WO2019181786A1 - 被覆工具及びこれを備えた切削工具 - Google Patents

被覆工具及びこれを備えた切削工具 Download PDF

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Publication number
WO2019181786A1
WO2019181786A1 PCT/JP2019/010855 JP2019010855W WO2019181786A1 WO 2019181786 A1 WO2019181786 A1 WO 2019181786A1 JP 2019010855 W JP2019010855 W JP 2019010855W WO 2019181786 A1 WO2019181786 A1 WO 2019181786A1
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Prior art keywords
layer
ticn
compressive stress
substrate
coated tool
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
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PCT/JP2019/010855
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English (en)
French (fr)
Inventor
綾乃 田中
涼馬 野見山
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Kyocera Corp
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Kyocera Corp
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Publication date
Application filed by Kyocera Corp filed Critical Kyocera Corp
Priority to KR1020207029264A priority Critical patent/KR102412791B1/ko
Priority to US16/982,059 priority patent/US11311946B2/en
Priority to CN201980019713.3A priority patent/CN111867758B/zh
Priority to JP2020507753A priority patent/JP7105299B2/ja
Priority to EP19772223.4A priority patent/EP3769879A4/en
Publication of WO2019181786A1 publication Critical patent/WO2019181786A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B23B27/148—Composition of the cutting inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/16—Milling-cutters characterised by physical features other than shape
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/005—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides comprising a particular metallic binder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
    • C22C29/04—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbonitrides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/34—Nitrides
    • C23C16/347—Carbon nitride
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/36—Carbonitrides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C23C16/403—Oxides of aluminium, magnesium or beryllium
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/044—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/241—Chemical after-treatment on the surface
    • B22F2003/242—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
    • B23B2228/10—Coatings
    • B23B2228/105—Coatings with specified thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2224/00—Materials of tools or workpieces composed of a compound including a metal
    • B23C2224/04—Aluminium oxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2224/00—Materials of tools or workpieces composed of a compound including a metal
    • B23C2224/32—Titanium carbide nitride (TiCN)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules

Definitions

  • the present disclosure relates to a coated tool used in cutting and a cutting tool provided with the same.
  • cermets mainly composed of titanium are widely used as a base material for members that require wear resistance, slidability, and fracture resistance, such as cutting tools, wear-resistant members, and sliding members.
  • Patent Document 1 a coating is formed on the surface of a substrate made of cermet, a compressive stress of 30 kgf / mm 2 or more is applied to the surface of the substrate, and a compressive stress of 50 kgf / mm 2 or more is applied to the coating. It is described to improve the peel resistance, impact resistance and fracture resistance of the steel.
  • Patent Document 2 has a CVD film free from cooling cracks that cause performance degradation by providing a wear-resistant CVD film on the surface of a titanium-based carbonitride and setting the compression stress of this CVD film to 0 to 1000 MPa. Providing a cutting tool insert is described.
  • the coated tool of the present disclosure includes a substrate and a coating layer that covers at least a part of the substrate.
  • the substrate has a carbonitride hard phase containing Ti and a binder phase containing at least one of Co and Ni, and has a thermal expansion coefficient of 9.0 ⁇ 10 ⁇ 6 / 25 at 25 to 1000 ° C. It is above °C.
  • the covering layer has a TiCN layer and an Al 2 O 3 layer located on the TiCN layer.
  • the TiCN layer has a compressive stress of 250 to 500 MPa.
  • the Al 2 O 3 layer has a thickness of 2 ⁇ m or more, a compressive stress of 450 MPa or more, and a compressive stress value larger than that of the TiCN layer.
  • the cutting tool of the present disclosure includes a holder extending from the first end toward the second end and having a pocket on the first end side, and the above-described covering tool positioned in the pocket.
  • FIG. 1 is a perspective view illustrating an example of the coated tool of the present disclosure.
  • FIG. 2 is an enlarged schematic view of a cross section near the surface of the coated tool of the present disclosure.
  • FIG. 3 is a plan view illustrating an example of the cutting tool of the present disclosure.
  • the coated tool of the present disclosure will be described in detail with reference to the drawings.
  • each drawing referred to below shows only the main members necessary for explaining the embodiment in a simplified manner for convenience of explanation. Accordingly, the coated tool of the present disclosure may include any constituent member that is not shown in the referenced drawings.
  • the dimension of the member in each figure does not faithfully represent the dimension of the actual component member, the dimension ratio of each member, or the like. These points are the same in the cutting tool described later.
  • the coated tool 1 of the present disclosure includes a base body 3 and a coating layer 5 that covers at least a part of the base body 3 as shown in FIGS.
  • the shape of the coated tool 1 of the present disclosure is, for example, a square plate shape, and the upper surface in FIG. 1 is a so-called rake surface. Moreover, it has a lower surface opposite to the upper surface, and has side surfaces connected to each between the upper surface and the lower surface. At least a part of the side surface is a so-called flank.
  • the coated tool 1 of the present disclosure has a cutting edge 7 positioned at at least a part of a ridge line where the upper surface and the side surface intersect. In other words, it has the cutting edge 7 located in at least one part of the ridgeline where a rake face and a flank face cross.
  • the entire outer periphery of the rake face may be the cutting edge 7, but the coated tool 1 is not limited to such a configuration, for example, only one side of the rectangular rake face, Or you may have the cutting blade 7 partially.
  • the size of the coated tool 1 is not particularly limited.
  • the length of one side of the rake face is set to about 3 to 20 mm.
  • the thickness of the coated tool 1 is set to about 5 to 20 mm, for example.
  • the substrate 3 of the coated tool 1 of the present disclosure has a carbonitride hard phase containing Ti and a binder phase containing at least one of Co and Ni, and has a thermal expansion coefficient of 9 to 9 at 25 to 1000 ° C. 0.0 ⁇ 10 ⁇ 6 or more.
  • the hard phase is, for example, TiCN.
  • the substrate 3 is a so-called cermet, and contains TiCN and Co or Ni having a larger thermal expansion coefficient than TiCN so that the thermal expansion coefficient at 25 to 1000 ° C. is 9.0 ⁇ 10 ⁇ 6 / ° C. or more. It has been adjusted.
  • Cermet is a sintered composite material in which a metal is combined with a ceramic component.
  • examples of the cermet include compounds mainly composed of TiCN, TiC, TiN, or the like.
  • the base 3 may further contain WC as a hard phase.
  • the coated tool 1 of the present disclosure has a TiCN layer 5 a on a substrate 3.
  • the TiCN layer 5a contains TiCN crystals.
  • the thermal expansion coefficient of the TiCN crystal is about 8 ⁇ 10 ⁇ 6 / ° C., which is smaller than the thermal expansion coefficient of the substrate 3 having a thermal expansion coefficient of 9.0 ⁇ 10 ⁇ 6 / ° C. or more.
  • An Al 2 O 3 layer 5b is located on the TiCN layer 5a.
  • the Al 2 O 3 layer 5b contains Al 2 O 3 crystals.
  • the thermal expansion coefficient of the Al 2 O 3 crystal is about 7.2 ⁇ 10 ⁇ 6 / ° C., which is smaller than the thermal expansion coefficients of the substrate 3 and the TiCN layer 5a.
  • the substrate 3 and the TiCN layer 5a may be in direct contact with each other, and for example, a TiN phase (not shown) may be located between them. Further, the TiCN layer 5a and the Al 2 O 3 layer 5b may be in direct contact with each other, and for example, a TiN phase (not shown) may be located between them.
  • coated tool 1 having such a configuration, applying a thermal expansion coefficient of the base body 3, by adjusting the thickness of the Al 2 O 3 layer 5b, an appropriate compressive stress to TiCN layer 5a and the Al 2 O 3 layer 5b be able to.
  • the compressive stress applied to the TiCN layer 5b is set to 250 to 500 MPa, the compressive stress applied to the Al 2 O 3 layer 5b is set to 450 MPa or more, the thickness of the Al 2 O 3 layer 5b is set to 2 ⁇ m or more, and the compressive stress applied to the TiCN layer 5b is set.
  • the value of the compressive stress applied to the Al 2 O 3 layer 5b is increased, the coated tool is excellent in wear resistance and durability.
  • the compressive stress applied to the TiCN layer 5a and the Al 2 O 3 layer 5b may be determined based on, for example, measurement using a 2D method. Specifically, an X-ray diffraction peak is measured using a portion of the flank that is 1 mm or more away from the cutting edge 7 as a measurement position. Regarding the crystal structure specified from the measurement result, it can be obtained by confirming how the 2 ⁇ value in the measurement result is deviated from the reference 2 ⁇ value described in the JCPDS card.
  • the residual stress When the residual stress is a negative value, the residual stress is a compressive stress. When the value of the compressive stress is indicated, it is expressed as an absolute value without adding a minus.
  • the value of the compressive stress applied to the TiCN layer 5a and the Al 2 O 3 layer 5b tends to increase.
  • the Al 2 O 3 layer 5b is located farther from the substrate 3. Therefore, when the workpiece is machined using the cutting tool 1 of the present disclosure, the Al 2 O 3 layer 5b comes into contact with the workpiece before the TiCN layer 5a. Since the Al 2 O 3 layer 5b has high hardness and a thickness of 2 ⁇ m or more, it has high wear resistance and oxidation resistance. Further, if the thickness of the Al 2 O 3 layer 5b is 2.5 ⁇ m or more and 8.0 ⁇ m or less, the wear resistance and oxidation resistance are further excellent.
  • the thickness of the TiCN layer 5a may be 5 ⁇ m or more and 10 ⁇ m or less. With such a range, the wear resistance and fracture resistance of the coated tool 1 are excellent.
  • the thickness of the Al 2 O 3 layer 5b, to the sum of the thicknesses of the the Al 2 O 3 layer 5b of TiCN layer 5a, may be 0.2-0.4 times.
  • the coated tool 1 having such a configuration is excellent in wear resistance and fracture resistance.
  • the Al 2 O 3 layer 5b may have the C-axis of the Al 2 O 3 crystal oriented along a direction perpendicular to the main surface of the substrate 3.
  • ⁇ -Al 2 O 3 crystals may be contained, and the ⁇ -Al 2 O 3 crystals may be columnar extending in the direction perpendicular to the main surface of the substrate 3.
  • the value of compressive stress on the Al 2 O 3 layer 5b may tend to decrease.
  • the TiCN layer 5a is between the base 3 and the Al 2 O 3 layer 5b, and prevents the Al 2 O 3 layer 5b from being peeled off and suppresses abrasive wear.
  • the sum of the thicknesses of the the Al 2 O 3 layer 5b of TiCN layer 5a is, 7 [mu] m or more, may be less 18 [mu] m. Moreover, it is good also as 8 micrometers or more and 16 micrometers or less.
  • the base 3 in the coated tool 1 of the present disclosure may include a binder phase enriched layer having a higher binder phase ratio than the inside of the base 3 on the surface.
  • the thickness of the binder phase enriched layer may be 1 ⁇ m or more and 10 ⁇ m or less.
  • a substrate having a hard phase of carbonitride containing Ti and a binder phase containing at least one of Co and Ni and having a thermal expansion coefficient at 25 to 1000 ° C. of 9.0 ⁇ 10 ⁇ 6 or more is prepared.
  • the substrate only needs to have a thermal expansion coefficient satisfying the above conditions, and so-called cermet is preferably used. What is necessary is just to prepare the shape of a base
  • the binder phase may be made of only Co.
  • the substrate 3 contains W and Co, and may contain Co 0.93 W 0.07 .
  • a substrate containing Co 0.93 W 0.07 can be obtained by adjusting the amount of C contained during preparation of the raw material.
  • C / (hard phase) is 9.1 or less, a substrate containing Co 0.93 W 0.07 can be obtained.
  • C / (hard phase) is 8.0 or more, an increase in the ⁇ phase can be suppressed, so that a relative decrease in Co 0.93 W 0.07 can be suppressed.
  • the amount of C in the raw material includes, for example, C contained in each raw material powder in addition to carbon to be added.
  • a hard phase refers to what can exist as a hard phase in an insert, for example, the metal, oxide, and carbonate of Fe, Ni, Co, Mn, Mo are not contained.
  • a dense substrate can be obtained by baking in the temperature range.
  • each is held at 200 ° C. and 300 ° C. for 1 hour in a vacuum, and then heated to 450 ° C. and held for 1 hour.
  • CO 2 gas is introduced into the degreasing furnace so as to have a pressure of 1 to 5 kPa in order to suppress a decrease in C added as a raw material in the process at 450 ° C. By doing in this way, C amount can be controlled precisely.
  • Co 0.93 W 0.07 may be prepared in advance and used as a raw material powder.
  • a TiCN layer is formed on the surface of the substrate. Further, an Al 2 O 3 layer is formed thereon.
  • the TiCN layer and the Al 2 O 3 layer may be formed by a chemical vapor deposition (CVD) method.
  • CVD chemical vapor deposition
  • the compressive stress applied to the TiCN layer and the Al 2 O 3 layer can also be controlled by controlling the thicknesses of the TiCN layer and the Al 2 O 3 layer.
  • the cutting tool 101 of the present disclosure is, for example, a rod-shaped body that extends from a first end (upper end in FIG. 3) to a second end (lower end in FIG. 3), as shown in FIG.
  • the cutting tool 101 includes a holder 105 having a pocket 103 on the first end side (front end side) and the above-described covering tool 1 positioned in the pocket 103. Since the cutting tool 101 includes the coated tool 1, stable cutting can be performed over a long period of time.
  • the pocket 103 is a part to which the covering tool 1 is attached, and has a seating surface parallel to the lower surface of the holder 105 and a restraining side surface inclined with respect to the seating surface. Further, the pocket 103 is opened on the first end side of the holder 105.
  • the covering tool 1 is located in the pocket 103. At this time, the lower surface of the covering tool 1 may be in direct contact with the pocket 103, or a sheet (not shown) may be sandwiched between the covering tool 1 and the pocket 103.
  • the covering tool 1 is mounted on the holder 105 so that at least a part of the portion used as the cutting edge 7 on the ridge line where the rake face and the flank face intersect protrudes outward from the holder 105.
  • the coated tool 1 is attached to the holder 105 with a fixing screw 107. That is, by inserting the fixing screw 107 into the through-hole 17 of the coated tool 1, inserting the tip of the fixing screw 107 into a screw hole (not shown) formed in the pocket 103, and screwing the screw portions together, The covering tool 1 is attached to the holder 105.
  • steel cast iron or the like
  • steel having high toughness may be used.
  • a cutting tool used for so-called turning is illustrated.
  • the turning process include an inner diameter process, an outer diameter process, a grooving process, and an end face process.
  • the cutting tool is not limited to that used for turning.
  • the substrate was produced as follows.
  • a tool-shaped compact was produced using the proportion of raw material powder shown in Table 1, and was fired after the degreasing step to produce a substrate.
  • each was held at 200 ° C. and 300 ° C. for 1 hour in a vacuum, then heated to 450 ° C. and held for 1 hour.
  • CO 2 gas was introduced into the degreasing furnace at a pressure of 3 kPa at a process of 450 ° C.
  • the thermal expansion coefficient of the substrate is as shown in Table 1.
  • the substrate had a binder phase enriched layer.
  • a TiCN layer having a thickness shown in Table 2 was formed on the surface of the substrate by CVD deposition. Further, an Al 2 O 3 layer having a thickness shown in Table 2 was formed on the TiCN layer. The thicknesses of the TiCN layer and the Al 2 O 3 layer were controlled by adjusting the film formation time.
  • the residual stress of the TiCN layer and the Al 2 O 3 layer was measured using a 2D method. Specifically, an X-ray diffraction peak was measured from the surface side of the produced coated tool, with a portion at a distance of 1 mm or more from the cutting edge 7 on the flank as the measurement position. The residual stress was obtained by confirming the deviation of the 2 ⁇ value in the measurement result from the reference 2 ⁇ value described in the JCPDS card with respect to the crystal structure specified from the measurement result. In addition, about the TiCN layer, the residual stress was calculated
  • the sample has a thermal expansion coefficient of less than 9.0 ⁇ 10 ⁇ 6 / ° C.
  • the value of the compressive stress applied to the TiCN layer and the Al 2 O 3 layer was small.
  • the value of the compressive stress applied to the TiCN layer was less than 250 MPa, and the value of the compressive stress applied to the Al 2 O 3 layer was also lower than 450 MPa. As a result, the chipping resistance was poor.
  • a thermal expansion coefficient of the substrate is 9.0 ⁇ 10 -6 / °C above, compressive stress on the TiCN layer 250 ⁇ 500 MPa, a thickness of the Al 2 O 3 layer is 2 ⁇ m or more, the the Al 2 O 3 layer The applied compressive stress was 450 MPa or more, and any sample having a larger compressive stress value than the TiCN layer was excellent in wear resistance and fracture resistance.

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Abstract

本開示の被覆工具は、基体と、該基体の少なくとも一部を覆う被覆層と、を具備する。前記基体は、Ｔｉを含む炭窒化物の硬質相と、ＣｏおよびＮｉの少なくともいずれかを含む結合相と、を有し、２５～１０００℃における熱膨張係数が９．０×１０-6／℃以上である。前記被覆層は、ＴｉＣＮ層と、該ＴｉＣＮ層の上に位置するＡｌ2Ｏ3層と、を有する。前記ＴｉＣＮ層は、圧縮応力が２５０～５００ＭＰａである。前記Ａｌ2Ｏ3層は、２μｍ以上の厚みを有し、圧縮応力が４５０ＭＰａ以上であり、前記ＴｉＣＮ層よりも圧縮応力の値が大きい。また、本開示の切削工具は、第１端から第２端に向かって延び、前記第１端側にポケットを有するホルダと、前記ポケットに位置するポケットに位置する上述の被覆工具とを備える。

Description

被覆工具及びこれを備えた切削工具
　本開示は、切削加工において用いられる被覆工具およびこれを備えた切削工具に関する。
　現在、切削工具や耐摩耗性部材、摺動部材等の耐摩耗性や摺動性、耐欠損性を必要とする部材の基体として、チタンを主成分とするサーメットが広く使われている。
　特許文献１には、サーメットからなる基体の表面に被膜を形成し、基体表面に３０ｋｇｆ／ｍｍ2以上の圧縮応力を付与し、被膜に５０ｋｇｆ／ｍｍ2以上の圧縮応力を付与することで、被膜の耐剥離性と耐衝撃性および耐欠損性を向上させることが記載されている。
　また、特許文献２には、チタニウム基炭窒化物の表面に耐摩耗性ＣＶＤ膜を設け、このＣＶＤ膜の圧縮応力を０～１０００ＭＰａとして、性能低下の原因となる冷却割れのないＣＶＤ膜を有する切削工具インサートを提供することが記載されている。
特開平８－９２６８５号公報 特表平１１－５１１０７８号公報
　本開示の被覆工具は、基体と、該基体の少なくとも一部を覆う被覆層とを具備する。前記基体は、Ｔｉを含む炭窒化物の硬質相と、ＣｏおよびＮｉの少なくともいずれかを含む結合相とを有しており、２５～１０００℃における熱膨張係数が９．０×１０-6／℃以上である。前記被覆層は、ＴｉＣＮ層と、該ＴｉＣＮ層の上に位置するＡｌ2Ｏ3層とを有している。前記ＴｉＣＮ層は、圧縮応力が２５０～５００ＭＰａである。前記Ａｌ2Ｏ3層は、２μｍ以上の厚みを有し、圧縮応力が４５０ＭＰａ以上であり、前記ＴｉＣＮ層よりも圧縮応力の値が大きい。
　また、本開示の切削工具は、第１端から第２端に向かって延び、前記第１端側にポケットを有するホルダと、前記ポケットに位置する上述の被覆工具と、を備える。
図１は、本開示の被覆工具の一例を示す斜視図である。 図２は、本開示の被覆工具の表面付近の断面の拡大概要図である。 図３は、本開示の切削工具の一例を示す平面図である。
　＜被覆工具＞
　以下、本開示の被覆工具について、図面を用いて詳細に説明する。但し、以下で参照する各図は、説明の便宜上、実施形態を説明する上で必要な主要部材のみを簡略化して示したものである。したがって、本開示の被覆工具は、参照する各図に示されていない任意の構成部材を備え得る。また、各図中の部材の寸法は、実際の構成部材の寸法及び各部材の寸法比率などを忠実に表したものではない。これらの点は、後述する切削工具においても同様である。
　本開示の被覆工具１は、図１、２に示すように基体３と、基体３の少なくとも一部を覆う被覆層５とを具備する。
　本開示の被覆工具１の形状は、例えば、四角板形状であって、図１における上面は、いわゆるすくい面である。また、上面の反対に下面を有し、上面と下面との間にそれぞれに繋がる側面を有する。側面において少なくても一部は、いわゆる逃げ面である。
　本開示の被覆工具１は、上面と側面とが交わる稜線の少なくとも一部に位置する切刃７を有している。言い換えれば、すくい面と逃げ面とが交わる稜線の少なくとも一部に位置する切刃７を有している。
　被覆工具１においては、すくい面の外周の全体が切刃７となっていてもよいが、被覆工具１はこのような構成に限定されるものではなく、例えば、四角形のすくい面における一辺のみ、若しくは、部分的に切刃７を有するものであってもよい。
　被覆工具１の大きさは特に限定されるものではないが、例えば、すくい面の一辺の長さが３～２０ｍｍ程度に設定される。また、被覆工具１の厚みは、例えば５～２０ｍｍ程度に設定される。
　本開示の被覆工具１の基体３は、Ｔｉを含む炭窒化物の硬質相と、ＣｏおよびＮｉの少なくともいずれかを含む結合相とを有しており、２５～１０００℃における熱膨張係数が９．０×１０-6以上である。硬質相は、例えば、ＴｉＣＮである。基体３はいわゆるサーメットであり、ＴｉＣＮと、ＴｉＣＮよりも熱膨張係数の大きなＣｏやＮｉを含有することで２５～１０００℃における熱膨張係数が９．０×１０-6／℃以上になるように調整されている。
　サーメットは、セラミック成分に金属を複合させた焼結複合材料である。具体的には、サーメットとして、ＴｉＣＮ、ＴｉＣ又はＴｉＮ等を主成分とした化合物などが挙げられる。また、基体３には、硬質相としてＷＣをさらに含有していてもよい。
　図２に示すように、本開示の被覆工具１は、基体３の上にＴｉＣＮ層５ａを有している。ＴｉＣＮ層５ａにはＴｉＣＮ結晶が含まれている。ＴｉＣＮ結晶の熱膨張係数は、８×１０-6／℃程度であり、熱膨張係数が９．０×１０-6／℃以上である基体３の熱膨張係数よりも小さい。
　ＴｉＣＮ層５ａの上にはＡｌ2Ｏ3層５ｂが位置している。Ａｌ2Ｏ3層５ｂにはＡｌ2Ｏ3結晶が含まれている。Ａｌ2Ｏ3結晶の熱膨張係数は、７．２×１０-6／℃程度であり、基体３およびＴｉＣＮ層５ａの熱膨張係数よりも小さい。
　基体３とＴｉＣＮ層５ａとは、直接接触していてもよく、両者の間に、例えば、ＴｉＮ相（図示しない）が位置していてもよい。また、ＴｉＣＮ層５ａとＡｌ2Ｏ3層５ｂとは直接接触していてもよく、両者の間に、例えば、ＴｉＮ相（図示しない）が位置していてもよい。
　このような構成を有する被覆工具１では、基体３の熱膨張係数と、Ａｌ2Ｏ3層５ｂの厚みを調整することで、ＴｉＣＮ層５ａおよびＡｌ2Ｏ3層５ｂに適度な圧縮応力を掛けることができる。
　そして、ＴｉＣＮ層５ａに掛かる圧縮応力を２５０～５００ＭＰａとし、Ａｌ2Ｏ3層５ｂに掛かる圧縮応力を４５０ＭＰａ以上とし、Ａｌ2Ｏ3層５ｂの厚みを２μｍ以上とし、ＴｉＣＮ層５ｂに掛かる圧縮応力よりもＡｌ2Ｏ3層５ｂに掛かる圧縮応力の値を大きくしたとき、耐摩耗性及び耐久性に優れた被覆工具となる。
　なお、ＴｉＣＮ層５ａ及びＡｌ2Ｏ3層５ｂに掛かる圧縮応力は、例えば、２Ｄ法を用いた測定に基づき判断すればよい。具体的には、逃げ面における切刃７から１ｍｍ以上離れた部分を測定位置とし、Ｘ線回折ピークを測定する。測定結果から特定された結晶構造に関して、測定結果における２θの値が、ＪＣＰＤＳカードに記載された基準となる２θの値に対してどのようにずれているかを確認して求めることができる。
　なお、残留応力がマイナスの値である場合、残留応力は、圧縮応力である。圧縮応力の値を示す場合には、マイナスを付けず、絶対値で表現する。
　基体３の熱膨張係数が大きくなると、ＴｉＣＮ層５ａ及びＡｌ2Ｏ3層５ｂに掛かる圧縮応力の値は大きくなる傾向にある。
　被覆層５を構成するＴｉＣＮ層５ａとＡｌ2Ｏ3層５ｂとを比較すると、Ａｌ2Ｏ3層５ｂの方が基体３から離れた位置にある。したがって、本開示の切削工具１を用いて被加工物を加工するとき、ＴｉＣＮ層５ａよりも先にＡｌ2Ｏ3層５ｂが被加工物と接触することになる。Ａｌ2Ｏ3層５ｂは、硬度が高く、２μｍ以上の厚みを有するため、耐摩耗性、耐酸化性が高い。また、Ａｌ2Ｏ3層５ｂの厚みが、２．５μｍ以上、８．０μｍ以下であれば、さらに耐摩耗性および耐酸化性に優れる。
　ＴｉＣＮ層５ａは、厚みが５μｍ以上、１０μｍ以下としてもよい。このような範囲とすると被覆工具１の耐摩耗性と耐欠損性が優れる。
　また、Ａｌ2Ｏ3層５ｂの厚みは、ＴｉＣＮ層５ａの厚みとＡｌ2Ｏ3層５ｂの厚みの和に対して、０．２～０．４倍としてもよい。このような構成の被覆工具１は耐摩耗性、耐欠損性に優れる。
　また、Ａｌ2Ｏ3層５ｂは、基体３の主面に垂直な方向に沿うように、Ａｌ2Ｏ3結晶のＣ軸が配向していてもよい。他の言い方をすると、α－Ａｌ2Ｏ3結晶を含有しており、そのα－Ａｌ2Ｏ3結晶が基体３の主面に対して、垂直方向に延びる柱状になっていてもよい。
　他の条件が同じであれば、Ａｌ2Ｏ3層５ｂの厚みを厚くすると、Ａｌ2Ｏ3層５ｂに掛かる圧縮応力の値は、小さくなる傾向にある。
　ＴｉＣＮ層５ａは、基体３とＡｌ2Ｏ3層５ｂとの間にあって、Ａｌ2Ｏ3層５ｂが剥がれてしまうことを抑制するとともに、アブレシブ摩耗を抑制する。
　他の条件が同じであれば、ＴｉＣＮ層５ａの厚みを厚くすると、ＴｉＣＮ層５ａに掛かる圧縮応力の値は、小さくなる傾向にある。
　ＴｉＣＮ層５ａとＡｌ2Ｏ3層５ｂの機能を考慮すると、ＴｉＣＮ層５ａの厚みとＡｌ2Ｏ3層５ｂの厚みの和は、７μｍ以上、１８μｍ以下としてもよい。また、８μｍ以上、１６μｍ以下としてもよい。
　また、本開示の被覆工具１における基体３には、表面において、基体３の内部よりも結合相の割合が多い結合相富化層が存在していてもよい。この結合相富化層の厚みは、１μｍ以上、１０μｍ以下であってもよい。
　以下に本開示の切削工具の製造方法を説明する。
　まず、Ｔｉを含む炭窒化物の硬質相と、ＣｏおよびＮｉの少なくともいずれかを含む結合相とを有し、２５～１０００℃における熱膨張係数が９．０×１０-6以上の基体を準備する。基体は、熱膨張係数が上記の条件を満たすものであればよく、いわゆるサーメットを用いるとよい。基体の形状は必要に応じて、整えればよい。
　結合相は、Ｃｏのみからなるものとしてもよい。また、基体３は、ＷとＣｏとを含有し、Ｃｏ0.93Ｗ0.07を含んでいてもよい。原料の調合の際に、含有するＣの量を調整することで、Ｃｏ0.93Ｗ0.07を含有する基体を得ることができる。原料中のＣの量は、調合組成比でＣ／（硬質相）＝８．０～９．１とするとよい。Ｃ／（硬質相）を９．１以下とすると、Ｃｏ0.93Ｗ0.07を含有する基体を得ることができる。Ｃ／（硬質相）を８．０以上とすると、η相が増加することを抑制できるため、相対的にＣｏ0.93Ｗ0.07が減少することを抑制できる。
　なお、原料中のＣの量とは、添加する炭素のほかに、例えば、各原料粉末に含まれるＣも含まれる。また、硬質相とは、インサート中に硬質相として存在しうるものを指し、例えば、Ｆｅ、Ｎｉ、ＣｏやＭｎ、Ｍｏの金属や酸化物、炭酸化物は含まれない。
　このような組成範囲の原料粉末にバインダーを添加した後、例えば、プレス成型によって、所望の形状に整え、バインダー成分を除去する脱脂工程の後、例えば、窒素や真空雰囲気で、１５００～１５５０℃の温度域で焼成することで、緻密質の基体が得られる。
　なお、脱脂工程では、真空中で２００℃、３００℃でそれぞれ１時間保持し、その後、４５０℃まで昇温し、１時間保持する。このとき、４５０℃の工程で、原料として加えたＣが減少するのを抑制するため、ＣＯ2ガスを１～５ｋＰａの圧力となるように脱脂炉に導入する。このようにすることで、Ｃ量を精密に制御することができる。なお、予め、Ｃｏ0.93Ｗ0.07を準備しておき、原料粉末として用いてもよい。
　次に、基体の表面にＴｉＣＮ層を形成する。さらにその上にＡｌ2Ｏ3層を形成する。ＴｉＣＮ層とＡｌ2Ｏ3層とは、化学蒸着（ＣＶＤ）法によって形成するとよい。このＣＶＤ蒸着法によって、成膜する際の成膜温度が高いほど、成膜された膜に掛かる圧縮応力は大きくなる。そこで、必要に応じて成膜温度を調整するとよい。
　また、上述したように、ＴｉＣＮ層、Ａｌ2Ｏ3層の厚みを制御することでも、ＴｉＣＮ層、Ａｌ2Ｏ3層に掛かる圧縮応力を制御することができる。
　一旦、作製した被覆工具のＴｉＣＮ層、Ａｌ2Ｏ3層の圧縮応力を測定して、その結果に基づき、成膜温度や成膜時間を調整して、所望の圧縮応力を有する被覆工具を製造することができる。
　＜切削工具＞
　次に、本開示の切削工具について図面を用いて説明する。
　本開示の切削工具１０１は、図３に示すように、例えば、第１端（図３における上端）から第２端（図３における下端）に向かって延びる棒状体である。切削工具１０１は、図３に示すように、第１端側（先端側）にポケット１０３を有するホルダ１０５と、ポケット１０３に位置する上記の被覆工具１とを備えている。切削工具１０１は、被覆工具１を備えているため、長期に渡り安定した切削加工を行うことができる。
　ポケット１０３は、被覆工具１が装着される部分であり、ホルダ１０５の下面に対して平行な着座面と、着座面に対して傾斜する拘束側面とを有している。また、ポケット１０３は、ホルダ１０５の第１端側において開口している。
　ポケット１０３には被覆工具１が位置している。このとき、被覆工具１の下面がポケット１０３に直接に接していてもよく、また、被覆工具１とポケット１０３との間にシート（不図示）が挟まれていてもよい。
　被覆工具１は、すくい面及び逃げ面が交わる稜線における切刃７として用いられる部分の少なくとも一部がホルダ１０５から外方に突出するようにホルダ１０５に装着される。本実施形態においては、被覆工具１は、固定ネジ１０７によって、ホルダ１０５に装着されている。すなわち、被覆工具１の貫通孔１７に固定ネジ１０７を挿入し、この固定ネジ１０７の先端をポケット１０３に形成されたネジ孔（不図示）に挿入してネジ部同士を螺合させることによって、被覆工具１がホルダ１０５に装着されている。
　ホルダ１０５の材質としては、鋼、鋳鉄などを用いることができる。これらの部材の中で靱性の高い鋼を用いてもよい。
　本実施形態においては、いわゆる旋削加工に用いられる切削工具を例示している。旋削加工としては、例えば、内径加工、外径加工、溝入れ加工及び端面加工などが挙げられる。なお、切削工具としては旋削加工に用いられるものに限定されない。例えば、転削加工に用いられる切削工具に上記の実施形態の被覆工具１を用いてもよい。
　以下に、本開示の被覆工具について、説明する。
　基体は、以下のように作製した。
　表１に示す、割合の原料粉末を用いて工具形状の成形体を作製し、脱脂工程の後、焼成して、基体を作製した。なお、脱脂工程では、真空中で２００℃、３００℃でそれぞれ１時間保持し、その後、４５０℃まで昇温し、１時間保持した。このとき、４５０℃の工程で、ＣＯ2ガスを３ｋＰａの圧力で脱脂炉に導入した。基体の熱膨張係数は、表１に示すとおりである。基体は、結合相富化層を有していた。
Figure JPOXMLDOC01-appb-T000001
　この基体の表面に、ＣＶＤ蒸着法にて、表２に示す厚みのＴｉＣＮ層を形成した。さらに、ＴｉＣＮ層の上に表２に示す厚みのＡｌ2Ｏ3層を形成した。ＴｉＣＮ層及びＡｌ2Ｏ3層の厚みは成膜時間を調整して制御した。
　ＴｉＣＮ層およびＡｌ2Ｏ3層の残留応力の測定は、２Ｄ法を用いて測定した。具体的には、逃げ面における切刃７から１ｍｍ以上離れた部分を測定位置とし、作製した被覆工具の表面側から、Ｘ線回折ピークを測定した。残留応力は、測定結果から特定された結晶構造に関して、測定結果における２θの値が、ＪＣＰＤＳカードに記載された基準となる２θの値に対するずれを確認して求めた。なお、ＴｉＣＮ層については、４２２面を基準として残留応力を求めた。また、Ａｌ2Ｏ3層については１３１０面を基準として残留応力を求めた。求めた残留応力は、表２に示した。
　得られた被覆工具は、以下の条件で、切削試験を行った。その結果を表２に示す。
（耐摩耗性試験）
被削材：ＳＡＰＨ４４０
切削速度：１０００ｍ／ｍｉｎ
送り：０．１５ｍｍ／ｒｅｖ
切込み：０．２５ｍｍ
切削状態：湿式
評価方法：切削長５．０ｋｍ切削した時点での逃げ面摩耗幅（μｍ）
（耐チッピング性試験）
被削材：ＳＡＰＨ４４０　１２本溝(１０ｍｍ幅)付き
切削速度：１０００ｍ／ｍｉｎ
送り：０．１５ｍｍ／ｒｅｖ
切込み：０．２５ｍｍ
切削状態：湿式
評価方法：欠損するまでの衝撃回数（回）
Figure JPOXMLDOC01-appb-T000002
　表２より、基体の熱膨張係数が、９．０×１０-6／℃を下回る、試料Ｎｏ．１２、１８では、基体とＴｉＣＮ層およびＡｌ2Ｏ3層との熱膨張差が小さいため、ＴｉＣＮ層およびＡｌ2Ｏ3層に掛かる圧縮応力の値が小さかった。これらの試料では、ＴｉＣＮ層に掛かる圧縮応力の値は２５０ＭＰａを下回り、Ａｌ2Ｏ3層に掛かる圧縮応力の値も４５０ＭＰａを下回った。その結果、耐欠損性が劣っていた。
　一方、基体の熱膨張係数が９．０×１０-6／℃以上であり、ＴｉＣＮ層に掛かる圧縮応力が２５０～５００ＭＰａ、Ａｌ2Ｏ3層の厚みが２μｍ以上で、Ａｌ2Ｏ3層に掛かる圧縮応力が４５０ＭＰａ以上であり、ＴｉＣＮ層よりも圧縮応力の値が大きい試料はいずれも、耐摩耗性、耐欠損性に優れていた。
　　１・・・被覆工具
　　３・・・基体
　　５・・・被覆膜
　　５ａ・・ＴｉＣＮ層
　　５ｂ・・Ａｌ2Ｏ3層
　　７・・・切刃
　　１７・・・貫通孔
１０１・・・切削工具
１０３・・・ポケット
１０５・・・ホルダ
１０７・・・固定ネジ

Claims (6)

  1. 　基体と、該基体の少なくとも一部を覆う被覆層と、を具備する被覆工具であって、
    　前記基体は、
    　　Ｔｉを含む炭窒化物の硬質相と、
    　　ＣｏおよびＮｉの少なくともいずれかを含む結合相と、を有し、
    　　２５～１０００℃における熱膨張係数が９．０×１０-6／℃以上であり、
    　前記被覆層は、
    　　ＴｉＣＮ層と、該ＴｉＣＮ層の上に位置するＡｌ2Ｏ3層と、を有し、
    　前記ＴｉＣＮ層は、
    　　圧縮応力が２５０～５００ＭＰａであり、
    　前記Ａｌ2Ｏ3層は、
    　　２μｍ以上の厚みを有し、圧縮応力が４５０ＭＰａ以上であり、前記ＴｉＣＮ層よりも圧縮応力の値が大きい、被覆工具。
  2. 　前記Ａｌ2Ｏ3層は、厚みが２．５μｍ以上、８．０μｍ以下である、請求項１に記載の被覆工具。
  3. 　前記ＴｉＣＮ層は、厚みが５μｍ以上、１０μｍ以下である、請求項１または２に記載の被覆工具。
  4. 　前記Ａｌ2Ｏ3層の厚みは、前記ＴｉＣＮ層の厚みと前記Ａｌ2Ｏ3層の厚みの和の０．２～０．４倍の範囲である、請求項１～３のいずれかに記載の被覆工具。
  5. 　前記Ａｌ2Ｏ3被覆層は、α－Ａｌ2Ｏ3結晶を含有しており、該α－Ａｌ2Ｏ3結晶は、基体の主面に対して垂直方向に延びている、請求項１～４のいずれかに記載の被覆工具。
  6. 　第１端から第２端に向かって延び、前記第１端側にポケットを有するホルダと、
    　前記ポケットに位置する請求項１～５のいずれかに記載の被覆工具と、を備えた切削工具。
PCT/JP2019/010855 2018-03-20 2019-03-15 被覆工具及びこれを備えた切削工具 Ceased WO2019181786A1 (ja)

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