In recent years, all industrialized countries in the world are committed to developing advanced cutting tool materials that match high-speed, high-efficiency, high-quality machining. Tool materials have a great impact on tool life, machining efficiency, machining quality and machining costs. The tool must be subjected to high pressure, high temperature, friction, shock and vibration during cutting. Therefore, the tool material must have the following basic properties: high hardness, that is, the hardness of the tool material must be higher than the material to be processed; high strength and toughness, tool cutting Part of the material is subjected to large cutting force and impact force during cutting. Therefore, the tool material must have sufficient strength and toughness; wear resistance and heat resistance are good. Generally speaking, the hardness of the tool material is higher and wear resistance. The better the properties, the closer the wear resistance and heat resistance of the tool are. The better the thermal conductivity and the better the thermal conductivity, the lower the temperature of the cutting part, thus reducing the tool wear; the process and economy are good.

(1) New high speed steel

High-speed steel (HSS) is a high-alloy tool steel with alloying elements such as W, Mo, Cr, and V. Although there are many types of tool materials available at present, high-speed steel has excellent comprehensive properties in terms of strength, toughness, hot hardness, and processability, especially sharpness (tip radius of 12 to 15 μm). It still accounts for a large proportion in the manufacture of certain difficult-to-machine materials and in the manufacture of complex tools, especially cutters, broaches and end mills.

(2) New fine-grained and ultra-fine grained carbide

Cemented carbide is a high-hardness, refractory metal compound (mainly WC, TiC, etc., also known as high-temperature carbide) micron-sized powder, a powder metallurgy product sintered by using a metal such as cobalt or nickel as a binder. Cemented carbide is the most widely used cutting tool material in the field of cutting, and its cutting efficiency is about 5-10 times that of high speed steel. The production of cemented carbides in the world has grown extremely fast, and new materials and new grades of carbide tools have emerged, and the proportion of all kinds of tools is increasing. However, its poor manufacturability is still very limited for complex tools.

The development of fine-grained (1~0.5μm) and ultra-fine grain (less than 0.5μm) cemented carbide materials and solid carbide tools has greatly improved the bending strength of cemented carbide and can be used as an alternative to high-speed steel. Small-scale drills, end mills, taps, and other general-purpose tools with a wide range of cutting tools and tool life far exceed high-speed steel. The use of solid carbide tools has significantly improved the cutting efficiency of most applications where high speed steel was originally used. In order to improve the toughness of the cemented carbide, a method of increasing the Co content is usually adopted, and the resulting hardness reduction can now be compensated by refining the crystal grains, and the bending strength of the cemented carbide can be increased to 4.3 GPa, which has been achieved. Exceeding the bending strength of ordinary high speed steel. Another advantage of fine-grained carbide is the sharp edge of the tool, especially for high-speed cutting of sticky and tough materials.

(3) Superhard tool

The so-called superhard tool material refers to synthetic diamond and cubic boron nitride, and polycrystalline diamond and polycrystalline cubic boron nitride sintered by using these powders and a binder. Since the super-hard tool has better wear resistance than cemented carbide and can adapt to higher cutting speed, it has become the main tool material for high-speed cutting, and more importantly, it can meet the cutting needs of difficult-to-machine materials. Therefore, superhard tool materials have played an increasingly important role in the entire cutting process.

Diamond is an allotrope of carbon, divided into natural diamond and synthetic diamond (PCD). PCD is converted from graphite under the action of high temperature, high pressure and catalyst. Diamond tools have extremely high hardness and wear resistance, with sharp cutting edges and good thermal conductivity. At the same time, the affinity between PCD tools and non-ferrous metals and non-metallic materials is very small, and it is not easy to produce on the tool tip during processing. Sputum. At present, PCD tools are mainly used in the following two aspects: a. difficult to process non-ferrous metals and their alloys. For example, when machining silicon-aluminum alloy with PCD tools, the tool life can reach 50~200 times that of hard alloys; b. Metal materials, PCD tools are ideal for the processing of difficult-to-machine non-metallic materials such as stone, hard carbon, carbon fiber reinforced plastics and artificial boards. Therefore, it can be said that the diamond cutter is the best tool for precision machining of non-metallic materials such as non-ferrous metals and their alloys, ceramics, glass, and wood. However, the thermal stability of diamond is low, and when the cutting temperature exceeds 700 to 800 ° C, the hardness is completely lost. In addition, carbon and iron in diamond have a strong affinity. Under high temperature and high pressure, iron atoms interact with carbon atoms, resulting in graphitization of diamond, which makes the tool extremely wearable. Therefore, diamond tools are generally not used to process materials such as steel.

After the first synthesis of cubic boron nitride by GE in the United States in 1957, cubic boron nitride was polymerized on the cemented carbide under high temperature and high pressure conditions, and a cubic boron nitride (CBN) insert with a composite structure was obtained. CBN knife has two kinds of polycrystalline agglomerates and composite blades. It can process hardened steel and cast iron at a high cutting speed, and it can be used for car grinding, and can cut some high-temperature alloys at high speed. The machining precision is high and the surface roughness is quite low. Moreover, cubic boron nitride is also suitable for processing various hardened steel, Ni-based, Fe-based and other wear-resistant and corrosion-resistant thermal spray (welding) materials, wear-resistant cast iron such as vanadium-titanium cast iron and chilled cast iron, and titanium. Alloy materials, etc.

(4) Ceramic materials

Ceramic knives have high hardness, wear resistance and good high temperature mechanical properties, have low affinity with metals, are not easy to bond with metals, and have good chemical stability. Therefore, ceramic tools can process superhard materials that are difficult or impossible to machine with conventional tools. Ceramic knives have two types of Al2O3 and Si3N4. Adding various carbides, nitrides, borides and oxides can improve their properties. They can also be toughened by particles, whiskers, phase transitions, microcracks and several kinds. The synergy of the mechanism increases its fracture toughness.

At present, some domestically produced whisker toughened ceramics, gradient functional ceramics and other products have reached the performance of similar foreign blades, and some are better than foreign countries. The main raw materials used in ceramic knives, such as alumina and silica, are abundant in the earth's crust and are also important for saving precious metals. Ceramic tools are mainly used for high-speed machining of difficult-to-machine materials. Ceramic tooling has been recognized internationally as one of the most promising tools for further productivity gains.

A coating tool formed by coating one or more layers of a high-hardness, wear-resistant metal or non-metallic compound film (such as TiAlN, TiC, TiN, Al2O3, etc.) on a relatively soft tool substrate is a cutting tool A revolution in development. Compared with uncoated tools, coated tools have obvious advantages: significantly reduce the friction coefficient, improve the tribological properties and chip removal ability of the tool surface; significantly improve the wear resistance and impact toughness, and improve the cutting of the tool. Performance, improve machining efficiency and tool life; improve the surface oxidation resistance of the tool, enable the tool to withstand higher cutting heat, improve cutting speed and machining efficiency, and expand the application range of dry cutting. In advanced manufacturing, more than 80% of carbide tools and high-performance high-speed steel tools use surface coating technology, while more than 90% of the cutting tools used on CNC machines are coated tools.

Since its inception, tool coating technology has played an increasingly important role in the improvement of tool technology and processing technology, and has become a symbol of modern tools. The coated tool is obtained by coating a thin layer of high-wear refractory metal compound on a tough hard carbide substrate or a high-speed steel substrate, which greatly changes the tool performance. Commonly used coating materials are TiC, TiN, Al2O3, etc., wherein TiC has higher hardness than TiN and better wear resistance. For cemented carbides, chemical vapor deposition (CVD) is generally used, and the deposition temperature is 1000 °C. For high-speed steel tools, physical vapor deposition (PVD) is generally used, and the deposition temperature is about 500 °C. As the coating process matures and evolves, from the beginning of a single coating, to the development of a new stage of multi-component, multi-layer, gradient, nano-coating. With regard to the current development of PVD technology, the coating film structure can be roughly divided into single coating, composite coating, gradient coating, multi-layer coating, nano-multilayer coating, and nano-composite coating.

1. Composite coating is a structure composed of coating films with various functions or characteristics, also known as composite coating structural film. The typical coating is the current hard coating plus soft coating, each layer has its own film. Different characteristics, so that the coating has a better overall performance.

2. Gradient coating means that the coating composition changes stepwise along the growth direction of the film. This change can be a change in the proportion of each element of the compound, such as the change of Ti and Al content in TiAlCN, or a gradual transition from one compound to another. A compound, such as CrN, gradually transitions to a CBC carbon-based coating.

3. The multi-layer coating is formed by stacking a plurality of films with different properties, and the chemical composition of each layer is substantially constant. At present, there are two different film compositions in practical applications. Due to the difference in the processes used, the size of each film layer is not the same. It is usually composed of more than ten layers of films, each of which has a film size larger than several tens of nanometers. Representative examples include AlN+TiN, TiAlN+TiN coatings and the like. Compared with the single-layer coating, the multi-layer coating can effectively improve the microstructure of the coating and inhibit the growth of coarse grain structure.

4. The nano-multilayer coating structure is similar to the multi-layer coating, except that the size of each layer of the film is on the order of nanometers, which may also be referred to as ultra-microscopic structure. Theoretical studies have confirmed that in the nano-modulation cycle (several nanometers to tens of nanometers), compared with conventional single-layer films or ordinary multilayer films, such films have ultra-hardness and super-modulus effects, and their microhardness is expected to exceed 40GPa, and at fairly high temperatures, the film retains very high hardness.

Because the coated tool has a surface layer with high hardness, good chemical stability and low friction coefficient, it is not easy to produce diffusion wear, and at the same time has the toughness of the substrate, so the cutting force and cutting temperature are low, which can significantly improve the tool. Cutting performance. Therefore, coated tools have become the mainstream of modern cutting tools. The proportion of coated tools used in Western industrialized countries to indexable inserts has increased from 26% in the 1980s to the current 90%. About 80% of the tools are coated tools. Sweden's Sandvik Coromant and the United States Kenner (Kenner's official website, Kennametal product list) metal company's coated blades have reached more than 85%; the proportion of carbide coated blades used in CNC machine tools in the United States is 80%; coating tools for turning in Sweden and Germany are above 70%. China's coated tools started late, but the progress is fast, and their coating outlets are spread all over the country. Many cities have their own coating centers and undertake external processing operations. China has been conducting research on CVD coating technology since the early 1970s. In the mid-1980s, China's CVD coating technology has entered a practical level, and its technological level has reached international standards. Overall, the level of domestic CVD coating technology is not much different from the international level. However, China began to study PVD coating technology in early 1980. At present, foreign tool PVD coating technology has been developed to the fourth generation, while the domestic is still in the second generation level, and still dominated by single-layer TiN coating.

Since the beginning of the 21st century, with the globalization of manufacturing technology, the competition in manufacturing has become increasingly fierce. In the cutting process system consisting of machine tools, tools, fixtures and workpieces, the tool is the most active factor. Therefore, in the high-speed machining technology widely used in production today, high-performance tools are getting more and more attention and a large number of traditional tools. Although high-performance tools are expensive compared to conventional tools, even 10 times that of conventional tools, the use of high-performance tools can still effectively reduce production costs. Tool materials, geometric parameters and their structure are the most important key technologies for high-performance tool design and manufacture. At present, advanced tools are developing rapidly, and various special high-performance tools are constantly being introduced. In terms of tool materials, ultra-fine grained carbide tools and super-hard material tools have been widely used; in coatings, multi-layer gradient composite coatings and high-strength heat-resistant nano-coatings have also been greatly developed, and It has been applied in aerospace, automotive and marine fields; in terms of tool structure, it will be developed in the direction of indexable, multi-functional, special-purpose composite tools and modules.

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