A method of making a cutting tool, the cutting tool having a WC—Co based cemented carbide body and a multi-layer coating, the method including: applying a first innermost bonding layer TiN to the body; applying a second layer in the form of a mutlilayered structure having sublayers of (TixAl1-x)N were x varies according to 0.45<x<0.55 and 0.70<x<0.80; applying a third layer of (TixAl1-x)N where x is 0.45<x<0.55; and applying a forth outermost layer on TiN.
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1. A method of making a cutting tool, the cutting tool comprising a WC—Co based cemented carbide body comprising WC with an average grain size of about 1.4 μm, 12-13 wt-% Co and 0.4-1.8 wt-% TaC+NbC, and a W-alloyed binder phase with a CW-ratio of 0.82-0.91, the method comprising:
applying a first innermost 0.1-0.5 μm bonding layer of TiN to the body;
applying a second layer comprising a mutlilayered structure comprising a plurality of 0.05-0.2 μm thick sublayers of a composition (TixAl1-x)N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80, a first sublayer of (TixAl1-x)N adjacent to the TiN bonding layer having an x-value of 0.45<x<0.55, a second sublayer of (TixAl1-x)N having an x-value of 0.70<x<0.80 and a third sublayer having x in the range 0.45<x<0.55, the sequence of sublayers alternating and repeating until 12-25 sublayers are built up;
applying a third 0.1-0.5 μm thick layer of (TixAl1-x)N, where x is 0.45<x<0.55; and
applying a fourth outermost 0.1-0.2 μm layer of TiN;
wherein the total coating thickness close to a cutting edge of the tool is in the range of 1-8 μm and the thickness of the second layer constitutes 75-95% of the total coating thickness.
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It has now been found according to the present invention that improved cutting performance is achieved if the cemented carbide body has a CW-ratio of 0.80-0.92, preferably 0.82-0.91, and most preferably 0.85-0.90. The cemented carbide may contain small amounts, <1 volume %, of η-phase (M6C), without any detrimental effect. From the CW-value it follows that no free graphite is allowed in the cemented carbide body according to the present invention.
The hard and wear resistant refractory coating deposited on the cemented carbide substrate A according to the present invention comprises a first (innermost) thin 0.1-0.5 μm bonding layer of TiN B.
The coating includes a second layer comprising a multi-layered structure of sublayers C of the composition (TixAl1-x)N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80. The first sublayer of (TixAl1-x)N adjacent to the TiN bonding layer having an x-value of 0.45<x<0.55, the second sublayer of (TixAl1-x)N having an x-value of 0.70<x<0.80 and the third sublayer having x of 0.45<x<0.55 and so forth repeated until 12-25 sublayers, preferably 22-24 sublayers, are built up. The thickness of this second layer comprising a multilayered structure of sublayers constitutes 75-95% of the total coating thickness. The individual sublayers of (TixAl1-x)N are essentially of the same thickness but their thickness may also vary in a regular or irregular way and said sublayer thickness is 0.05-0.2 μm.
The coating further includes a third 0.1-0.5 μm layer of (TixAl1-x)N D having an x-value of 0.45<x<0.55, and a fourth (innermost) thin 0.1-0.2 μm layer of TiN E.
The total thickness of the coating is 1-8 μm, preferably 2-5 μm. The layer thickness, the sublayer thickness and the coating thickness quoted above refer to measurements made close to the cutting edge, i.e.—the functional part of the cutting tool.
The present invention will now be further described by reference to the following examples, which are intended to be illustrative rather restrictive.
A. A cemented carbide parting tool insert in accordance with the present invention with a composition of 12.6 wt-% Co, 1.25 wt-% TaC, 0.30 wt-% NbC and balance WC with a 1.4 μm grain size and with a binder phase alloyed with W corresponding to a CW-ratio of 0.91 was coated with a 4 μm thick coating by applying a conventional PVD cathodic arc technique. The coating considered of a first (innermost) 0.2 μm layer of TiN followed by a 3.2 μm thick second layer comprising 23 alternating sublayers (TixAl1-x)N, where x alternatively varied between 0.55 and 0.75, a third layer 0.2 μm (TixAl1-x)N, where x=0.55, and, finally, an outermost 0.4 μm layer of TiN.
B. A cemented carbide parting tool insert not of the present invention with a composition of 8.0 wt-% Co, no cubic carbides, balance WC and a CW-ratio of 0.94. The insert was coated with an innermost 0.5 μm equiaxed TiCN-layer. A 1.5 μm TiN layer was deposited, during the same cycle, on top of the TiCN-layer. No post treatment was applied.
C. For comparison, a competitive cemented carbide parting tool insert in style similar to previously mentioned inserts was obtained from an external leading cemented carbide procedure. The carbide had a composition of 12.5 wt-% Co, 0.1 wt-% TiC, 1.8 wt-% TaC, 0.2 wt-% NbC, and balance WC with a CW-ratio of 0.87. The insert had a coating consisting of 1.4 μm TiN, and, outermost, 1.4 μm TiCN. Examination under a high optical microscope revealed no edge treatment subsequent to coating.
Inserts A, B and C were tested in a parting off to center in stainless steel SS2321 with OD 26 mm. The cutting speed was varied from 86 to 0 m/min with a feed rate of 0.05 mm/r. The wear mechanism was uneven flank wear and chipping.
Insert
Number of components
A
50
B
13
C
41
Inserts A and B were tested at an end user's machine shop in a parting of a stainless steel component (AISI 316 OD 42 mm). The cutting speed was varied from 110 to 0 m/min with a feed rate varying from 0.08 to 003 mm/r. The low feed rate was used close to the center of the bar. The wear mechanism was fracture in the cutting zone.
Insert
Number of components
A
201
B
224
Inserts A and B were tested at an end user's machine shop in a parting of a steel component (SS2172 OD 47 mm). The rotating speed was 1800 rpm with a feed rate of 0.1 mm/r. The wear mechanism was flank wear and flaking.
Insert
Number of components
A
163
B
50
Inserts A and C were tested at an end user's machine shop in a parting of a stainless steel component (AISI 316 OD 31 mm). The cutting speed was varied from 60 to 0 m/min with a feed rate varying from 0.06 to 0.03 mm/r. The low feed rate was used close to the center of the bar. The wear mechanism was flank wear and chipping.
Insert
Number of components
A
182
C
43
The present invention also relates to a method of making a coating cutting tool insert consisting of a cemented carbide body with a composition of 11.5-13.6 wt % Co, preferably 12.0-13.0 wt % Co, most preferably 12.3-12.9 wt % Co, 0.2-1.8 wt % cubic carbides, preferably 0.4-1.8 wt % cubic carbides, most preferably 0.5-1.7 wt % cubic carbides of the metals Ta, Nb and Ti and balance WC. The cemented carbide may also contain other carbides from elements from group IVb, Vb or VIb of the periodic table. The content of Ti is preferably on a level corresponding to a technical impurity. The average grain size of the WC is about 1.1-2.1 μm, preferably about 1.4 μm.
The hard and wear resistant refractory coating is deposited onto the cemented carbide substrate by applying conventional PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) methods and, according to the present invention, said coating comprises a first (innermost) thin 0.1-0.5 μm bonding layer of TiN, a second layer comprising a multilayered structure of sublayers of the composition (TixAl1-x)N in which x varies repeatedly between the two range 0.45<x<0.55 and 0.70<x<0.80. The first sublayer of (TixAl1-x)N adjacent to the TiN bonding layer having an x-value of 0.45<x<0.55, the second sublayer of (TixAl1-x)N having an x-value of 0.70<x<0.80 and the third sublayer having x of 0.45<x<0.55 and so forth repeated until 12-25 sublayers, preferably 22-24 sublayers, are built up. The thickness of this second layer comprising a multilayered structure of sublayers constitutes 74-95% of the total coating thickness. The individual sublayers of (TixAl1-x)N are essentially of the same thickness but their thickness may also vary in a regular or irregular way and said sublayer thickness is 0.05-0.2 μm, a third thin 0.1-0.5 μm layer of (TixAl1-x)N having an x-value of 0.45<x<0.55 and a fourth (outermost) 0.1-0.2 μlayer of TiN.
Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.
Jonsson, Anders, Piirhonen, Anders, Selinder, Torbjörn, Kullander, Gregory
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