Surface coated cutting tool
09797040 · 2017-10-24
Assignee
Inventors
Cpc classification
C23C16/45523
CHEMISTRY; METALLURGY
B23B27/148
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23B27/14
PERFORMING OPERATIONS; TRANSPORTING
C23C16/455
CHEMISTRY; METALLURGY
Abstract
A hard coating layer on a cutting tool includes at least a Ti and Al complex nitride or carbonitride layer and has an average layer thickness of 1 to 20 μm. In a case where a composition of the complex nitride or carbonitride layer is expressed by: (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y), a content ratio x and a content ratio y satisfy 0.60≦x≦0.95 and 0≦y≦0.005, where x and y are in atomic ratio. Crystal grains constituting the complex nitride or carbonitride layer include cubic phase crystal grains and hexagonal phase crystal grains. An area ratio occupied by the cubic phase crystal grains is 30-80%. An average grain width W is 0.05-1.0 μm. An average aspect ratio A of the crystal grains with the cubic grain structure is 5 or less. A periodic content ratio change of Ti and Al in (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) exists in each of the cubic phase crystal grains.
Claims
1. A surface coated cutting tool comprising: a cutting tool body made of any one of tungsten carbide-based cemented carbide, titanium carbonitride-based cermet, and cubic boron nitride-based ultra-high pressure sintered material; and a hard coating layer provided on a surface of the cutting tool body, wherein the hard coating layer comprises at least a Ti and Al complex nitride or carbonitride layer, which is formed by a chemical vapor deposition method and has an average layer thickness of 1 to 20 μm, in a case where a composition of the complex nitride or carbonitride layer is expressed by a composition formula: (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y), a content ratio x, which is a ratio of Al to a total amount of Ti and Al; and a content ratio y, which is a ratio of C to a total amount of C and N, satisfy 0.60≦x≦0.95 and 0≦y≦0.005, respectively, provided that each of x and y is in atomic ratio, crystal grains constituting the complex nitride or carbonitride layer includes cubic phase crystal grains; and hexagonal phase crystal grains, an area ratio occupied by the cubic phase crystal grains is 30-80% in a plane perpendicular to the surface of the cutting tool body, an average grain width W; and an average aspect ratio A of the crystal grains with the cubic grain structure are 0.05-1.0 μm; and 5 or less, respectively, a periodic content ratio change of Ti and Al in the composition formula: (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) exists in each of the cubic phase crystal grains, and a difference obtained by subtracting a local minimum value x from a local maximum value x in the periodic content ratio change is 0.05-0.25.
2. The surface coated cutting tool according to claim 1, wherein in the cubic phase crystal grains having the periodic content ratio change of Ti and Al in the complex nitride or carbonitride layer: the periodic content ratio change of Ti and Al is aligned along with a direction belonging to equivalent crystal directions expressed by <001> in a cubic crystal system; a period along the direction is 3-30 nm; and a change of content ratio x of Ti and Al in a plane perpendicular to the direction is 0.01 or less.
3. The surface coated cutting tool according to claim 1, wherein in the cubic phase crystal grains having the periodic content ratio change of Ti and Al in the complex nitride or carbonitride layer: a region A and a region B exist; and a boundary of the region A and region B is formed in a crystal plane belonging to equivalent crystal planes expressed by {110}, wherein (a) the region A is a region, in which the periodic content ratio change of Ti and Al is aligned along with a direction belonging to equivalent crystal directions expressed by <001> in a cubic crystal system; and in a case where the direction is defined as a direction d.sub.A, a period along the direction d.sub.A is 3-30 nm and a change of content ratio x of Ti and Al in the plane perpendicular to the direction d.sub.A is 0.01 or less; and (b) the region B is a region, in which the periodic content ratio change of Ti and Al is aligned along with a direction, which is perpendicular to the direction d.sub.A, belonging to equivalent crystal directions expressed by <001> in a cubic crystal system; and in a case where the direction is defined as a direction d.sub.B, a period along the direction d.sub.B is 3-30 nm and a change of content ratio x of Ti and Al in the plane perpendicular to the direction d.sub.B is 0.01 or less.
4. The surface coated cutting tool according to any one of claims 1 to 3, further comprising a lower layer between the cutting tool body made of any one of tungsten carbide-based cemented carbide, titanium carbonitride-based cermet, and cubic boron nitride-based ultra-high pressure sintered material; and the Ti and Al complex nitride or carbonitride layer, the lower layer comprises a Ti compound layer, which is made of one or more layer selected from a group consisting of a Ti carbide layer; a Ti nitride layer; a Ti carbonitride layer; a Ti carbonate layer; and a Ti oxycarbonitride layer, and has an average total layer thickness of 0.1-20 μm.
5. The surface coated cutting tool according to any one of claims 1 to 3, further comprising an upper layer in an upper part of the complex nitride or carbonitride layer the upper layer comprises at least an aluminum oxide layer with an average layer thickness of 1-25 μm.
6. The surface coated cutting tool according to any one of claims 1 to 3, the complex carbonitride layer is formed by a chemical vapor deposition method, a reaction gas component of which includes at least trimethyl aluminum.
7. The surface coated cutting tool according to claim 4, further comprising an upper layer in an upper part of the complex nitride or carbonitride layer, the upper layer comprises at least an aluminum oxide layer with an average layer thickness of 1-25 μm.
8. The surface coated cutting tool according to claim 4, the complex carbonitride layer is formed by a chemical vapor deposition method, a reaction gas component of which includes at least trimethyl aluminum.
9. The surface coated cutting tool according to claim 5, the complex carbonitride layer is formed by a chemical vapor deposition method, a reaction gas component of which includes at least trimethyl aluminum.
10. The surface coated cutting tool according to claim 7, the complex carbonitride layer is formed by a chemical vapor deposition method, a reaction gas component of which includes at least trimethyl aluminum.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
DETAILED DESCRIPTION OF THE INVENTION
(5) Next, the coated cutting tool of the present invention is explained specifically by Examples.
Example 1
(6) As raw material powders, the WC powder, the TiC powder, the ZrC powder, the TaC powder, the NbC powder, the Cr.sub.3C.sub.2 powder, and the Co powder, all of which had the average grain sizes of 1-3 μm, were prepared. These raw material powders were blended in the blending composition shown in Table 1. Then, wax was added to the blended mixture, and further mixed in acetone for 24 hours with a ball mill. After drying under reduced pressure, the mixtures were press-molded into green compacts with a predetermined shape under pressure of 98 MPa. Then, the obtained green compacts were sintered in vacuum in the condition of 5 Pa vacuum at the predetermined temperature in the range of 1370-1470° C. for 1 hour retention. After sintering, the cutting tool bodies A-C, which had the insert-shape defined by ISO-SEEN1203AFSN and made of WC-based cemented carbide, were produced.
(7) Also, as raw material powders, the TiCN powder (TiC/TiN=50/50 in mass ratio), the Mo.sub.2C powder, the ZrC powder, the NbC powder, the WC powder, the Co powder, and the Ni powders, all of which had the average grain sizes of 0.2-2 μm, were prepared. These raw material powders were blended in the blending composition shown in Table 2. Then, with a ball mill, the obtained mixtures were subjected to wet-mixing for 24 hours. After drying, the mixtures were press-molded into green compacts under pressure of 98 MPa. The obtained green compacts were sintered in the condition of: in nitrogen atmosphere of 1.3 kPa; at a temperature of 1500° C.; and for 1 hour of the retention time. After sintering, the cutting tool body D, which had the insert-shape defined by ISO-SEEN1203AFSN and made of TiCN-based cermet, was produced.
(8) Next, the coated cutting tools of the present invention 1-15 were produced by performing following the processes (a)-(c) explained below.
(9) (a) The (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer in the granular structure, which has the average grain width W and the average grain length L shown in Table 6, is formed on the surfaces of the cutting tool bodies A-D using a standard chemical vapor deposition apparatus by performing a thermal CVD for a predetermined time in the formation conditions A-J shown in Table 4. In the formation conditions A-J, the reaction gas composition (volume %) includes: 0.5-1.5% of TiCl.sub.4; 0-2.0% of Al(CH.sub.3).sub.3; 1.5-2.5% of AlCl.sub.3; 1.0-3.0% of NH.sub.3; 11-15% of N.sub.2; 0-0.5% of C.sub.2H.sub.4; and the H.sub.2 balance. The pressure of the reaction atmosphere is 2.0-5.0 kPa. The temperature of the reaction atmosphere is 700-900° C. (Layer forming process).
(10) (b) In the coating process (a), the TiCl.sub.4 etching process for a predetermined lapse time is inserted predetermined multiple times in the formation conditions a-j shown in Table 4. In the formation conditions a-j, the reaction gas composition (volume %) includes: 2.0-5.0 of TiCl.sub.4; and the H.sub.2 balance. The pressure of the reaction atmosphere is 2.0-5.0 kPa. The temperature of the reaction atmosphere is 700-900° C. (Etching process).
(11) (c) By inserting the etching process made of (b) for the predetermined time; and the predetermined repeating number shown in Table 6 in the above-described coating process (a), the hard coating layer made of the granular-structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer with the intended layer thickness shown in Table 6, in which the cubic phase and hexagonal phase crystal grains presented, was formed; and the coated cutting tools of the present invention 1-15 were produced.
(12) In regard to the coated cutting tools of the present invention 6-13, the lower layer as shown in Table 5 and/or the upper layer were formed as shown in Table 6 in the forming condition shown in Table 3.
(13) In regard to the Ti and Al complex nitride or carbonitride layer constituting the hard coating layers of the coated cutting tools of the present invention 1-15, multiple fields of view were observed by using a scanning electron microscope (magnifying power: ×5000 to ×20000). In the observation, the presence of the granular-structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer in which the cubic phase and hexagonal phase crystal grains existed, was confirmed as indicated in the schematic diagram of the layer constitution shown in
(14) In addition, in regard to the complex nitride or carbonitride layer, when the crystal structure of the individual crystal grains was analyzed in the vertical cross section direction of the Ti and Al complex nitride or carbonitride layer using the electron backscatter diffraction apparatus, it was confirmed that the layer was a mixed structure of: the cubic crystal phase, in which the electron backscatter diffraction pattern of the cubic crystal lattice was observed; and the hexagonal crystal phase, in which the electron backscatter diffraction pattern of the hexagonal crystal lattice was observed. In addition, it was confirmed that the area ratio occupied by the cubic crystal phase relative to the total of the cubic and hexagonal crystal phases whose electron backscatter diffraction patterns were observed, was 30-80 area %.
(15) In addition, for a comparison purpose, the hard coating layers including at least a Ti and Al complex nitride or carbonitride layer were formed by vapor deposition of the surface of the cutting tool bodies A-D, in the conditions shown in Tables 3 and 4; and in the intended total layer thicknesses (μm) shown in Table 7 as in the coated cutting tools of the present invention 1-15. At this time, the comparative coated cutting tools 1-13 were produced by forming the hard coating layer without inserting the etching process in the coating process of the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer.
(16) As in the coated cutting tools 6-13 of the present invention, in regard to the comparative coated cutting tools 6-13, the lower layer shown in Table 5 and/or the upper layer shown in Table 7 were formed in the forming condition shown in Table 3.
(17) For purpose of reference, the reference coated cutting tools 14 and 15 shown in Table 7 were produced by forming the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer of the reference example on the surface of the cutting tool body B and cutting tool body C in the intended layer thickness with a standard physical vapor deposition by arc-ion plating.
(18) The conditions for the arc-ion plating for vapor deposition of the reference examples were as explained below.
(19) (a) The bodies B and C were subjected to ultrasonic cleaning in acetone. Then, the cleaned tool bodies B and C in a dried state were set along the outer peripheral part in positions spaced away from the central axis in a predetermined distance in the radius direction on the rotating table in the arc-ion plating apparatus. As the cathode electrode (vaporization source), an Al—Ti alloy with a predetermined composition was placed.
(20) (b) Inside of the apparatus was heated to 500° C. by a heater while retaining vacuum less than 10.sup.−2 Pa by exhausting atmosphere in the apparatus. Then, direct current bias voltage of −1000V was applied to the bodies rotating and orbiting on the rotation table. At the same time, arc discharge was generated by flowing current of 200 A between the cathode electrode made of the Al—Ti alloy and the anode electrode. By following the procedure described above, Al and Ti ions were formed in the apparatus to perform bombard treatment on the surfaces of the tool bodies.
(21) (c) Next, direct current bias voltage of −50V was applied to the tool bodies rotating and orbiting on the rotating table while turning the atmosphere in the apparatus to the reaction atmosphere of 4 Pa by introducing nitrogen gas as a reaction gas in the apparatus. At the same time, arc discharge was generated by flowing current of 120 A between the cathode electrode (vaporization source) made of the Al—Ti alloy and the anode electrode. By following above-described procedure, the (Ti, Al)N layers with the intended compositions and the intended layer thicknesses shown in Table 7 were formed on the surfaces of the bodies by vapor deposition and the coated cutting tools of the reference example 14 and 15 were produced.
(22) The cross sections of each constituent layer of: the coated cutting tools of the present invention 1-15; the comparative coated cutting tools 1-13; and the reference coated cutting tools 14 and 15, were measured by using a scanning electron microscope (magnifying power: ×5000). The average layer thicknesses were obtained by averaging layer thicknesses measured at 5 points within the observation viewing field. In any measurement, the obtained layer thickness was practically the same as the intended layer thicknesses shown in Tables 6 and 7.
(23) In regard to the average Al content ratio, x, of the complex nitride layer or the complex carbonitride layer, an electron beam was irradiated to the polished surface of the samples from the surface side of the sample by using EPMA (Electron-Probe-Micro-Analyzer). Then, the average Al content ratio, x, was obtained from 10-point average of the analysis results of the characteristic X-ray. The average C content ratio, y, was obtained by secondary-ion-mass-spectroscopy (SIMS). An ion beam was irradiated on the range of 70 μm×70 μm from the front surface side of the sample. In regard to the components released by sputtering effect, content ratio measurement in the depth direction was performed. The average C content ratio, y, indicates the average value in the depth direction of the Ti and Al complex nitride layer or the Ti and Al complex carbonitride layer.
(24) In regard to the coated cutting tools of the present invention 1-15; the comparative coated cutting tools 1-13; and the reference coated cutting tools 14 and 15, the average aspect ratio A and the average grain width W were obtained as explained below. In regard to the individual crystal grains in the granular structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer constituting the complex nitride or carbonitride layer existing in the length range of 10 μm horizontal to the surface of the cutting tool body, the grain width “w” parallel to the surface of the cutting tool body; and the grain length “1” perpendicular to the surface of the cutting tool body were measured by using a scanning electron microscope (magnifying power: ×5000 and ×20000). Then, the aspect ratio “a” (=1/w) of each of the individual crystal grains were calculated; and the average aspect ratio A was obtained as the average value of the aspect ratios “a.” The average grain width W was obtained as the average value of the grain widths “w” obtained from each of the crystal grains. The measurement results are shown in Tables 6 and 7.
(25) In the condition where the cross section of the hard coating layer, which was made of the Ti and Al complex nitride or carbonitride layer, in the perpendicular direction to the surface of the cutting tool body was polished to be a polished surface, the area ratio occupied by the cubic crystal phase in the crystal grains constituting the Ti and Al complex nitride or carbonitride layer was obtained: by setting the sample in the lens barrel of the electron backscatter diffraction apparatus; by irradiating an electron beam to each crystal grain existing within the measurement range in the above-described polished surface of the cross section in the condition where the angle of incidence was 70°, the accelerating voltage was 15 kV, and the irradiation current was 1 nA; by measuring the electron backscatter diffraction pattern in the length of 100 μm in the direction horizontal to the cutting tool body at the interval of 0.01 μm/step in the hard coating layer; and by identifying whether each of crystals was in the cubic crystal phase or in the hexagonal crystal phase by analyzing the crystal structure of each crystal grain, by using an electron backscatter diffraction apparatus. The results are shown in Tables 6 and 7 in the same manner.
(26) In addition, observation of the micro region of the complex nitride or carbonitride layer was performed by using a transmission electron microscope (magnifying power: ×20000); and the plane analysis from the cross section side was performed by using the energy dispersive X-ray spectroscopy method (EDS). By these observation and analysis, existence of the periodic content ratio change of Ti and Al in the composition formula (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) was confirmed in the cubic phase crystal grain. In addition, by performing electron diffraction to the crystal grain, it was confirmed that the periodic content ratio change of Ti and Al is aligned along with a direction belonging to equivalent crystal directions expressed by <001> in a cubic crystal system. In addition, the difference obtained by subtracting the local minimum value from the local maximum value of the content ratio of Ti and Al, x, was obtained as change of the content ratio of Ti and Al, x, by performing the line analysis by EDS along with the direction; by obtaining the difference of each of the average values of the local maximum values and the local minimum values of the periodic content ratio change of Ti and Al as the difference Δx between the local maximum value and the local minimum value; by obtaining the period of the local maximum values as the period of the periodic content ratio change of Ti and Al; and performing the line analysis along with the direction perpendicular the direction. In regard to the crystal grain in which the region A and the region B exist in the crystal grain, it was confirmed that the direction d.sub.A and the direction d.sub.B were orthogonal each other; and the boundary of the region A and region B was formed in a crystal plane belonging to equivalent crystal planes expressed by {110}, in the case where the periodic content ratio change of Ti and Al is aligned along with a direction belonging to equivalent crystal directions expressed by <001> in the region A, and the direction is defined as the direction d.sub.A; and the periodic content ratio change of Ti and Al is aligned along with a direction belonging to equivalent crystal directions expressed by <001> in the region B, and the direction is defined as the direction d.sub.B. The confirmation was done by obtaining the difference Δx between the maximum and local minimum values of the periodic content ratio change of Ti and Al; the period; and the content ratio change in the planes orthogonal each other as explained above to the region A and the region B.
(27) TABLE-US-00001 TABLE 1 Blending composition (mass %) Type Co TiC TaC NbC Cr.sub.3C.sub.2 WC Cutting tool body A 8.0 1.5 — 3.0 0.4 balance B 8.5 — 1.8 0.2 — balance C 7.0 — — — — balance
(28) TABLE-US-00002 TABLE 2 Blending composition (mass %) Type Co Ni ZrC NbC Mo.sub.2C WC TiCN Cutting tool body D 8 5 1 6 6 10 balance
(29) TABLE-US-00003 TABLE 3 Constituting layer of Formation condition (pressure and temperature of the reaction the hard coating layer atmosphere is in kPa and ° C., respectively) Formation Reaction atmosphere Type symbol Reaction gas composition (volume %) Pressure Temperature (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) TiAlCN TiAlCN refer Table 4 7 1000 layer Ti compound layer TiC TiC TiCl.sub.4: 4.2%, CH.sub.4: 8.5%, H.sub.2: balance 7 1020 TiN TiN-1 TiCl.sub.4: 4.2%, N.sub.2: 30%, H.sub.2: balance 30 900 TiN-2 TiCl.sub.4: 4.2%, N.sub.2: 35%, H.sub.2: balance 50 1040 TiN-3 TiCl.sub.4: 4.2%, N.sub.2: 30%, H.sub.2: balance 30 780 l-TiCN l-TiCN-1 TiCl.sub.4: 2%, CH.sub.3CN: 0.7%, N.sub.2: 10%, H.sub.2: balance 7 900 l-TiCN-2 TiCl.sub.4: 2%, CH.sub.3CN: 0.7%, N.sub.2: 10%, H.sub.2: balance 7 780 TiCN TiCN TiCl.sub.4: 2%, CH.sub.4: 1%, N.sub.2: 15%, H.sub.2: balance 13 1000 TiCO TiCO TiCl.sub.4: 4.2%, CO: 4%, H.sub.2: balance 7 1020 TiCNO TiCNO TiCl.sub.4: 2%, CO: 1%, CH.sub.4: 1%, N.sub.2: 5%, H.sub.2: balance 13 1000 Al.sub.2O.sub.3 layer Al.sub.2O.sub.3 Al.sub.2O.sub.3 AlCl.sub.3: 2.2%, CO.sub.2: 5.5%, HCl: 2.2%, H.sub.2S: 0.2%, H.sub.2: balance 7 1000
(30) TABLE-US-00004 TABLE 4 Formation of the hard Formation condition (pressure and temperature of the reaction coating layer atmosphere is in kPa and ° C., respectively) Process Formation Reaction gas composition Reaction atmosphere type symbol (volume %) Pressure Temperature Coating process A TiCl.sub.4: 0.5%, Al(CH.sub.3).sub.3: 2.0%, AlCl.sub.3: 3.5 800 2.0%, NH.sub.3: 2.0%, N.sub.2: 11%, C.sub.2H.sub.4: 0%, balance H.sub.2 B TiCl.sub.4: 1.0%, Al(CH.sub.3).sub.3: 1.0%, AlCl.sub.3: 2 700 2.0%, NH.sub.3: 2.5%, N.sub.2: 14%, C.sub.2H.sub.4: 0.5%, balance H.sub.2 C TiCl.sub.4: 1.5%, Al(CH.sub.3).sub.3: 0%, AlCl.sub.3: 5 900 2.5%, NH.sub.3: 1.0%, N.sub.2: 12%, C.sub.2H.sub.4: 0%, balance H.sub.2 D TiCl.sub.4: 1.5%, Al(CH.sub.3).sub.3: 0%, AlCl.sub.3: 3.5 750 2.5%, NH.sub.3: 2.5%, N.sub.2: 11%, C.sub.2H.sub.4: 0%, balance H.sub.2 E TiCl.sub.4: 1.0%, Al(CH.sub.3).sub.3: 1.0%, AlCl.sub.3: 2 800 2.5%, NH.sub.3: 2.0%, N.sub.2: 15%, C.sub.2H.sub.4: 0%, balance H.sub.2 F TiCl.sub.4: 1.0%, Al(CH.sub.3).sub.3: 1.5%, AlCl.sub.3: 3.5 800 1.5%, NH.sub.3: 3.0%, N.sub.2: 14%, C.sub.2H.sub.4: 0%, balance H.sub.2 G TiCl.sub.4: 1.5%, Al(CH.sub.3).sub.3: 2.0%, AlCl.sub.3: 2 700 2.5%, NH.sub.3: 1.0%, N.sub.2: 15%, C.sub.2H.sub.4: 0%, balance H.sub.2 H TiCl.sub.4: 0.5%, Al(CH.sub.3).sub.3: 1.0%, AlCl.sub.3: 5 900 2.0%, NH.sub.3: 3.0%, N.sub.2: 12%, C.sub.2H.sub.4: 0%, balance H.sub.2 I TiCl.sub.4: 1.0%, Al(CH.sub.3).sub.3: 2.0%, AlCl.sub.3: 3.5 750 1.5%, NH.sub.3: 2.0%, N.sub.2: 11%, C.sub.2H.sub.4: 0%, balance H.sub.2 J TiCl.sub.4: 1.0%, Al(CH.sub.3).sub.3: 0%, AlCl.sub.3: 2 800 1.5%, NH.sub.3: 3.0%, N.sub.2: 12%, C.sub.2H.sub.4: 0.5%, balance H.sub.2 Etching process a TiCl.sub.4: 2.0%, balance H.sub.2 3.5 800 b TiCl.sub.4: 3.0%, balance H.sub.2 2 700 c TiCl.sub.4: 2.0%, balance H.sub.2 5 900 d TiCl.sub.4: 4.0%, balance H.sub.2 3.5 750 e TiCl.sub.4: 3.0%, balance H.sub.2 2 800 f TiCl.sub.4: 3.0%, balance H.sub.2 3.5 800 g TiCl.sub.4: 2.0%, balance H.sub.2 2 700 h TiCl.sub.4: 4.0%, balance H.sub.2 5 900 i TiCl.sub.4: 3.0%, balance H.sub.2 3.5 750 j TiCl.sub.4: 2.0%, balance H.sub.2 2 800
(31) TABLE-US-00005 TABLE 5 Hard coating layer (the number at the bottom indicates the intended layer thickness (μm) of the hard coating layer) Cutting tool Lower layer Type body symbol 1st layer 2nd layer 3rd layer Coated 1 A — — — cutting tool of 2 B — — — the present 3 C — — — invention, 4 D — — — comparative 5 A — — — coated 6 B TiC — — cutting tool, (0.5) and reference 7 C TiN-1 — — coated (0.3) cutting tool 8 D TiN-1 l-TiCN-1 — (0.5) (4) 9 A TiN-1 l-TiCN-1 TiCN (0.3) (2) (0.7) 10 B — — — 11 C TiN-1 — — (0.5) 12 D TiC — — (1) 13 A TiN-1 — — (0.1) 14 B — — — 15 C — — —
(32) TABLE-US-00006 TABLE 6 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Ave. value of the period of the content TiAlCN Difference ratio change coating Etching Etching between of Ti and Al process process time the local along with Cutting formation formation per Number maximum the crystal tool symbol symbol single of Al C and local direction body (refer (refer etching etching content content minimum <001> Type symbol Table 4) Table 4) (sec) times ratio x ratio y values of x (μm) Coated 1 A A a 30 500 0.95 0.0043 0.16 5 cutting tool 2 B B b 15 900 0.76 0.0047 0.11 11 of the 3 C C c 15 60 0.79 less 0.09 9 present than invention 0.0001 4 D D d 5 800 0.75 less 0.11 30 than 0.0001 5 A E e 30 600 0.93 0.0015 0.18 8 6 B F f 5 240 0.67 0.0028 0.09 21 7 C G g 5 600 0.83 0.0040 0.05 10 8 D H h 30 600 0.93 0.0023 0.25 12 9 A I i 30 420 0.68 0.0046 0.14 5 10 B J j 15 750 0.60 0.0032 0.07 3 11 C A f 15 400 0.95 0.0041 0.15 23 12 D B g 5 600 0.76 0.0050 0.05 7 13 A C h 15 150 0.79 less 0.15 16 than 0.0001 14 B D i 5 600 0.75 less 0.09 13 than 0.0001 15 C E j 30 300 0.93 0.0020 0.15 4 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Change of content ratio x in the plane perpendicular to the Upper layer periodic (the number at the content ratio Area bottom indicates change of Ti ratio the intended and Al along of the average layer with the Ave. cubic Intended thickness (μm) of crystal grain Ave. crystal layer the layer) direction width W aspect phase thickness 2nd Type <001> (μm) ratio A (%) (μm) 1st layer layer Coated 1 less than 0.01 0.6 5.0 50 5 — — cutting tool 2 less than 0.01 0.3 0.7 54 6 — — of the 3 less than 0.01 0.1 2.5 30 1 — — present invention 4 less than 0.01 0.2 0.8 49 8 — — 5 less than 0.01 1.0 1.5 48 3 — — 6 less than 0.01 0.3 0.9 80 4 — — 7 less than 0.01 0.9 2.0 38 6 — — 8 less than 0.01 0.7 1.4 65 2 — — 9 less than 0.01 0.3 1.0 60 7 — — 10 less than 0.01 0.05 0.3 69 5 Al.sub.2O.sub.3 — (5) 11 less than 0.01 1.0 1.8 50 4 TiCN Al.sub.2O.sub.3 (0.5) (3) 12 less than 0.01 0.5 1.0 54 3 TiCO Al.sub.2O.sub.3 (1) (2) 13 less than 0.01 0.7 1.3 33 1 TiCNO Al.sub.2O.sub.3 (0.3) (1) 14 less than 0.01 0.4 1.0 49 10 — — 15 less than 0.01 0.8 3.2 48 3 — —
(33) TABLE-US-00007 TABLE 7 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Ave. value of the period of the content TiAlCN Difference ratio change of coating Etching between Ti and Al process process Etching the local along with the Cutting formation formation time per Number maximum crystal tool symbol symbol single of Al C and local direction body (refer (refer etching etching content content minimum <001> Type symbol Table 4) Table 4) (sec) times ratio x ratio y values of x (μm) Comparative 1 A A — — — 0.92 0.0042 — — coated cutting 2 B B — — — 0.78 0.0047 — — tool 3 C C — — — 0.82 less — — than 0.0001 4 D D — — — 0.73 less — — than 0.0001 5 A E — — — 0.92 0.0017 — — 6 B F — — — 0.69 0.0031 — — 7 C G — — — 0.81 0.0036 — — 8 D H — — — 0.89 0.0028 — — 9 A I — — — 0.65 0.0050 — — 10 B J — — — 0.60 0.0034 — — 11 C A — — — 0.93 0.0046 — — 12 D B — — — 0.79 0.0048 — — 13 A C — — — 0.81 less — — than 0.0001 Reference 14 B AIP — — — 0.77 less — — coated cutting than tool 0.0001 15 C AIP — — — 0.90 less — — than 0.0001 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Change of content ratio x in the plane Upper layer perpendicular (the number at the to the periodic Area bottom indicates content ratio ratio of the intended change of Ti the average layer and Al along Ave. cubic Intended thickness (μm) of with the crystal grain Ave. crystal layer the layer) direction width W aspect phase thickness 1st 2nd Type <001> (μm) ratio A (%) (μm) layer layer Comparative 1 — 0.7 5.0 51 5 — — coated cutting 2 — 0.4 0.8 51 6 — — tool 3 — 0.2 3.1 35 1 — — 4 — 0.2 1.2 53 8 — — 5 — 1.0 1.8 47 3 — — 6 — 0.4 1.5 80 4 — — 7 — 0.9 2.5 38 6 — — 8 — 0.8 1.5 67 2 — — 9 — 0.4 2.1 62 7 — — 10 — 0.08 0.5 72 5 Al.sub.2O.sub.3 — (5) 11 — 1.0 1.6 49 4 TiCN Al.sub.2O.sub.3 (0.5) (3) 12 — 0.5 1.5 59 3 TiCO Al.sub.2O.sub.3 (1) (2) 13 — 0.7 1.2 38 1 TiCNO Al.sub.2O.sub.3 (0.3) (1) Reference 14 — 1.5 3.3 — 10 — — coated cutting tool 15 — 0.6 2.2 — 3 — — Note: “AIP” indicates coating by arc-ion plating.
(34) Next, each of the coated cutting tools described above was clamped on the face milling cutter made of tool steel with the cutter diameter of 125 mm by a fixing jig. Then, the cutting test of high-speed-dry-center-cutting-face-milling was performed on the coated cutting tools of the present invention 1-15; the comparative coated cutting tools 1-13; and the reference coated cutting tools 14 and 15, in the clamped-state. The cutting test of high-speed-dry-center-cutting-face-milling is a type of high speed intermittent cutting of alloy steel, and was performed under the condition shown below. After the test, width of flank wear of the cutting edge was measured.
(35) The results of the cutting test are shown in Table 8.
(36) Cutting tool body: Tungsten carbide-based cemented carbide, titanium carbonitride-based cermet
(37) Cutting test: High speed dry face milling, center cut cutting
(38) Work: Block material of JIS-SCM440 standard having width of 100 mm and length of 400 mm
(39) Rotation speed: 917 min.sup.−1
(40) Cutting speed: 360 m/min
(41) Cutting depth: 1.0 mm
(42) Feed rate per tooth: 0.14 mm/tooth
(43) Cutting time: 8 minutes
(44) TABLE-US-00008 TABLE 8 Width of Cutting test flank wear result Type (mm) Type (min) Coated 1 0.09 Comparative 1 3.3* cutting tool 2 0.11 coated 2 2.3* of the 3 0.10 cutting tool 3 3.3* present 4 0.11 4 2.1* invention 5 0.09 5 3.8* 6 0.13 6 3.6* 7 0.08 7 3.9* 8 0.08 8 2.3* 9 0.13 9 4.2* 10 0.14 10 4.3* 11 0.07 11 4.8* 12 0.09 12 4.4* 13 0.08 13 4.7* 14 0.12 Reference 14 1.5* 15 0.11 coated 15 1.9* cutting tool Asterisk marks in the column of the comparative and reference coated cutting tool indicate the cutting time (min) until reaching to its service life due to occurrence of chipping.
Example 2
(45) As raw material powders, the WC powder, the TiC powder, the ZrC powder, the TaC powder, the NbC powder, the Cr.sub.3C.sub.2 powder, the TiN powder, and the CO powder, all of which had the average grain sizes of 1-3 μm, were prepared. These raw material powders were blended in the blending composition shown in Table 9. Then, wax was added to the blended mixture, and further mixed in acetone for 24 hours with a ball mill. After drying under reduced pressure, the mixtures were press-molded into green compacts with a predetermined shape under pressure of 98 MPa. Then, the obtained green compacts were sintered in vacuum in the condition of 5 Pa vacuum at the predetermined temperature in the range of 1370-1470° C. for 1 hour retention. After sintering, the cutting tool bodies α-γ, which had the insert-shape defined by ISO standard CNMG120412 and made of WC-based cemented carbide, were produced by performing honing (R: 0.07 mm) on the cutting edge part.
(46) Also, as raw material powders, the TiCN powder (TiC/TiN=50/50 in mass ratio), the NbC powder, the WC powder, the Co powder, and the Ni powder, all of which had the average grain sizes of 0.5-2 μm, were prepared. These raw material powders were blended in the blending composition shown in Table 10. Then, the mixtures were wet-mixed for 24 hours with a ball mill. After drying, the mixtures were press-molded into green compacts under pressure of 98 MPa. The, the obtained green compacts were sintered in nitrogen atmosphere of 1.3 kPa at 1500° C. for 1 hour retention. After sintering, the cutting tool body γ, which had the insert-shape defined by ISO standard CNMG120412 and made of TiCN-based cermet, was produced by performing honing (R: 0.09 mm) on the cutting edge part.
(47) Next, the coated cutting tools of the present invention 16-30 were produced by following the processes (a)-(c) described below.
(48) Process (a)
(49) By performing thermal CVD method for the predetermined lapse time in the formation conditions A-J, the granular structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layers having the average grain width W and the aspect ratio A shown in Table 12 were formed (Layer forming process). In the formation conditions A-J: the reaction gas composition (volume %) included: 1.5-2.5% of TiCl.sub.4; 3.0-5.0% of Al(CH.sub.3).sub.3; 3.0-5.0% of AlCl.sub.3; 2.0-5.0% of NH.sub.3; 6.0-7.0% of N.sub.2; 0-1.0% of C.sub.2H.sub.4; 6.0-7.0% of Ar; and the balance H.sub.2. The pressure of the reaction atmosphere was set in the range of 2.0-5.0 kPa. The temperature of the reaction atmosphere was set in the range of 750-900° C.
(50) Process (b)
(51) The TiCl.sub.4 etching process of the predetermined lapse time was inserted predetermined times in the above-described coating process (a) in the forming conditions a-j shown in Table 4 (Etching process). In the forming conditions a-j: the reaction gas composition (volume %) included: 2.0-5.0% of TiCl.sub.4, and the balance H.sub.2. The pressure of the reaction atmosphere was set in the range of 2.0-5.0 kPa. The temperature of the reaction atmosphere was set in the range of 750-900° C.
(52) Process (c)
(53) The coated cutting tools of the present invention 16-30 were produced by forming the hard coating layers made of the granular structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer, which had the intended layer thicknesses shown in Table 12 and the cubic phase and hexagonal phase crystal grains existed in, by inserting the etching process (b) for the predetermined lapse time and the predetermined repeating time shown in Table 12 during the coating process (a).
(54) For the coated cutting tools of the present invention 19-28, the lower layer shown in Table 11 and/or the upper layer shown in Table 12 were formed in the coating process conditions indicted in Table 3.
(55) For comparison purposes, the coated cutting tools of Comparative Examples 16-28 indicated in Table 13 were produced by vapor depositing the hard coating layer on the surface of the cutting tool bodies α-γ and the cutting tool body δ in intended thicknesses shown in Table 13 using a standard chemical vapor deposition apparatus in the conditions indicated in Tables 3 and 4 in the same manner.
(56) Similarly to the coated cutting tools of the present invention 19-28, in regard to the coated cutting tools of comparative coated cutting tools 19-28, the lower layer shown in Table 11 and/or the upper layer shown in Table 13 were formed in the coating conditions shown in Table 3.
(57) For reference, the coated cutting tools of Reference Example 29 and 30 indicated in Table 13 were produced by vapor depositing (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer of Reference Example on the surface of the cutting tool bodies β and γ in intended thicknesses using a conventional physical vapor deposition apparatus by arc-ion plating.
(58) The condition for the arc-ion plating was the same as described in Example 1.
(59) In regard to the coated cutting tools of the present invention 16-30; the comparative coated cutting tools 16-28; and the reference coated cutting tools 29 and 30, the cross sections of each constituting layers were subjected to measurement by the scanning electron microscopy (magnifying power: ×20000); and the average layer thicknesses were obtained by averaging the layer thicknesses measured at 5 points within the observation viewing field. In any measurement, the obtained layer thickness was practically the same as the intended total layer thicknesses shown in Tables 12 and 13.
(60) In addition, in regard to the hard coating layers of the coated cutting tools of the present invention 16-30; the comparative coated cutting tools 16-28; and the reference coated cutting tools 29 and 30, the average Al content ratio x; the average C content ratio y; the average grain width W and the average aspect ratio A of the crystal grains constituting the granular structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer; and the area ratio occupied by the cubic crystal phase in the crystal grains were obtained by using the same methods indicated in Example 1.
(61) Results were indicated in Tables 12 and 13.
(62) In regard to the Ti and Al complex nitride or carbonitride layer constituting the hard coating layers of the coated cutting tools of the present invention 16-30, multiple fields of view were observed by using a scanning electron microscope (magnifying power: ×5000 to ×20000). In the observation, the presence of the granular-structured (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer in which the cubic phase and hexagonal phase crystal grains existed, was confirmed as indicated in the schematic diagram of the layer constitution shown in
(63) In addition, in regard to the complex nitride or carbonitride layer, when the crystal structure of the individual crystal grains was analyzed in the vertical cross section direction of the Ti and Al complex nitride or carbonitride layer using the electron backscatter diffraction apparatus, it was confirmed that the layer was a mixed structure of: the cubic crystal phase, in which the electron backscatter diffraction pattern of the cubic crystal lattice was observed; and the hexagonal crystal phase, in which the electron backscatter diffraction pattern of the hexagonal crystal lattice was observed. In addition, it was confirmed that the area ratio occupied by the cubic phase crystal grains relative to the total of the cubic and hexagonal crystal phases whose electron backscatter diffraction patterns were observed, was 30-80 area %.
(64) TABLE-US-00009 TABLE 9 Blending composition (mass %) Type Co TiC ZrC TaC NbC Cr.sub.3C.sub.2 TiN WC Cutting α 6.5 — 1.5 — 2.9 0.1 1.5 balance tool β 7.6 2.6 — 4.0 0.5 — 1.1 balance body γ 6.0 — — — — — — balance
(65) TABLE-US-00010 TABLE 10 Blending composition (mass %) Type Co Ni NbC WC TiCN Cutting tool body δ 11 4 6 15 balance
(66) TABLE-US-00011 TABLE 11 Hard coating layer (the number at the bottom indicates the average intended layer thickness (μm) of the hard coating layer) Cutting tool body Lower layer Type symbol 1st layer 2nd layer 3rd layer 4th layer Coated cutting tool of 16 α — — — — the present invention, 17 β — — — — comparative coated 18 γ — — — — cutting tool, and 19 δ TiC — — — reference coated cutting (0.5) tool 20 α TiN-1 — — — (0.1) 21 β TiN-1 1-TiCN-1 — — (0.5) (7) 22 γ TiN-1 1-TiCN-1 TiN-2 — (0.3) (10) (0.7) 23 δ TiN-1 1-TiCN-1 TiCN TiN-2 (0.3) (4) (0.4) (0.3) 24 α — — — — 25 β TiN-1 — — — (0.5) 26 γ TiC — — — (1) 27 δ TiN-1 — — — (0.1) 28 α TiN-1 — — — (0.1) 29 β — — — — 30 γ — — — —
(67) TABLE-US-00012 TABLE 12 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Ave. value of the period of the content ratio Difference change TiAlCN between of Ti coating Etching the local and Al process time maximum along formation Etching per Number and with the Cutting symbol process single of Al C local crystal tool (refer formation etching etching content content minimum direction Type symbol Table 4) symbol (sec) times ratio x ratio y values of x <001> Comparative 16 α A a 30 800 0.94 0.0046 0.18 5 coated 17 β B b 15 2100 0.78 0.0050 0.13 10 cutting tool 18 γ C c 15 1200 0.76 less 0.07 7 than 0.0001 19 δ D d 5 300 0.71 less 0.12 27 than 0.0001 20 α E e 30 2400 0.89 0.0011 0.19 9 21 β F f 5 420 0.71 0.0022 0.09 23 22 γ G g 5 1300 0.87 0.0034 0.06 12 23 δ H h 30 900 0.92 0.0016 0.25 11 24 α I i 30 420 0.65 0.0037 0.17 6 25 β J j 15 1200 0.62 0.0039 0.09 4 26 γ A f 15 600 0.95 0.0035 0.14 21 27 δ B g 5 200 0.78 0.0049 0.06 8 28 α C h 15 1350 0.73 less 0.14 16 than 0.0001 Reference 29 β D i 5 360 0.71 less 0.07 12 coated than cutting tool 0.0001 30 γ E j 30 800 0.91 0.0022 0.16 3 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Change of content ratio x in the plane perpendicular to the periodic Upper layer content ratio Area (the number at change of Ti ratio the bottom indicates and Al of the the intended average along with Ave. cubic Intended layer thickness (μm) the crystal grain Ave. crystal layer of the layer) direction width W aspect phase thickness 1st 2nd 3rd 4th Type <001> (μm) ratio A (%) (μm) layer layer layer layer Comparative 16 less than 0.5 4.8 56 8 — — — — coated 0.01 cutting tool 17 less than 0.4 0.7 58 14 — — — — 0.01 18 less than 0.2 2.4 30 20 — — — — 0.01 19 less than 0.2 0.7 47 3 — — — — 0.01 20 less than 1.0 1.3 46 12 — — — — 0.01 21 less than 0.4 0.8 79 7 — — — — 0.01 22 less than 0.8 1.6 41 13 TiN-2 — — — 0.01 (0.7) 23 less than 0.6 1.3 71 3 TiCN TiN-2 — — 0.01 (0.4) (0.3) 24 less than 0.4 1.1 58 7 Al.sub.2O.sub.3 — — — 0.01 (4) 25 less than 0.08 0.4 72 8 TiCN Al.sub.2O.sub.3 — — 0.01 (0.5) (5) 26 less than 0.9 1.6 53 6 TiCO Al.sub.2O.sub.3 — — 0.01 (1) (2) 27 less than 0.5 1.2 58 1 TiCNO Al.sub.2O.sub.3 — — 0.01 (0.3) (1) 28 less than 0.6 1.1 31 9 TiN-2 TiCN TiCNO Al.sub.2O.sub.3 0.01 (0.3) (0.8) (0.3) (5) Reference 29 less than 0.3 1.3 47 6 — — — — coated 0.01 cutting tool 30 less than 0.9 2.9 53 8 — — — — 0.01
(68) TABLE-US-00013 TABLE 13 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Ave. value of the period of the content ratio change Difference of Ti TiAlCN between and Al coating Etching the local along process time maximum with the formation Etching per Number and crystal Cutting symbol process single of Al C local direction tool (refer formation etching etching content content minimum <001> Type symbol Table 4) symbol (sec) times ratio x ratio y values of x (μm) Comparative 16 α A — — — 0.95 0.0044 — — coated 17 β B — — — 0.79 0.0049 — — cutting tool 18 γ C — — — 0.78 less — — than 0.0001 19 δ D — — — 0.72 less — — than 0.0001 20 α E — — — 0.86 0.0014 — — 21 β F — — — 0.73 0.0023 — — 22 γ G — — — 0.86 0.0037 — — 23 δ H — — — 0.95 0.0018 — — 24 α I — — — 0.67 0.0036 — — 25 β J — — — 0.63 0.0037 — — 26 γ A — — — 0.95 0.0031 — — 27 δ B — — — 0.79 0.0046 — — 28 α C — — — 0.75 less — — than — — 0.0001 Reference 29 β AIP — — — 0.76 less — — coated than cutting tool 0.0001 30 γ AIP — — — 0.91 less — — than 0.0001 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) Change of content ratio x in the plane perpendicular to the periodic content ratio Area change of Ti ratio Upper layer and Al of the (the number at the bottom along with Ave. cubic Intended indicates the intended average the crystal grain Ave. crystal layer layer thickness (μm) of the layer) direction width W aspect phase thickness 1st 2nd 3rd 4th Type <001> (μm) ratio A (%) (μm) layer layer layer layer Comparative 16 — 0.9 5.0 58 8 — — — — coated 17 — 0.5 0.9 60 14 — — — — cutting tool 18 — 0.3 2.8 33 20 — — — — 19 — 0.4 1.3 51 3 — — — — 20 — 1.0 1.5 48 12 — — — — 21 — 0.5 0.9 81 7 — — — — 22 — 0.9 2.0 43 13 TiN-2 — — — (0.7) 23 — 0.7 1.5 73 3 TiCN TiN-2 — — (0.4) (0.3) 24 — 0.5 1.3 62 7 Al.sub.2O.sub.3 — — — (4) 25 — 0.1 0.5 72 8 TiCN Al.sub.2O.sub.3 — — (0.5) (5) 26 — 1.0 2.1 51 6 TiCO Al.sub.2O.sub.3 — — (1) (2) 27 — 0.6 1.1 63 1 TiCNO Al.sub.2O.sub.3 — — (0.3) (1) 28 — 0.9 1.3 35 9 TiN-2 TiCN TiCNO Al.sub.2O.sub.3 (0.3) (0.8) (0.3) (5) Reference 29 — 1.2 2.0 — 6 — — — — coated 30 — 1.3 3.5 — 8 — — — — cutting tool Note: “AIP” indicates film formation by arc-ion plating.
(69) Next, each of the coated cutting tools described above was clamped on the front end part of the bit made of tool steel by a fixing jig. Then, the dry high-speed intermittent cutting test on carbolized steel and the wet high-speed intermittent cutting test on a cast iron were performed on the coated cutting tools of the present invention 16-30; the comparative coated cutting tools 16-28; and the reference coated cutting tools 29 and 30, in the clamped-state. After the test, width of flank wear of the cutting edge was measured.
(70) Cutting Condition 1:
(71) Work: Round bar in JIS-SCM435 standard with 4 evenly spaced slits in the longitudinal direction
(72) Cutting speed: 360 m/min
(73) Cutting depth: 1.2 mm
(74) Feed rate: 0.2 mm/rev.
(75) Cutting time: 5 minutes
(76) (the normal cutting speed is 220 m/min)
(77) Cutting Condition 2:
(78) Work: Round bar in JIS-FCD450 standard with 4 evenly spaced slits in the longitudinal direction
(79) Cutting speed: 340 m/min
(80) Cutting depth: 1.0 mm
(81) Feed rate: 0.2 mm/rev.
(82) Cutting time: 5 minutes
(83) (the normal cutting speed is 200 m/min)
(84) The results of the cutting tests are shown in Table 14.
(85) TABLE-US-00014 TABLE 14 Cutting test result (min) Width of Cutting Cutting flank wear condition condition Type (mm) Type 1 2 Coated 16 0.20 0.23 Comparative 16 3.8* 2.7* cutting 17 0.21 0.23 coated 17 3.9* 2.6* tool of the 18 0.21 0.22 cutting tool 18 3.3* 3.9* present 19 0.21 0.24 19 2.3* 2.1* invention 20 0.20 0.23 20 4.2* 3.6* 21 0.23 0.25 21 4.2* 3.5* 22 0.19 0.11 22 3.8* 4.6* 23 0.12 0.13 23 3.3* 2.7* 24 0.22 0.25 24 4.7* 4.4* 25 0.23 0.26 25 4.8* 4.3* 26 0.09 0.10 26 4.3* 4.6* 27 0.19 0.22 27 3.3* 3.3* 28 0.10 0.20 28 4.8* 3.9* 29 0.22 0.24 Reference 29 2.3* 1.9* 30 0.22 0.22 coated 30 2.1* 2.0* cutting tool Asterisk marks in the column of the comparative and reference coated cutting tool indicate the cutting time (min) until reaching to its service life due to occurrence of chipping.
Example 3
(86) The cutting tool bodies A2 and B2 were produced by the process explained below. First, as raw material powders, the cBN powder, the TiN powder, the TiCN powder, the TiC powder, the Al powder, and Al.sub.2O.sub.3 powder, all of which had the average grain sizes of 0.5-4 μm, were prepared. These raw material powders were blended in the blending composition shown in Table 15. Then, the mixtures were wet-mixed for 80 hours with a ball mill After drying, the mixtures were press-molded into green compacts with a dimension of: diameter of 50 mm; and thickness of 1.5 mm, under pressure of 120 MPa. Then, the obtained green compacts were sintered in vacuum in the condition of 1 Pa vacuum at the predetermined temperature in the range of 900-1300° C. for 60 minutes retention to obtain preliminary sintered bodies for the cutting edge pieces. The obtained preliminary sintered bodies were placed on separately prepared supporting pieces made of WC-based cemented carbide alloy, which had the composition of: 8 mass % of Co; and the WC balance, and the dimension of: diameter of 50 mm; and thickness of 2 mm They were inserted into a standard ultra-high pressure sintering apparatus in the stacked state. Then, they were subjected to ultra-high-pressure sintering in the standard condition of: 4 GPa of pressure; a predetermined temperature within the range of 1200-1400° C.; and 0.8 hour of the retention time. Then, the top and bottom surfaces of the sintered bodies were grinded by using a diamond grind tool. Then, they were divided into a predetermined dimension with a wire-electrical discharge machine. Then, they were brazed on the brazing portion (corner portion) of the insert main cutting tool body made of WC-based cemented carbide alloy, which had the composition of: 5 mass % of Co; 5 mass % of TaC; and the WC balance, and the shape defined by ISO CNGA120412 standard (the diamond shape of: thickness of 4.76 mm; and inscribed circle diameter of 12.7 mm) by using the brazing material made of Ti—Zr—Cu alloy having composition made of: 37.5% of Zr; 25% of Cu; and the Ti balance in volume %. Then, after performing outer peripheral machining into a predetermined dimension, the cutting edges of the brazed parts were subjected to a honing work of: width of 0.13 mm; and angle of 25°. Then, by performing the final polishing on them, the cutting tool bodies A2 and B2 with the insert shape defined by ISO CNGA120412 standard were produced.
(87) TABLE-US-00015 TABLE 15 Blending composition (mass %) Type TiN TiC Al Al.sub.2O.sub.3 cBN Cutting tool body A2 50 — 5 3 balance B2 — 50 4 3 balance
(88) Next, the coated cutting tools of the present invention 31-40 indicated in Tables 17 were produced by vapor depositing the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer related to the present invention on the surfaces of the cutting tool bodies A2 and B2 in the intended layer thicknesses using a standard chemical vapor deposition apparatus in the conditions indicated in Tables 3 and 4 as in the same method as Example 1
(89) In regard to the coated cutting tools of the present invention 34-38, the lower layer shown in Table 16 and/or the upper layer shown in Table 17 were formed in the forming condition shown in Table 3.
(90) For comparison purposes, the comparative coated cutting tools 31-38 indicated in Table 18 were produced by vapor depositing the hard coating layer including at least the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer on the surface of the tool bodies A2 and B2 in intended thicknesses using a standard chemical vapor deposition apparatus in the conditions indicated in Tables 3 and 4.
(91) As in the coated cutting tools of the present invention 34-38, the lower layer as shown in Table 16 and/or the upper layer as shown in Table 18 were formed in the formation conditions shown in Table 3 in the comparative coated cutting tools 34-38.
(92) For reference, the reference coated cutting tools 39 and 40 indicated in Table 18 were produced by vapor depositing the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer on the surfaces of the cutting tool bodies A2 and B2 in the intended thickness using a conventional physical vapor deposition apparatus by arc-ion plating.
(93) The condition for the arc-ion plating was the same as described in Example 1. By vapor depositing (Ti.sub.1-XAl.sub.X)(C.sub.YN.sub.1-Y) layer on the surfaces of the above-mentioned cutting tool bodies in the intended compositions and layer thicknesses indicated in Table 18 in the arc-ion plating, the reference coated cutting tools 39 and 40 were produced.
(94) Cross sections of each constituent layer of the coated cutting tools of the present invention 31-40; the comparative coated cutting tools 31-38; and the reference coated cutting tools 39 and 40, were subjected to measurement by using a scanning electron microscope (magnifying power: ×5000), and the layer thicknesses were obtained by averaging layer thicknesses measured at 5 points within the observation viewing field. In any measurement, the obtained layer thickness was practically the same as the intended total layer thicknesses shown in Tables 17 and 18.
(95) In regard to the coated cutting tools of the present invention 31-40; the comparative coated cutting tools 31-38; and the reference coated cutting tools 39 and 40, the average Al content ratio x; the average C content ratio y; the average grain width W of the crystal grains constituting the (Ti.sub.1-xAl.sub.x)(C.sub.yN.sub.1-y) layer in the granular structure; the average aspect ratio A; and the area ratio occupied by the cubic crystal phase in the crystal grain, were obtained as in the method indicated in Example 1. The measurement results are shown in Tables 17 and 18.
(96) TABLE-US-00016 TABLE 16 Hard coating layer (the number at the bottom indicates the intended layer thickness (μm) of the hard coating layer) Cutting tool Lower layer Type body symbol 1st 2nd 3rd Coated cutting 31 A2 — — — tool of the 32 B2 — — — present 33 A2 — — — invention, 34 B2 TiC — — comparative (0.5) coated 35 A2 TiN-3 — — cutting tool, (0.5) and reference 36 B2 TiN-3 — — coated (0.1) cutting tool 37 A2 TiN-3 l-TiCN-2 — (0.5) (3) 38 B2 TiN-3 l-TiCN-2 TiN-3 (0.3) (7) (0.7) 39 A2 — — — 40 B2 — — —
(97) TABLE-US-00017 TABLE 17 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) TiAlCN Difference coating Etching between process process Etching the local Cutting formation formation time per Number maximum tool symbol symbol single of Al C and local body (refer (refer etching etching content content minimum Type symbol Table 4) Table 4) (sec) times ratio x ratio y values of x Coated 31 A2 B b 15 150 0.83 0.0048 0.14 cutting tool 32 B2 D d 5 500 0.79 less than 0.10 of the 0.0001 present 33 A2 G g 5 900 0.89 0.0039 0.07 invention 34 B2 I i 30 120 0.73 0.0047 0.15 35 A2 D i 5 240 0.79 less than 0.08 0.0001 36 B2 B g 5 800 0.86 0.0048 0.05 37 A2 I d 30 900 0.75 0.0044 0.16 38 B2 G b 5 200 0.89 0.0041 0.19 39 A2 B g 15 400 0.81 0.0046 0.21 40 B2 D i 15 420 0.82 less than 0.16 0.0001 Hard coating layer TiAl complex carbonitride layer Upper (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) layer Change of (the content ratio number x in the plane at the perpendicular bottom Ave. value of to the indicates the period of periodic the the content content ratio Area intended ratio change change of Ti ratio of layer of Ti and Al and Al along the thickness along with with the Ave. cubic Intended (μm) of the crystal crystal grain Ave. crystal layer the direction direction width W aspect phase thickness upper Type <001> <001> (μm) ratio A (%) (μm) layer) Coated 31 12 less than 0.01 0.5 0.8 49 1 — cutting tool 32 27 less than 0.01 0.3 0.9 43 5 — of the 33 9 less than 0.01 0.9 1.8 36 9 — present 34 6 less than 0.01 0.4 1.1 57 2 — invention 35 11 less than 0.01 0.3 1.2 46 4 TiN-3 (0.5) 36 6 less than 0.01 0.6 1.1 57 4 — 37 8 less than 0.01 0.3 0.9 59 6 — 38 7 less than 0.01 0.9 1.7 34 2 — 39 8 less than 0.01 0.4 0.8 51 2 — 40 16 less than 0.01 0.3 0.9 46 7 —
(98) TABLE-US-00018 TABLE 18 Hard coating layer TiAl complex carbonitride layer (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) TiAlCN Difference coating between the process Etching local Cutting formation Etching time per maximum tool symbol process single Number of C and local body (refer formation etching etching Al content content minimum Type symbol Table 4) symbol (sec) times ratio x ratio y values of x Comparative 31 A2 B — — — 0.85 0.0048 — coated 32 B2 D — — — 0.80 less — cutting tool than 0.0001 33 A2 G — — — 0.88 0.0039 — 34 B2 I — — — 0.75 0.0047 — 35 A2 D — — — 0.79 less — than 0.0001 36 B2 B — — — 0.87 0.0048 — 37 A2 I — — — 0.78 0.0044 — 38 B2 G — — — 0.90 0.0041 — Reference 39 A2 AIP — — — 0.78 less — coated than cutting tool 0.0001 40 B2 AIP — — — 0.90 less — than 0.0001 Hard coating layer TiAl complex carbonitride layer Upper (Ti.sub.1−xAl.sub.x)(C.sub.yN.sub.1−y) layer Ave. value (the of the Change of number at period of content ratio x in the bottom the content the plane indicates ratio perpendicular to Area the change of the periodic ratio of intended Ti and Al content ratio the layer along with change of Ti and Ave. cubic Intended thickness the crystal Al along with grain Ave. crystal layer (μm) of the direction the crystal width W aspect phase thickness upper Type <001> direction <001> (μm) ratio A (%) (μm) layer) Comparative 31 — — 0.6 0.8 52 1 — coated 32 — — 0.4 1.0 45 5 — cutting tool 33 — — 0.9 1.7 36 9 — 34 — — 0.4 1.1 56 2 — 35 — — 0.4 1.3 48 4 TiN-3 (0.5) 36 — — 0.7 1.2 60 4 — 37 — — 0.5 0.8 62 6 — 38 — — 0.9 1.6 36 2 — Reference 39 — — 0.8 1.2 — 2 — coated 40 — — 1.2 3.0 — 7 — cutting tool
(99) Next, each coated cutting tool was screwed on the tip of the insert holder made of tool steel by a fixing jig. Then, the dry high speed intermittent cutting test of carbolized steel explained below were performed on the coated cutting tools of the present invention 31-40; the comparative coated cutting tools 31-38; and the reference coated cutting tools 39 and 40. After the tests, width of flank wear of the cutting edge was measured.
(100) Cutting tool body: Cubic boron nitride-based ultra-high pressure sintered material
(101) Cutting test: Dry high-speed intermittent cutting work of a carbolized steel
(102) Work: Round bar in JIS-SCr420 standard (hardness: HRC60) with 4 evenly spaced slits in the longitudinal direction
(103) Cutting speed: 220 m/min
(104) Cutting depth: 0.12 mm
(105) Feed rate: 0.10 mm/rev.
(106) Cutting time: 4 minutes
(107) Results of the cutting test are shown in Table 19.
(108) TABLE-US-00019 TABLE 19 Width of Cutting test flank wear result Type (mm) Type (min) Coated 31 0.07 Comparative 31 2.1* cutting tool 32 0.10 coated 32 2.0* of the 33 0.08 cutting tool 33 2.2* present 34 0.12 34 2.0* invention 35 0.08 35 2.3* 36 0.08 36 2.3* 37 0.09 37 2.3* 38 0.07 38 2.2* 39 0.09 Reference 39 1.8* 40 0.09 coated 40 1.6* cutting tool Asterisk marks in the column of the comparative and reference coated cutting tool indicate the cutting time (min) until reaching to its service life due to occurrence of chipping.
(109) Based on the results shown in Tables 8, 14, and 19, it was demonstrated that hardness was improved due to the strain in the crystal grains and toughness was improved too while keeping a high abrasion resistance in the coated cutting tool of the present invention by having the content ratio change of Ti and Al in the cubic crystal grains constituting the Al and Ti complex nitride or complex carbonitride layer constituting the hard coating layer. In addition, the surface coated cutting tools of the present invention showed an excellent chipping resistance and an excellent fracturing resistance even if they were used in high speed intermittent cutting work. It is clear that they exhibited an excellent wear resistance for a long-term usage because of these.
(110) Contrary to that, in regard to: the comparative coated cutting tools 1-13, 16-28, and 31-38; and the reference coated cutting tools 14, 15, 29, 30, 39, and 40, in which there were no content ratio change of Ti and Al in the cubic crystal grains constituting the Al and Ti complex nitride or complex carbonitride layer constituting the hard coating layer, they reached to their service lives in a relatively short period of time due to occurrence of chipping, fracturing, or the like when they were used in the high speed intermittent cutting work in which intermittent and impacting high load impinges on the cutting edge.
INDUSTRIAL APPLICABILITY
(111) The coated cutting tool of the present invention can be utilized in high speed intermittent cutting of a wide variety of works as well as of alloy steel as described above. Furthermore, the coated cutting tool of the present invention exhibits an excellent chipping resistance and an excellent wear resistance for a long-term usage. Thus, the coated cutting tool of the present invention can be sufficiently adapted to high-performance cutting apparatuses; and labor-saving, energy-saving, and cost-saving of cutting work.
BRIEF DESCRIPTION OF THE REFERENCE SYMBOLS
(112) 1: Cutting tool body 2: Hard coating layer 3: Complex nitride layer or complex carbonitride layer 4: Region in which Al content amount is relatively high 5: Region in which Al content amount is relatively low 6: Region A 7: Region B