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DESCRIPTION
Surface-Coated Cutting Tool
Technical Field
The present invention relates to such cutting tools as drill, end mill, throwaway
tip for milling or turning, metal saw, gear cutting tool, reamer, and tap. In particular,
the invention relates to a cutting tool having its surface on which a wear-resistant
coating is formed.
Background Art
In these years, the cutting machining pursues, in addition to high-speed, highprecision
and high-efficiency machining, dry machining for addressing environmental
issues. Further, with advances in industrial technology, some industries that frequently
use difficult-to-cut materials and new materials for aircrafts, space development and
nuclear power generation for example perform increasingly intense activities. It is thus
expected that such materials will increase in variation in terms of quality and increase in
amount. Accordingly, the cutting machining of these materials should address such
increases of the materials. A number of surface-coated cutting tools that address the
issue have been proposed and in actual use.
For example, Patent Document 1 discloses a hard-layer-coated tool and a hardlayer-
coated member. Specifically, on a surface of such a hard base material as WC
cemented carbide, cermet or high-speed steel of such a tool as cutting tool and wearresistant
tool, a hard coating layer that is an AlTiSi-based layer like (AlxTi1-x.ySiy) (NzC1.
z) layer (where 0.05
improving wear resistance and surface protection function.
Patent Document 2 discloses that at least one layer of nitride, carbonitride,
oxynitride or oxycarbonitride containing an appropriate amount of Si and Ti as a main
component and at least one layer of nitride, carbonitride, oxynitride or oxycarbonitride
containing Ti and Al as a main component are alternately formed as coating layers.
Here, in the fine structure of such a compound as TiSi-based compound, Si3N4 and Si
are present as independent phases in the carbonitride, oxynitride or oxycarbonitride
containing Ti as a main component. It is disclosed that the performance of a cutting
tool having the above-described coating and used for dry and high-speed cutting
machining is considerably improved. According to Patent Document 2, as for a
conventional TiAIN film, while an alumina layer that is generated through surface
oxidation occurring in a cutting process serves as an oxidation protection layer for
inward diffusion of oxygen, the uppermost alumina layer is insufficient for addressing
advances of the oxidation since the alumina layer is readily peeled off from the porous Ti
oxide layer immediately below. It is disclosed that the TiSi-based coating of the
invention described in Patent Document 2 itself is highly oxidation-resistant. In
addition, since the composite oxide of Ti and Si that contains Si and is highly dense is
formed at the uppermost surface, no porous Ti oxide layer that is a source of the
problem of the conventional art is formed, the performance is improved.
Moreover, Patent Document 3 discloses that carbonitride or nitride of AlCrV
can be used to generate coating quality for cutting tools that is higher in hardness and
wear resistance as compared with the TiAIN film.
Patent Document 1: Japanese Patent No. 2793773
Patent Document 2: Japanese Patent No. 3347687
Patent Document 3: Japanese Patent Laying-Open No. 2003-34859
Disclosure of the Invention
Problems to be Solved by the Invention
In order to perform high-speed and high-efficiency machining or dry machining
completely eliminating use of lubricating oil in a cutting process, the stability of the
coating at high temperatures is insufficient. In other words, the challenge is to find
how a coating having superior properties can be maintained on a surface of a base
material with enough adhesion for a long period of time without occurrences of peeling
and breakage.
Specifically, when cutting is performed on such a material as low-carbon steel,
stainless material or ductile iron that is readily deposited on a cutting edge, the
deposition of the material is likely to cause peeling of the coating and breakage due to
the coating peeling is likely to occur as well. Thus, for prevention of the peeling, it is
important how the deposition of the material is prevented and simultaneously an
important challenge is to find how the coating property can be made superior in wear
resistance.
The present invention has been made to solve the aforementioned problems, and
an object of the invention is to provide a surface-coated cutting tool that is appropriately
used for such tools as drill, end mill, throwaway tips for milling and turning, metal saw,
gear cutting tool, reamer, and tap and that is improved in peeling resistance and wear
resistance as compared with conventional tools.
Means for Solving the Problems
The inventors of the present invention have conducted studies of various
coatings to be formed on a surface of a tool with the purpose of solving the problems to
find that, a surface-coated cutting tool with a structure having a base material coated
with an inner layer formed on the base material and an outermost layer formed on the
inner layer, the inner layer being composed of a compound containing Al, one or both of
elements Cr and V and at least one of nitrogen, carbon and oxygen, and the outermost
layer being composed of a carbonitride of TiSi, can prevent peeling of the coating while
exhibiting superior wear resistance and chipping resistance, and accordingly the
inventors achieve the present invention.
The invention is specifically as follows.
According to the present invention, a surface-coated cutting tool includes a base
material coated with an inner layer formed on the base material and an outermost layer
formed on the inner layer, the inner layer being composed of a compound containing Al,
at least one of elements Cr and V and at least one element selected from the group
consisting of nitrogen, carbon and oxygen, and the outermost layer being composed of a
carbonitride of TiSi.
Preferably, regarding the surface-coated cutting tool of the present invention, the
outermost layer has a thickness of 0.1-2 μm.
Preferably, the carbonitride of TiSi of the outermost layer has an average crystal
diameter of at most 0.1 μm.
Preferably, regarding the surface-coated cutting tool of the present invention, the
inner layer is composed of a compound containing (Al1-a-bCraVb) (where 0
b
Here, more preferably, the a+b satisfies 0.3
a value satisfying 0
"a" and "b" preferably have respective values satisfying 20
Preferably, regarding the surface-coated cutting tool of the present invention, the
inner layer contains, in atomic percent, less than 5 % of Ti.
Further, regarding the surface-coated cutting tool of the present invention, the
inner layer preferably contains, in atomic percent, at most 30 % of Si and/or B.
Furthermore, regarding the surface-coated cutting tool of the present invention,
the surface-coated cutting tool preferably has a TiSiN layer between the base material
and the inner layer and/or between the inner layer and the outermost layer.
Preferably, the inner layer is divided by a TiSiCxN1-x (where 0
The TiSiCxN1-x is preferably TiSiN.
Regarding the surface-coated cutting tool of the present invention, the base
material is coated with the layers that have a total thickness of 0.5-8 (am.
Effects of the Invention
According to the present invention, improvements in peeling resistance and wear
resistance can be made for such tools as drill, end mill, throwaway tips for milling and
turning, metal saw, gear cutting tool, reamer, and tap. Thus, the present invention can
provide a surface-coated cutting tool with a long lifetime.
Best Modes for Carrying Out the Invention
A surface-coated cutting tool of the present invention includes a base material
coated with an inner layer and an outermost layer formed on the inner layer. The inner
layer is composed of a compound containing Al, at least one of the elements Cr and V
and at least one element selected from the group consisting of nitrogen, carbon and
oxygen. The outermost layer is composed of a carbonitride of TiSi (TiSiCN). The
inner layer may be formed to directly cover a surface of the base material or may be
formed to cover the base material with another layer (for example an innermost layer
described hereinlater) therebetween. Similarly, the outermost layer may be formed to
directly cover the inner layer or may be formed to cover the inner layer with another
layer (for example an intermediate layer described hereinlater) therebetween.
The surface-coated cutting tool of the present invention has a feature that the
base material is coated with the inner layer superior in chemical stability and exhibiting
superior wear resistance in a process of cutting metal materials, wherein the inner layer
is composed of the compound containing Al, at least one of the elements Cr and V and
at least one element selected from the group consisting of nitrogen, carbon and oxygen.
The surface-coated cutting tool of the present invention further has a feature that the
inner layer is coated with the carbonitride of TiSi that has a low friction coefficient and
lubricity with respect to metal materials, exhibits high chemical stability and has good
adhesion with the inner layer which is composed of the compound containing Al, at least
one of the elements Cr and V and at least one element selected from the group
consisting of nitrogen, carbon and oxygen, and thus the outermost layer having high
chemical stability is formed. The present invention with the above-described features
can improve the peeling resistance and wear resistance of such tools as drill, end mill,
throwaway chips for milling and turning, metal saw, gear cutting tool, reamer, and tap,
so that the invention can provide the surface-coated cutting tool having a long lifetime.
Here, when the layer is composed of the compound containing Al, at least one of
the elements Cr and V and at least one element selected from the group consisting of
nitrogen, carbon and oxygen (for example AlCrN), the layer shows good performance in
terms of high hardness and high oxidation resistance. However, through cutting
evaluations, low chipping-resistance and low peeling-resistance due to occurrence of
chipping were confirmed. With the purpose of overcoming this shortcoming, various
studies have been conducted to find that, the inner layer composed of the abovedescribed
compound and the outermost layer composed of a carbonitride of TiSi
(TiSiCN) formed on the inner layer can provide a surface-coated cutting tool improved
in chipping resistance and peeling resistance. This may be for the reason that the
TiSiCN of the outermost layer forms a fine-particle structure to provide a high
resistance against impact in ^cutting process so that the impact is alleviated to be
conveyed to the inner layer and accordingly the performance is improved. It is
considered that, since the adhesion between the TiSiCN or TiSiN layer and the layer
composed of the compound containing Al, at least one of the elements Cr and V and at
least one element selected from the group consisting of nitrogen, carbon and oxygen is
remarkably excellent, the particularly superior peeling property as a property of the layer
of the cutting tool can be achieved. The adhesion is especially excellent when the
component defined by (Al1-a-bCraVb) (where 0
satisfies the condition 0.3
Regarding the surface-coated cutting tool of the present invention, although the
thickness of the outermost layer is not particularly limited to a specific thickness, the
thickness is preferably 0.1-2 um that is more preferably 0.2-1 (am for the following
reasons. When the thickness of the outermost layer is smaller than 0.1 μm, the
superior effects of the outermost layer could not be exhibited. When the thickness of
the outermost layer is larger than 2 μm, the coating could be likely to peel off. The
thickness of the outermost layer can be measured by cutting the surface-coated cutting
tool and observing the cross section with an SEM (scanning electron microscope).
According to the present invention, the outermost layer of the surface-coated
cutting tool is preferably composed of a carbonitride of TiSi having an average crystal
diameter of at most 0.1 μm that is more preferably at most 0.05 urn. Thus, the outer
most layer that is particularly superior in lubricity as well as strength of adhesion with
the inner layer can be obtained. In terms of wear resistance, the average crystal
diameter of the carbonitride of TiSi forming the outermost layer is preferably at least 1
nm that is more preferably at least 3 nm. The average crystal diameter of the
carbonitride of TiSi in the outermost layer of the surface-coated cutting tool can be
measured for example through observation of a coating cross-section or fracture by
means of an SEM or TEM.
Regarding the surface-coated cutting tool having the outermost layer composed
of the carbonitride of TiSi having such a preferable average crystal diameter as the one
described above, when the surface-coated cutting tool is produced through a cathode
arc ion plating process for example that is described hereinlater, the outermost layer is
preferably formed under the condition that the base-material bias voltage is in the range
of-150 to-10 V.
The surface-coated cutting tool of the present invention has the inner layer that
is composed of a compound containing Al, at least one of the elements Cr and V and at
least one element selected from the group consisting of nitrogen, carbon and oxygen, as
described above. The compound forming the inner layer may contain any element
other than those described above (for example Ti, Si, B described hereinlater) to the
extent that does not spoil the effects of the present invention. According to the present
invention, as the inner layer contains Al, the oxidation-resistant property is improved
and the thermal conductivity is enhanced. An effect accordingly obtained is that the
heat generated in a cutting process can be released from the surface of the tool.
Regarding the compound of which the inner layer of the invention is composed,
the contents of Cr and V except for Al are preferably defined by (Al1-a-bCraVb) (where 0
cutting tool of the present invention is preferably composed of at least a
compound containing (Al1-a-bCraVb) (where 0
at least one of carbon, nitrogen and oxygen, for the following reason. Regarding (Al1-abCraVb),
when at least one of a and b is larger than 0.5, the hardness of the inner layer
could decrease and accordingly wear resistance could not sufficiently be exhibited.
Especially preferable wear resistance is achieved when the condition 0.3
satisfied. The value determined by a+b that is in this range is preferable since adhesion
with a TiSiCN layer of an outermost layer or a TiSiN layer of an intermediate layer is
improved so that the coating has superior peeling resistance. Further, regarding (Al1-abCraVb),
preferably the value of a satisfies the condition 0
satisfies the condition 0
from the fact that Cr and V are contained simultaneously and respective values of a and
b are both less than 0.35. Although the reason therefor is not clarified, it is presumed
that lubricity of Cr at low temperatures and lubricity of V in a relatively high
temperature range can be improved and Cr and V that are simultaneously contained
provide the excellent peeling resistance over a wide range of cutting conditions.
Moreover, it is particularly preferable that the values of a and b have the relation 20
a/b
compound of which the inner layer is composed can be identified by an X-ray
photoelectron spectroscope (XPS) or Auger electron spectroscope (AES).
Regarding the surface-coated cutting tool having the inner layer composed of the
preferable compound with the contents of Cr and V except for Al expressed by (Ah...
bCraVb) (where 0
tool is produced through a cathode arc ion plating process for example that is discussed
hereinlater, the inner layer can be formed under the condition that the base-material bias
voltage is in the range of-3 00 to -20 V for example. In particular, the surface-coated
cutting tool having the inner layer composed of the preferred compound expressed by
(Al1-a-bCraVb) where the values of a and b have the relation 20
achieved by setting the base-material bias voltage in the range of-250 to -40 V in the
process of manufacturing the surface-coated cutting tool.
Regarding the surface-coated cutting tool of the present invention, although the
thickness of the inner layer is not limited to a particular one, preferably the thickness is
0.4 to 8 urn that is more preferably 1 to 6 μm. When the thickness of the inner layer is
less than 0.4 μm, the wear resistance could be insufficient. When the thickness of the
inner layer is larger than 8 μm, the breakage resistance could be deteriorated. As the
outermost layer described above, the thickness of the inner layer can be measured by
cutting the surface-coated cutting tool and observing the cross section by means of an
SEM.
For the purpose of further enhancing adhesion between the outermost layer and
the inner layer, the inner layer preferably contains a small amount of Ti. Specifically,
the inner layer preferably contains, in atomic percent, less than 5 % of Ti that is more
preferably less than 3 %. When the inner layer contains, in atomic percent, 5 % or
more of Ti, there is a tendency that the wear resistance of the inner layer is deteriorated.
For allowing the effect of the improved adhesion between the outermost layer and the
inner layer to be exhibited sufficiently, Ti contained in the inner layer is preferably at
least 0.01 % in atomic percent that is more preferably at least 0.1 %. Here, the content
of Ti in the inner layer of the surface-coated cutting tool can be measured for example
by means of an XPS.
A TiSiN layer (intermediate layer) may be included between the inner layer and
the outermost layer. The presence of the intermediate layer between the inner layer
and the outermost layer further improves adhesion between the outermost layer and the
inner layer. Although the thickness of the intermediate layer is not limited to a
particular one, the thickness is preferably 0.05 to 2.0 μm that is more preferably 0.1 to
1.5 μm. When the thickness of the intermediate layer is less than 0.05 μm, the effect of
the improved adhesion could not sufficiently be exhibited. When the thickness of the
intermediate layer is larger than 2.0 μm, the wear resistance could be deteriorated. As
the outermost layer described above, the thickness of the intermediate layer can be
measured by cutting the surface-coated cutting tool and observing the cross section by
means of an SEM. It is noted that the conditions that the inner layer contains less than
5 % in atomic percent of Ti and the intermediate layer of TiSiN is included between the
inner layer and the outermost layer, as described above, are particularly preferable in
terms of improvement in adhesion as discussed above.
Further, regarding the surface-coated cutting tool of the present invention, for
the purpose of improving adhesion between the inner layer and the base material, a
TiSiN layer (innermost layer) may be included between the inner layer and the base
material. Although the thickness of the innermost layer is not limited to a particular
one, the thickness is preferably 0.01 to 1.0 μm that is more preferably 0.05 to 0.5 μm.
When the thickness of the innermost layer is less than 0.01 μm, the effect of the
improvement in adhesion could not sufficiently be exhibited. When the thickness of the
innermost layer is larger than 1.0 μm, the wear resistance could be deteriorated. As the
outermost layer described above, the thickness of the innermost layer can be measured
by cutting the surface-coated cutting tool and observing the cross section by means of
an SEM or TEM.
Furthermore, regarding the surface-coated cutting tool of the present invention,
when the inner layer is divided into multiple layers by a TiSiCxN1-x (where 0
layer, excellent peeling resistance can be achieved. Here, the division of the inner layer
means that the inner layer is divided into layers that are each almost in parallel with the
surface of the base material. When the inner layer is divided by the TiSiCxN1-x layer
and a large stress is suddenly applied in a cutting process, some layers of the multi-layer
could be broken at the interface therebetween at which the bonding strength is low.
Thus, the breakage of the inner layer in the cutting process occurs at the smaller layer as
compared with the original non-divided inner layer. Accordingly, a sudden large-scale
breakage of the layer can be prevented and consequently the stable and extended lifetime
of the surface-coated cutting tool can be achieved. Here, the reason why x in
TiSiCxNi.x is defined by 0
TiSiCxNi.x layer and the inner layer to be deteriorated excessively, resulting in
deterioration in wear resistance. It is particularly preferable that the value of x is 0
(namely TiSiN) since the adhesion between the TiSiN layer and the inner layer is
relatively superior and thus relatively superior wear resistance can be maintained.
When the inner layer is divided into multiple layers by the TiSiCxN1-x layer, the
number of layers produced by dividing the inner layer is not limited to a particular one.
Respective thicknesses of the layers of the inner layer may be equal to or different from
each other. When the inner layer is divided into layers having different thicknesses
respectively, it is advantageous that various breaking stresses can be addressed.
Although the thickness of the layers in the inner layer is not limited to a particular one, it
is preferable that all layers of the inner layer that are produced by dividing the inner layer
each have a thickness in the range of 0.01 to 1.0 (am and the total thickness of the layers
in the inner layer is in the above-described range of the thickness of the inner layer.
When any layer in the inner layer has a thickness less than 0.01 μrn, the wear resistance
could be insufficient. When any layer in the inner layer has a thickness larger than 1.0
urn, the advantage derived from dividing the inner layer could be deteriorated. As the
outermost layer described above, the thickness of the layers in the inner layer can be
measured by cutting the surface-coated cutting tool and observing the cross section by
means of an SEM or TEM.
Further, when the inner layer is divided by the TiSiCxN1-x layer into multiple
layers, the thickness of the TiSiCxN1-x layer (when a plurality of TiSiCxN1-x layers are
formed, the thickness of the layers each) is preferably 1 to 200 nm that is more
preferably 10 to 100 nm. When the thickness of the TiSiCxN1-x layer is less than 1 nm,
the advantage derived from the division of the inner layer into multiple layers could be
deteriorated. When the thickness of the TiSiCxN1-x layer is larger than 200 nm, the
wear resistance could be deteriorated. As the outermost layer described above, the
thickness of the TiSiCxN1-x layer can be measured by cutting the surface-coated cutting
tool and observing the cross section by means of an SEM or TEM.
In terms of improvements in oxidation resistance, wear resistance and peeling
resistance of the surface-coated cutting tool, the inner layer may preferably contain, in
atomic percent, at most 30 % of Si that is more preferably at most 20 % that is still
more preferably at most 15 %. When the inner layer contains Si, a finer structure of
the inner layer is achieved and the hardness of the inner layer is enhanced. Moreover,
the presence of Si in the inner layer improves adhesion between the inner layer and the
outermost layer composed of TiSiCN. However, the content of Si in the inner layer
that exceeds 30 % in atomic percent is not preferred since the inner layer becomes brittle
and undesirably wear is promoted. When the inner layer contains Si, for the purpose of
obtaining the effect of finer structure, preferably at least 1 % in atomic percent of Si is
contained that is more preferably at least 5 %. Here, the content of Si in the inner layer
of the surface-coated cutting tool can be measured for example by a XPS or AES.
Moreover, the inner layer may preferably contain, in atomic percent, at most
30 % of B that is more preferably at most 15 % that is still more preferably at most
10 %. The presence of B in the inner layer provides the advantages that the coating
has a high hardness and that an oxide of B generated through surface oxidation in a
cutting process particularly makes an oxide of Al denser. Further, since the oxide of B
has a low melting point, the B oxide serves as lubricating oil in a cutting process to
provide an advantage of superior peeling resistance. However, the content of B in the
inner layer that exceeds 30 % is not preferred since the wear resistance is undesirably
deteriorated. Furthermore, when the inner layer contains B, for the purpose of
improving the wear resistance and peeling resistance, preferably at least 1 % in atomic
percent of B is contained that is more preferably at least 5 %. The content of B in the
inner layer of the surface-coated cutting tool can be measured for example by means of a
XPS.
Regarding the surface-coated cutting tool of the present invention, preferably the
inner layer has a residual stress of-6 to 0 GPa that is more preferably -4 to -1 GPa.
When the residual stress is less than -6 GPa, compressive residual stress in the surface
coating is too large and consequently the strength of adhesion with the base material
tends to decrease. When the residual stress exceeds 0 GPa, tensile stress remains in the
coating. As a result, cracks are likely to open in the coating and chipping resistance
and breakage resistance could be deteriorated. The residual stress can be measured for
example by means of an X-ray residual stress measuring device or Sin2 ψ method.
The surface-coated cutting tool having the above-described preferable residual
stress can be implemented in the following way. When the surface-coated cutting tool
is produced for example through a cathode arc ion plating process as described
hereinlater, the inner layer is formed on the condition that the base-material bias voltage
for example is in the range of-300 to -20 V.
Further, regarding the surface-coated cutting tool of the present invention, the
layers with which the base material is coated (the layers are the inner layer, the
outermost layer, and the intermediate layer if the intermediate layer is formed) preferably
have a total thickness of 0.5 to 8 jam that is more preferably 1.0 to 6.0 u,m. When the
total thickness is smaller than 0.5 urn, the wear resistance could not sufficiently be
improved. When the total thickness exceeds 8 μrn, it could occur that the residual
stress in the layers covering the base material is large to cause the strength of adhesion
with the base material to decrease. As the thickness of the outermost layer as
described above, the total thickness can be measured by cutting the surface-coated
cutting tool and observing the cross section by means of an SEM.
As the base material used for the surface-coated cutting tool of the present
invention, any material that has been used widely in the art may appropriately be
employed, and the base material is not limited to a particular one. However, the base
material is preferably any of WC cemented carbide, cermet, high-speed steel, ceramics
(silicon carbide, silicon nitride, aluminum nitride, aluminum oxide, silicon carbide,
titanium carbide and a composite thereof), sintered cubic boron nitride, and sintered
diamond, since such materials have high hardness at high temperatures. In particular,
preferably WC cemented carbide, cermet or sintered cubic boron nitride is used as the
base material.
The surface-coated cutting tool of the present invention is applicable to various
known cutting tools that are used for cutting machining. In particular, the coated
cutting tool of the present invention is preferably any of drill, end mill, throwaway chip
for milling and turning, meal saw, gear cutting tool, reamer, and tap.
The surface-coated cutting tool of the present invention can be manufactured
through a known film-deposition process with which a compound of high crystallinity
can be produced and in which the base material is coated with the inner layer and the
outermost layer (the innermost layer, the intermediate layer and the like depending on
cases). As the film deposition process, physical vapor deposition is preferred since
compressive stress can be applied into the coating. The physical vapor deposition
includes for example ion plating, sputtering and electron beam vapor deposition. When
the surface-coated cutting tool of the present invention is manufactured and the ion
plating is employed, arc ion plating is preferable since adhesion with the base material is
readily ensured. When the sputtering is employed, magnetron sputtering (balanced and
unbalanced magnetron sputtering) is preferable since it is excellent in coating of a nonelectrically-
conductive material. Among them, the cathode ion plating with a high ion
ratio of elements is particularly preferred. When the cathode arc ion plating is used, a
metal ion bombardment process for the surface of the base material can be carried out
before the inner layer is formed so that the adhesion of the inner layer is remarkably
improved.
Using examples, how the wear resistance of the surface-coated cutting tool is
improved is specifically described now. The composition in the examples was
identified by means of an X-ray photoelectron spectroscope (XPS) and an Auger
electron spectroscope (AES).
As a base material, a cemented carbide with its grade of K20 defined by the JIS
and a tip with the shape of SPGN1020308 defined by the JIS were used and they were
mounted on a cathode arc ion plating apparatus.
First, a vacuum pump was used to decrease the pressure in a chamber while a
heater provided in the apparatus was used to heat the base material to a temperature of
650°C. The vacuum was generated until the pressure in the chamber reaches 1.0 x
10-4 Pa. Then, argon gas was supplied and the pressure in the chamber was kept at 3.0
Pa. While the voltage of a base-material bias voltage source was gradually increased to
reach -1500 V, the surface of the base material was cleaned for 15 minutes. After this,
the argon gas was discharged.
Next, in order for the composition of the compound of the inner layer to be any
shown in Table 1, an alloy target that is the source of metal evaporation was set. As
the reaction gas, any of nitrogen, methane and oxygen that would allow the coating of
the present invention to be generated was supplied. While the base-material
temperature of 650°C, the reaction-gas pressure of 2.0 Pa and the base-material bias
voltage of-100 V were kept, arc current of 100 A was supplied to a cathode electrode
to generate metal ions from the arc evaporation source and thereby form a coating
(inner layer). When the inner layer had any of the predetermined thicknesses shown in
Table 1, the electric current supplied to the evaporation source was stopped.
Successively, on the inner layer, an outermost layer that was a TiSiCN layer was
formed. Specifically, Ti and Si were set within the chamber. While nitrogen and
oxygen were supplied thereinto as reaction gasses, the base-material temperature was
set at 650°C, the reaction-gas pressure was set at 2.0 Pa and the base-material bias
voltage was set at -50 V. Then, arc current of 100 A was supplied to the cathode
electrode to cause metal ions to be generated from the arc evaporation source.
Accordingly, the outermost layer of the carbonitride of TiSi having an average crystal
diameter of 0.05 μm was formed. When the outermost layer had a predetermined
thickness, the electric current supplied to the evaporation source was stopped, and
gradual cooling was done.
Regarding Examples 5 to 7 and Comparative Example 2, before the inner layer
was formed, an innermost layer that was a TiSiN layer was formed on the base material.
Specifically, Ti and Si were set within the chamber, while nitrogen was supplied
thereinto as reaction gas, the base-material temperature of 650°C3 the reaction-gas
pressure of 2.0 Pa and the base-material bias voltage of-100 V were maintained.
Then, arc current of 100 A was supplied to the cathode electrode to cause metal ions to
be generated from the arc evaporation source and thereby form the innermost layer.
When the innermost layer had a predetermined thickness, the electric current supplied to
the evaporation source was stopped.
Regarding Example 7, after the inner layer was formed and before the outermost
layer was formed, an intermediate layer that was a TiSiN layer was formed in the same
manner as that for the innermost layer.
Further, regarding Example 8, the outermost layer was formed by setting the
base-material bias voltage at -30 V so that the outermost layer (TiSiCN layer)
composed of a carbonitride of TiSi with an average crystal diameter of 0.3 μm was
generated.
On the products of Examples 1 to 8 and Comparative Examples 1 to 3 obtained
through the above-described processes, dry milling tests were conducted under the
following conditions to measure the time taken for the flank at the cutting edge to be
worn by a width exceeding 0.2 mm. The cutting conditions were that a material to be
cut was SUS304 stainless steel (HB = 180), the cutting speed was 70 m/min, the feed
per revolution was 0.2 mm/rev and the depth of cut was 1 mm. The results are shown
in Table 1.
(Table Removed)
As clearly seen from Table 1, according to the present invention, the lifetime of
the cutting tools of Examples 1 to 8 each was remarkably improved relative to
Comparative Examples 1 to 3 when used for cutting SUS304 by which coating peeling
is likely to occur.
Surface-coated cutting tools of the present invention were produced in the same
manner as that for Example 1 discussed above except that the inner layer and the
outermost layer with the compositions shown in Table 2 were formed. As described
above, cutting tests were conducted on Examples 9 to 12 to find the performance as
shown in Table 2.
(Table Removed)
As shown in Table 2, Examples 9 to 12 having the inner layer composed of the
compound (Al1-a-bCraVb,) where the values of a and b satisfy the relation 5
are especially superior in cutting-tool lifetime.
An inner layer of the same composition as that of Example 6 was formed in the
same manner except that the process of forming the inner layer and the process of
forming a TiSiN layer similar to the formation of the innermost layer were carried out
alternately to produce a surface-coated cutting tool having the inner layer divided into
15 layers by the TiSiN layer of 0.05 um in thickness. The layers in the inner layer as
divided had the same thickness of 0.2 μm. On the resultant Example 13, a cutting test
was conducted in the same manner as that described above. Accordingly, the
performance shown in Table 3 was found.
(Table Removed)
From Table 3, it can be confirmed that Example 13 having the inner layer divided
by the TiSiN layer was remarkably superior in cutting-tool lifetime.
It should be noted that the embodiments and examples disclosed here are by of
illustration and example only and are not to be taken by way of limitation. It is
intended that the scope of the present invention is limited not by the description above
but by the scope of the appended claims, and covers all modifications and variations
within the meaning and the scope equivalent to those of the claims.
We Claim:
1. A surface coated cutting tool comprising a base material coated with an inner layer formed on the base material and an outermost layer formed on the inner layer, the inner layer being composed of a compound containing (Al1-a-.bCraVb)(where 0≤a≤0.5, 0≤b≤0.5, 0#a+b≤0.5) and at least one of elements that are carbon, nitrogen and oxygen, and the outermost layer being composed of a carbonitride of TiSi, and wherein a TiSiN layer of 0.05 to 0.5 µm in thickness is formed as an innermost layer.
2. A surface-coated cutting tool comprising a base material coated with an inner layer formed on the base material with an outermost layer formed on the inner layer, the inner layer being composed of a compound containing (Al1-a-bCraVb)(where 0≤a≤0.5, 0≤b≤0.5, 0#a+b≤0.5) and at least one of elements that are carbon, nitrogen and oxygen , and the outermost layer being composed of a carbonitride of TiSi,
wherein the suface-coated cutting tool has a TiSiN layer between the base material and the inner layer and/or between the inner layer and the outermost layer, and wherein a TiSiN layer of 0.05 to 0.5 µm in thickness is formed as an innermost layer
3. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the outermost layer has a thickness of 0.1-2 µm.
4. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the carbonitride of TiSi has an average crystal diameter of at most 0.1 µm.
5. The surface-coated cutting tool as claimed in claim 1 or 2, wherein said a+b satisfies 0.3
6. The surface-coated cutting tool as claimed in claim 1 or 2, whrein said a has a value satisfying 0
7. The surface-coated cutting tool as claimed in claim 1 or 2, wherein said a and b have respective values satisfying 20
8. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the inner layer contains, in atomic percent, less than 5% of Ti.
9. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the inner layer contains, in atomic percent, at most 30% of Si and/or B.
10. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the inner layer is divided by a TiSiCxN1-x (where 0≤x≤0.5) layer.
11. The surface-coated cutting tool as claimed in claim 10, wherein said TiSiCxN1-x is TiSiN.
12. The surface-coated cutting tool as claimed in claim 1 or 2, wherein the base material is coated with the layers that have a total thickness of 0.5-8 µm. |