寿命が得られた。以下本発明例の詳細について述べる。本発明例1から5は、本発明皮膜を被覆し、刃部直径Dが異なる場合を示す。D値が小さい程折損寿命が低下する傾向を示したが、それでも本発明例はD値が小さくても、折損寿命が長く優れた切削性能を示した。同じD値で比較すると、本発明例は比較例、従来例に比べて折損寿命が格段に優れていた。比較例25はD値が1000μmの場合であるが、従来例30に比べ、大幅に折損寿命が向上しているとはいえなかった。D値が800μmの本発明例5と比較すると、本発明は小径側で折損寿命の改善効果が大きかった。本発明例6は、硬質皮膜の被覆部位が刃部1に加えて、首部2の全体に被覆した場合を示す。本発明例2に比べ格段に折損寿命に優れた。この理由は、首部に圧縮応力を付与することにより工具強度が向上し、耐折損性を向上させたためである。本発明例7、8は、本発明で好ましいとされるSi含有皮膜のI(Si−N)の比率である、52%以上、85%以下の範囲を外ずれるものを示す。折損寿命が他の本発明例と比べて劣る結果となったことから、52%以上、85%以下が最適であることを示す。本発明例9は、Si含有皮膜の組織構造において非晶質相が認められない場合を示す。この場合も折損寿命が他の本発明例と比べて劣る結果となったことから、10原子%以下のSi含有量の結晶粒子と、10原子%以上のSi含有非晶質相が存在することが好ましいことを示す。本発明例12、13、14は、Si含有皮膜の組織構造において、非晶質相は認められたものの、非晶質相のSi含有量が10原子%に満たない場合であるが、折損寿命に優れていた。本発明例15は、各層の厚みが数ナノメートルからなり総層数が約3000層の場合を示す。本発明例1と比較すると、折損寿命が長く、好ましい被覆形態である。本発明例16、17、18、19は、3種類の硬質皮膜を積層させた場合を示し、折損寿命に優れていた。本発明例18の最外層は、二硫化モリブデンと(TiSi)Nを同時に被覆した場合である。本発明例19は、硬質皮膜を被覆後、イオン注入装置に設置し、Clを注入させた場合である。本発明例20は、(TiSi)N層の残留圧縮応力が6.2GPaの場合を示す。本発明例2に比較して、折損寿命が若干悪くなった。これより、好ましい残留圧縮応力値は6GPa以下である。一方、比較例27、28は、残留圧縮応力が本発明の規定範囲外の場合を示す。残留圧縮応力が2GPaよりも低い場合、耐折損性改善効果は認められず、残留圧縮応力が8GPaよりも高い場合、残留圧縮応力により硬質皮膜の剥離が認められ、耐折損性を改善するには至らなかった。本発明例21は、SiとHfを含有する層の場合を示すが、SiとTiを含有する本発明例1に比べ、折損寿命が劣っている。本発明22は、AIPにより50nmの(TiAl)Nを被覆した後、SPにより(TiSi)Nを被覆した場合であるが、AIPによる欠陥の影響がほとんど確認されず折損寿命に優れていた。本発明例23は、硬質皮膜の1部をAIPとSPによる被覆を同時に行った場合を示す。この時のAIPによる硬質皮膜の厚さは、10nmから100nmとした。AIPによる欠陥の影響がほとんど確認されず折損寿命に優れている。本発明例24は、刃部の1部が立方晶窒化硼素からなる場合を示す。耐折損性が改善されているため、立方晶窒化硼素本来の耐摩耗効果を発揮することができた。 Inventive Examples 1 to 23 shown in Table 1 showed a stable break life as compared with Comparative Examples 24 to 27 and Conventional Examples 28 to 32. Details of the present invention will be described below. Examples 1 to 5 of the present invention show cases where the coating of the present invention is coated and the blade diameter D is different. Although the breakage life tended to decrease as the D value was smaller, the examples of the present invention still exhibited long cutting life and excellent cutting performance even when the D value was small. When compared with the same D value, the breakage life of the example of the present invention was remarkably superior to that of the comparative example and the conventional example. In Comparative Example 25, the D value was 1000 μm, but it could not be said that the fracture life was significantly improved as compared with Conventional Example 30. Compared with Example 5 of the present invention having a D value of 800 μm, the present invention has a large effect of improving the breakage life on the small diameter side. Inventive Example 6 shows a case where the coating portion of the hard coating covers the entire neck portion 2 in addition to the blade portion 1. Compared to Example 2 of the present invention, the breakage life was remarkably excellent. This is because the tool strength is improved by applying compressive stress to the neck and the breakage resistance is improved. Examples 7 and 8 of the present invention show those that deviate from the range of 52% or more and 85% or less, which is the ratio of I (Si—N) of the Si-containing film considered preferable in the present invention. Since the fracture life was inferior to that of other examples of the present invention, 52% or more and 85% or less are optimal. Invention Example 9 shows a case where no amorphous phase is observed in the structure of the Si-containing coating. In this case as well, the fracture life was inferior to that of the other examples of the present invention, so that there are crystal grains having an Si content of 10 atomic% or less and an amorphous phase containing Si of 10 atomic% or more. Is preferred. Examples 12, 13, and 14 of the present invention are cases where the amorphous phase was observed in the structure of the Si-containing coating, but the Si content in the amorphous phase was less than 10 atomic%, but the fracture life It was excellent. Invention Example 15 shows a case where the thickness of each layer is several nanometers and the total number of layers is about 3000 layers. Compared with Example 1 of the present invention, the breakage life is long, which is a preferable coating form. Invention Examples 16, 17, 18, and 19 show the case where three types of hard coatings were laminated, and were excellent in breakage life. The outermost layer of Invention Example 18 is a case where molybdenum disulfide and (TiSi) N are coated simultaneously. Example 19 of the present invention is a case where Cl is implanted by installing in an ion implantation apparatus after coating a hard film. Invention Example 20 shows a case where the residual compressive stress of the (TiSi) N layer is 6.2 GPa. Compared with Example 2 of the present invention, the breakage life was slightly deteriorated. Accordingly, a preferable residual compressive stress value is 6 GPa or less. On the other hand, Comparative Examples 27 and 28 show cases where the residual compressive stress is outside the specified range of the present invention. When the residual compressive stress is lower than 2 GPa, the effect of improving the breakage resistance is not recognized. When the residual compressive stress is higher than 8 GPa, the peeling of the hard film is recognized by the residual compressive stress, and the breakage resistance is improved. It did not come. Invention Example 21 shows the case of a layer containing Si and Hf, but the breakage life is inferior to that of Invention Example 1 containing Si and Ti. The present invention 22 is a case where (TiSi) N is coated with 50 nm of (TiAl) N by AIP and then (TiSi) N is coated with SP, but the effect of defects due to AIP is hardly confirmed and the fracture life is excellent. Invention Example 23 shows the case where a part of the hard coating was simultaneously coated with AIP and SP. At this time, the thickness of the hard film by AIP was set to 10 nm to 100 nm. The effect of defects due to AIP is hardly confirmed, and the fracture life is excellent. Invention Example 24 shows a case where one part of the blade part is made of cubic boron nitride. Since the fracture resistance was improved, the original wear resistance effect of cubic boron nitride could be exhibited.
1:刃部
2:首部
3:シャンク部
4:逃げ面
5:すくい面
1: Blade part 2: Neck part 3: Shank part 4: Flank 5: Rake face
Claims (8)
The coated small diameter tool coated with the hard coating according to any one of claims 1 to 7, wherein the hard coating is coated by combining the sputtering method and the arc discharge ion plating method. Tool coating method.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008307628A (en) * | 2007-06-13 | 2008-12-25 | Osg Corp | Small-diameter cemented carbide endmill |
| JPWO2021181518A1 (en) * | 2020-03-10 | 2021-09-16 | ||
| KR20210121499A (en) * | 2020-03-30 | 2021-10-08 | 서울대학교산학협력단 | Laser assisted micro-machining system and method for micro-machining using the same |
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2004
- 2004-09-21 JP JP2004272829A patent/JP2006088229A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008307628A (en) * | 2007-06-13 | 2008-12-25 | Osg Corp | Small-diameter cemented carbide endmill |
| JPWO2021181518A1 (en) * | 2020-03-10 | 2021-09-16 | ||
| WO2021181518A1 (en) * | 2020-03-10 | 2021-09-16 | 住友電工ハードメタル株式会社 | Reamer |
| JP2022111374A (en) * | 2020-03-10 | 2022-07-29 | 住友電工ハードメタル株式会社 | Manufacturing method of reamer |
| US11660691B2 (en) | 2020-03-10 | 2023-05-30 | Sumitomo Electric Hardmetal Corp. | Reamer |
| JP7388615B2 (en) | 2020-03-10 | 2023-11-29 | 住友電工ハードメタル株式会社 | Reamer manufacturing method |
| KR20210121499A (en) * | 2020-03-30 | 2021-10-08 | 서울대학교산학협력단 | Laser assisted micro-machining system and method for micro-machining using the same |
| KR102349328B1 (en) * | 2020-03-30 | 2022-01-10 | 서울대학교 산학협력단 | Laser assisted micro-machining system and method for micro-machining using the same |
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