An object of the present invention is to provide a novel technique capable of suppressing the occurrence of cracks in an AlN layer.

The present invention is a method for manufacturing an AlN substrate, the method including: an embrittlement processing step S10 of reducing strength of a SiC underlying substrate 10; and a crystal growth step S20 of forming an AlN layer 20 on the SiC underlying substrate 10. In addition, the present invention is a method for suppressing the occurrence of cracks in the AlN layer 20, the method including the embrittlement processing step S10 of reducing the strength of the SiC underlying substrate 10 before forming the AlN layer 20 on the SiC underlying substrate 10.

A cBN sintered material comprising cBN particles and a binder phase, in which the binder phase contains AlN and AlB.sub.2, a content proportion of cBN particles is 70 to 97 vol %, cBN sintered material has a volume resistivity up to 5×10.sup.−3 Ωcm, a rate of a peak intensity derived from Al with respect to a peak intensity derived from cBN particles is less than 1.0%, cBN particles include fine particles and coarse particles, coarse particles optionally include ultra-coarse particles, with respect to the entire cBN particles, a content proportion α of fine particles is from 10 vol %, a content proportion β of coarse particles is from 30 vol %, a content proportion γ of ultra-coarse particles is 25 vol % or less, and a total of the content proportion α of fine particles and the content proportion β of coarse particles is 50 to 100 vol %.

A cBN sintered material comprising cBN particles and a binder phase, in which the binder phase contains AlN and AlB.sub.2, a content proportion of cBN particles is 70 to 97 vol %, cBN sintered material has a volume resistivity up to 5×10.sup.−3 Ωcm, a rate of a peak intensity derived from Al with respect to a peak intensity derived from cBN particles is less than 1.0%, cBN particles include fine particles and coarse particles, coarse particles optionally include ultra-coarse particles, with respect to the entire cBN particles, a content proportion α of fine particles is from 10 vol %, a content proportion β of coarse particles is from 30 vol %, a content proportion γ of ultra-coarse particles is 25 vol % or less, and a total of the content proportion α of fine particles and the content proportion β of coarse particles is 50 to 100 vol %.

A cubic boron nitride sintered body has between 50% and 75% cubic boron nitride by volume and between 25% and 50% binder phase by volume, and inevitable impurities. The binder phase contains an Al compound and a Zr compound. The Al compound contains Al and one or more of N, O and B; and the Zr compound contains Zr and one or more of C, N, O and B. At a polished surface of the cubic boron nitride sintered body, 40% or more of the Zr compounds satisfy the ratio 0.25≦n/N≦0.8, where: N represents the number of line segments drawn radially at equal intervals from a center of gravity of a given Zr compound to a boundary with a non-Zr compound; and n represents the number among those N line segments which intersect a boundary between the given Zr compound and cubic boron nitride.

A cubic boron nitride sintered body has between 50% and 75% cubic boron nitride by volume and between 25% and 50% binder phase by volume, and inevitable impurities. The binder phase contains an Al compound and a Zr compound. The Al compound contains Al and one or more of N, O and B; and the Zr compound contains Zr and one or more of C, N, O and B. At a polished surface of the cubic boron nitride sintered body, 40% or more of the Zr compounds satisfy the ratio 0.25≦n/N≦0.8, where: N represents the number of line segments drawn radially at equal intervals from a center of gravity of a given Zr compound to a boundary with a non-Zr compound; and n represents the number among those N line segments which intersect a boundary between the given Zr compound and cubic boron nitride.

A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAlN layer, the MAlN layer including crystal grains of M.sub.xAl.sub.1-xN in the cubic crystal system, n.sub.F<n.sub.R being satisfied, where n.sub.F represents a number of voids per 100 μm in length of the MAlN layer on the flank face in a cross section of the MAlN layer, and n.sub.R represents a number of voids per 100 μm in length of the MAlN layer on the rake face in a cross section of the MAlN layer, n.sub.D being 3 or less, where n.sub.D represents a number of droplets per 100 μm in length of the MAlN layer on the flank face in a cross section of the MAlN layer.

A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAlN layer, the MAlN layer including crystal grains of M.sub.xAl.sub.1-xN in the cubic crystal system, n.sub.F<n.sub.R being satisfied, where n.sub.F represents a number of voids per 100 μm in length of the MAlN layer on the flank face in a cross section of the MAlN layer, and n.sub.R represents a number of voids per 100 μm in length of the MAlN layer on the rake face in a cross section of the MAlN layer, n.sub.D being 3 or less, where n.sub.D represents a number of droplets per 100 μm in length of the MAlN layer on the flank face in a cross section of the MAlN layer.

In a surface-coated cutting tool, an A layer made of an (Al.sub.1-xTi.sub.x)N layer (0.35≦x≦0.6 by an atom ratio) and a B layer made of a (Al.sub.1-y-zTi.sub.ySi.sub.z)N layer (0.35≦y≦0.6 and 0.01≦z≦0.1 by an atom ratio) are layered on a surface of a tool body in which at least a cutting edge is made of a cBN sintered body. A layer thickness ratio of the A layer and the B layer (t.sub.B/t.sub.A) is 2 to 5, an X-ray diffraction intensity ratio I(200)/I(111) as the entire hard coating layer is more than 3 and 12 or less, a full width at half maximum of a peak of I(200) is 0.3 to 1.0, the I.sub.A(200)/I.sub.A(111) of the A layer is 2 to 10, and a full width at half maximum of the peak of the I.sub.A(200) is 0.3 to 1.0.

In a surface-coated cutting tool, an A layer made of an (Al.sub.1-xTi.sub.x)N layer (0.35≦x≦0.6 by an atom ratio) and a B layer made of a (Al.sub.1-y-zTi.sub.ySi.sub.z)N layer (0.35≦y≦0.6 and 0.01≦z≦0.1 by an atom ratio) are layered on a surface of a tool body in which at least a cutting edge is made of a cBN sintered body. A layer thickness ratio of the A layer and the B layer (t.sub.B/t.sub.A) is 2 to 5, an X-ray diffraction intensity ratio I(200)/I(111) as the entire hard coating layer is more than 3 and 12 or less, a full width at half maximum of a peak of I(200) is 0.3 to 1.0, the I.sub.A(200)/I.sub.A(111) of the A layer is 2 to 10, and a full width at half maximum of the peak of the I.sub.A(200) is 0.3 to 1.0.

A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAlN layer, when a cross section of the MAlN layer is subjected to an electron backscattering diffraction image analysis to determine a crystal orientation of each of the crystal grains of the M.sub.xAl.sub.1−xN and a color map is created based thereon, then on the color map, the flank face having the MAlN layer occupied in area by 45% to 75% by crystal grains of the M.sub.xAl.sub.1−xN having a (111) plane with a normal thereto extending in a direction within 25 degrees with respect to a direction in which a normal to the flank face extends, the MAlN layer having a residual stress of −2 GPa to −0.1 GPa.