金刚石、氮化碳涂层刀具干切削性能的研究
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摘要
当今机械切削加工领域大量使用切削液，目的是为了在切削加工过程中冷却工件、刀具和机械设备，此外还可以降低摩擦力和促进切屑排出切削区，但是由于使用了切削液，增加了生产成本，同时对环境造成污染，损害人们的身体健康。随着废弃物的处理对环境污染问题的日益加重，人们急需要找到可持续发展的制造技术，现在的研究工作主要集中在为干式机械加工的发展不断发展切削刀具，具体在改进制造技术及刀具几何参数的优化、发展适用的合金刀具和涂层刀具等方面。本文主要对两种涂层刀具(金刚石涂层、氮化碳涂层)进行研究，具体研究工作包括以下两部分：
1．金刚石涂层刀具的干式切削
金刚石薄膜涂层具有与天然金刚石相同的优异特性：高硬度，低擦系数，高耐磨和高导热性能；金刚石涂层刀具适用于车削，特别适用于现代高速干式切削加工，高速切削硅铝合金可提高生产率。本文通过用金刚石薄膜涂层刀具对硅铝合金进行干式切削，探讨其切削性能。试验结果表明，金刚石薄膜涂层刀具的磨损是由薄膜的显微断裂而逐渐脱落的过程；进给量是影响工件表面粗糙度的主要因素。在大量实验基础上，建立表面粗糙度的数学模型。
2．氮化碳涂层刀具的干式切削
氮化碳是一种新型超硬材料，在高硬度、耐磨损、低摩擦系数和导热性等方面与金刚石相似，同时没有金刚石的缺点，可以承受较高温度而不被氧化。生成氮化碳的C-N元素构成牢固的共价键，使其化学稳定性、耐氧化性方面与陶瓷材料SiN相似。将氮化碳涂层应用于金属切削刀具，可用来加工不锈钢、耐热合金钢、球墨铸铁、钛合金、高硅铝合金等难加工材料，可以大大提高刀具的耐用度和加工精度。本文采用dc反应磁控溅射法在硬质合金(YT15)上沉积氮化碳超硬涂层，其显微硬度Hv=72.04GPa，附着力达到JB／T8365-96标准的规定。将氮化碳涂层刀具应用于干切削领域，通过对淬火钢的干式切削试验，研究氮化碳涂层刀具的切削加工性能。在淬火钢加工中，刀具寿命较没有涂层的刀具有较大提高，效果明显，利用正交实验和回归分析建立刀具使用寿命的数学模型，为氮化碳涂层刀具的实际应用打下基础；通过对硅铝合金的干式切削，研究氮化碳涂层刀具的切削性能，试验表明，影响工件表面粗糙度的主要因素是进给量。
Today, many machining processes are conducted with cutting fluids, which are used for cooling the workpiece, the tool and the machine during cutting. Furthermore, the friction process is reduced and the created chips are removed from the cutting area. Unfortunately, coolants create high coats in production and can be hazardous to the environment and human health. Increasing environmental pollution and problems concerning waste disposal demand the development of ecological manufacturing technologies. Today's research activities are concentrated on improving the properties of cutting tools for dry machining by optimizing manufacturing technologies and tool geometries, by alloying of special cutting materials and by coating of tools. In this paper, two coating of tools(C3N4-film, diamond film)are studied, main study work include the following two parts:
1. The diamond film coating tools used in dry-cutting.
The diamond films coating has as high hardness, high wear resistance, low friction coefficient and high thermal conductivity as the natural diamond. The diamond films coated tools are used for turning, especially for modern high speed dry cutting, the productivity of cutting Si-Al alloy can be greatly improved by using cutter coated with diamond film in high speed dry cutting. In this paper, the dry-cutting tests were carried out by diamond film coated tool on Si-Al alloy and this tool s cutting properties were studied. The results indicate that the wearing process of diamond-film-coated cutter is from the micro-cracking of the film at the beginning to the gradual dropping in the end; The main effective factor of surface roughness is feed, the paper establishes the mathematical model of surface roughness through a large number of cutting experiments. 2. The C3N4 films coating tools used in dry-cutting.
C3N4 is a new kind of superhard material and has comparable properties with diamond in high hardness, wear-resistance, low friction coefficient and thermal conductivity. In this paper, the DC magnetic sputtered film method was used to deposit C3N4 film on cemented carbide (YT15), the micro-hardness Hv=72.04Gpa,adhersive force was qualified the standard of JB/T8365-96. This cutting tool was tested in dry-cutting area, and its cutting properties were studied to machine quenched steel. The cutting experiments show that in cutting of quenched steel the tool life of this cutter is longer than that of uncoated cutting tool. All of this indicates that this film has good cutting properties. The mathematical model of tool life of the cutting tool is established on the basis of orthotic
IK
2
experiments and regressing analysis, a number of dry-cutting tests were carried out
coated tool on Si-AI alloy, this tool' s cutting properties were studied, the results indicate that The
main effective factor of surface roughness is feed
1．金刚石涂层刀具的干式切削
金刚石薄膜涂层具有与天然金刚石相同的优异特性：高硬度，低擦系数，高耐磨和高导热性能；金刚石涂层刀具适用于车削，特别适用于现代高速干式切削加工，高速切削硅铝合金可提高生产率。本文通过用金刚石薄膜涂层刀具对硅铝合金进行干式切削，探讨其切削性能。试验结果表明，金刚石薄膜涂层刀具的磨损是由薄膜的显微断裂而逐渐脱落的过程；进给量是影响工件表面粗糙度的主要因素。在大量实验基础上，建立表面粗糙度的数学模型。
2．氮化碳涂层刀具的干式切削
氮化碳是一种新型超硬材料，在高硬度、耐磨损、低摩擦系数和导热性等方面与金刚石相似，同时没有金刚石的缺点，可以承受较高温度而不被氧化。生成氮化碳的C-N元素构成牢固的共价键，使其化学稳定性、耐氧化性方面与陶瓷材料SiN相似。将氮化碳涂层应用于金属切削刀具，可用来加工不锈钢、耐热合金钢、球墨铸铁、钛合金、高硅铝合金等难加工材料，可以大大提高刀具的耐用度和加工精度。本文采用dc反应磁控溅射法在硬质合金(YT15)上沉积氮化碳超硬涂层，其显微硬度Hv=72.04GPa，附着力达到JB／T8365-96标准的规定。将氮化碳涂层刀具应用于干切削领域，通过对淬火钢的干式切削试验，研究氮化碳涂层刀具的切削加工性能。在淬火钢加工中，刀具寿命较没有涂层的刀具有较大提高，效果明显，利用正交实验和回归分析建立刀具使用寿命的数学模型，为氮化碳涂层刀具的实际应用打下基础；通过对硅铝合金的干式切削，研究氮化碳涂层刀具的切削性能，试验表明，影响工件表面粗糙度的主要因素是进给量。
Today, many machining processes are conducted with cutting fluids, which are used for cooling the workpiece, the tool and the machine during cutting. Furthermore, the friction process is reduced and the created chips are removed from the cutting area. Unfortunately, coolants create high coats in production and can be hazardous to the environment and human health. Increasing environmental pollution and problems concerning waste disposal demand the development of ecological manufacturing technologies. Today's research activities are concentrated on improving the properties of cutting tools for dry machining by optimizing manufacturing technologies and tool geometries, by alloying of special cutting materials and by coating of tools. In this paper, two coating of tools(C3N4-film, diamond film)are studied, main study work include the following two parts:
1. The diamond film coating tools used in dry-cutting.
The diamond films coating has as high hardness, high wear resistance, low friction coefficient and high thermal conductivity as the natural diamond. The diamond films coated tools are used for turning, especially for modern high speed dry cutting, the productivity of cutting Si-Al alloy can be greatly improved by using cutter coated with diamond film in high speed dry cutting. In this paper, the dry-cutting tests were carried out by diamond film coated tool on Si-Al alloy and this tool s cutting properties were studied. The results indicate that the wearing process of diamond-film-coated cutter is from the micro-cracking of the film at the beginning to the gradual dropping in the end; The main effective factor of surface roughness is feed, the paper establishes the mathematical model of surface roughness through a large number of cutting experiments. 2. The C3N4 films coating tools used in dry-cutting.
C3N4 is a new kind of superhard material and has comparable properties with diamond in high hardness, wear-resistance, low friction coefficient and thermal conductivity. In this paper, the DC magnetic sputtered film method was used to deposit C3N4 film on cemented carbide (YT15), the micro-hardness Hv=72.04Gpa,adhersive force was qualified the standard of JB/T8365-96. This cutting tool was tested in dry-cutting area, and its cutting properties were studied to machine quenched steel. The cutting experiments show that in cutting of quenched steel the tool life of this cutter is longer than that of uncoated cutting tool. All of this indicates that this film has good cutting properties. The mathematical model of tool life of the cutting tool is established on the basis of orthotic
IK
2
experiments and regressing analysis, a number of dry-cutting tests were carried out
coated tool on Si-AI alloy, this tool' s cutting properties were studied, the results indicate that The
main effective factor of surface roughness is feed
引文
[1] 北京市《金属切削理论与实践》编委会：金属切削理论与实践(上册)，北京，北京出版社，1980
[2] 太原市金属切削刀具协会：金属切削实用刀具技术，北京，机械工业出版社，2002
[3] 潭美田，金属切削微观研究，上海科学技术出版社，1988
[4] 刘光复，刘志峰 绿色制造，中国科学文化出版社，2002．8
[5] 肖诗纲，现代刀具材料，重庆大学出版社，1992．2
[6] 方啸虎，超硬材料科学与技术 北京：中国建材工业出版社 1998
[7] 冯士光 新兴超硬材料-立方氮化硼及其刀具的应用 成都：四川科学技术出版社：2
[5] H.Pastor.Present status and Development of tool Masterials: Part 1. Cutting Tools. Int.J.Refr.Metals & Hard Mater., 1987; 6(4): 196-209
[9] 金卓仁 陶瓷刀具的性能及应用 机械工程材料 1991；6：1-6
[10] 超精密加工及微细加工技术机械工程师进修大学教材 1987
[11] K.T nshoff, B.Karpuschewski, Performance of oxygen-rich TiAION Coating in dry Cuting applications, Surface and Coatings Technology, 108-109(1998)535-542
[12] 俞世吉 邬钦崇 张志明等 WC-Co硬质合金表面MW—-PCVD制备金刚石薄膜去钻预处理的研究 高技术通讯 1998；4：35-38
[13] 陈明 张志明等 CVD金刚石薄膜涂层刀具研究及其应用 中国高校金属切削研究会华东分会97年会学术论文
[14] 王和照 朱万玉 张庆远 金刚石薄膜涂层刀具切削性能研究 微细加工技术 1997；3：70-74
[15] 彭友贵 黎明锴 范湘军等 氮化碳刀具在硬质面加工中的应用 中国机械工程第11卷 2000．10；1187-1189
[16] 吴大维 刘传胜 高鹏等 氮化碳超硬涂层材料在高速钢刀具上的应用 工具技术2000年第34卷增刊；8-10
[17] K Kanda, S Takehana, S Toshida, Application of diamond-coated cutting tools, surface and coating Technology, 1995, 73: 115-120
[18] Wanf Lijiang, A study on ultraprecision turning using PCD cutting tool, Proceedings of CIRP conf. On page & Ms, 1991(q)
[19] ASAI S, Observation of chip producing behavior in ultra-precision diamond machining and study on mirror-like surface generating mechanism [J]. precision Engineering, 1990, 12(3): 137-143
[20] 唐艳芹，PCD刀具超精切削表面质量的研究，工具技术，2000．1
[21] 张雷：精密超精密切削时PCD刀具后刀面的错位熨压作用，工具技术，成都，工具技术杂志社，2000．1
[22] 王大镇：SiC增强铝基复合材料切削加工中刀—屑摩擦模型及其磨损性能研究，摩擦学学报，北京，摩擦学学报杂志社，2000．2
[23] 王立江：用多点金刚石刀具进行镜面车削的研究，自然科学进展，1992．2
[24] 王立江：用PCD刀具精密超精密切削时表面粗糙度的实验研究，汽车工艺与材料，1997．9
[25] 王洪祥：金刚石车削表面微观形貌形成机理的研究，哈尔滨，哈尔滨工业大学学报，2002．4
[26] Toshimich Moriwaki, Koichi Okuda, Machinability of copper in ultra-precision micro diamond cutting, Annals of the CIPP, 1988, 37(1): 115-118
[27] T Nishiguchi, Mechanism of micro chip formation in diamond turning of Al-Mgally, annals of the CIPP, 1986, 37(1)117-120
[28] 温诗铸：纳米摩擦学，北京．清华大学出版社，2002
[29] 陶乾．金属切削原理，中国工业出版社，1965
[30] GB／T1173-1995铸造铝合金，中国标准出版社，1996
[31] 陈日曜，金属切削原理，机械工业出版社，1990
[32] 程正兴，数据拟合，西安交通大学出版社，1985
[33] 白新桂，数据分析和试验优化设计，清华大学出版社，1986
[34] 袁哲俊，金屆切削实验技术，机械出版社，1988
[35] 李湘鸣，SPSS软件应用指导，东南大学出版社，2000
[36] 马斌荣，SPSS for windows在医学统计中的应用，科学出版社，2003
[37] 华南工学院等，金属切削原理及刀具设计，上海科技出版社，1993
[2] 太原市金属切削刀具协会：金属切削实用刀具技术，北京，机械工业出版社，2002
[3] 潭美田，金属切削微观研究，上海科学技术出版社，1988
[4] 刘光复，刘志峰 绿色制造，中国科学文化出版社，2002．8
[5] 肖诗纲，现代刀具材料，重庆大学出版社，1992．2
[6] 方啸虎，超硬材料科学与技术 北京：中国建材工业出版社 1998
[7] 冯士光 新兴超硬材料-立方氮化硼及其刀具的应用 成都：四川科学技术出版社：2
[5] H.Pastor.Present status and Development of tool Masterials: Part 1. Cutting Tools. Int.J.Refr.Metals & Hard Mater., 1987; 6(4): 196-209
[9] 金卓仁 陶瓷刀具的性能及应用 机械工程材料 1991；6：1-6
[10] 超精密加工及微细加工技术机械工程师进修大学教材 1987
[11] K.T nshoff, B.Karpuschewski, Performance of oxygen-rich TiAION Coating in dry Cuting applications, Surface and Coatings Technology, 108-109(1998)535-542
[12] 俞世吉 邬钦崇 张志明等 WC-Co硬质合金表面MW—-PCVD制备金刚石薄膜去钻预处理的研究 高技术通讯 1998；4：35-38
[13] 陈明 张志明等 CVD金刚石薄膜涂层刀具研究及其应用 中国高校金属切削研究会华东分会97年会学术论文
[14] 王和照 朱万玉 张庆远 金刚石薄膜涂层刀具切削性能研究 微细加工技术 1997；3：70-74
[15] 彭友贵 黎明锴 范湘军等 氮化碳刀具在硬质面加工中的应用 中国机械工程第11卷 2000．10；1187-1189
[16] 吴大维 刘传胜 高鹏等 氮化碳超硬涂层材料在高速钢刀具上的应用 工具技术2000年第34卷增刊；8-10
[17] K Kanda, S Takehana, S Toshida, Application of diamond-coated cutting tools, surface and coating Technology, 1995, 73: 115-120
[18] Wanf Lijiang, A study on ultraprecision turning using PCD cutting tool, Proceedings of CIRP conf. On page & Ms, 1991(q)
[19] ASAI S, Observation of chip producing behavior in ultra-precision diamond machining and study on mirror-like surface generating mechanism [J]. precision Engineering, 1990, 12(3): 137-143
[20] 唐艳芹，PCD刀具超精切削表面质量的研究，工具技术，2000．1
[21] 张雷：精密超精密切削时PCD刀具后刀面的错位熨压作用，工具技术，成都，工具技术杂志社，2000．1
[22] 王大镇：SiC增强铝基复合材料切削加工中刀—屑摩擦模型及其磨损性能研究，摩擦学学报，北京，摩擦学学报杂志社，2000．2
[23] 王立江：用多点金刚石刀具进行镜面车削的研究，自然科学进展，1992．2
[24] 王立江：用PCD刀具精密超精密切削时表面粗糙度的实验研究，汽车工艺与材料，1997．9
[25] 王洪祥：金刚石车削表面微观形貌形成机理的研究，哈尔滨，哈尔滨工业大学学报，2002．4
[26] Toshimich Moriwaki, Koichi Okuda, Machinability of copper in ultra-precision micro diamond cutting, Annals of the CIPP, 1988, 37(1): 115-118
[27] T Nishiguchi, Mechanism of micro chip formation in diamond turning of Al-Mgally, annals of the CIPP, 1986, 37(1)117-120
[28] 温诗铸：纳米摩擦学，北京．清华大学出版社，2002
[29] 陶乾．金属切削原理，中国工业出版社，1965
[30] GB／T1173-1995铸造铝合金，中国标准出版社，1996
[31] 陈日曜，金属切削原理，机械工业出版社，1990
[32] 程正兴，数据拟合，西安交通大学出版社，1985
[33] 白新桂，数据分析和试验优化设计，清华大学出版社，1986
[34] 袁哲俊，金屆切削实验技术，机械出版社，1988
[35] 李湘鸣，SPSS软件应用指导，东南大学出版社，2000
[36] 马斌荣，SPSS for windows在医学统计中的应用，科学出版社，2003
[37] 华南工学院等，金属切削原理及刀具设计，上海科技出版社，1993