JP5283017B2 - Diamond sintered compact tool for ultra-precision cutting - Google Patents
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Description
本発明は、ダイヤモンドを主成分とした焼結体を基材とする超精密切削加工用ダイヤモンド焼結体工具に関する。 The present invention relates to a diamond sintered body tool for ultra-precise cutting using a sintered body mainly composed of diamond as a base material.
従来、アルミ合金等、軟質金属の超精密加工に単結晶ダイヤモンド工具が用いられている。しかし、大きなサイズの単結晶ダイヤモンドが高価であることから、単結晶ダイヤモンド工具は製造コストが高いという問題点がある。また、ダイヤモンド粉末をCo等の結合材により焼結した多結晶ダイヤモンド焼結体は、単結晶ダイヤモンド工具よりも安価であるが、多結晶体であるがゆえに超精密加工で要求されるRzで0.5μm以下の面粗度は得られず、被削材の表面にも筋が発生するという問題もある。 Conventionally, single crystal diamond tools have been used for ultra-precision machining of soft metals such as aluminum alloys. However, since a large size single crystal diamond is expensive, the single crystal diamond tool has a problem of high manufacturing cost. In addition, a polycrystalline diamond sintered body obtained by sintering diamond powder with a binding material such as Co is less expensive than a single crystal diamond tool, but because it is a polycrystalline body, Rz required for ultraprecision machining is 0. There is also a problem that a surface roughness of 0.5 μm or less cannot be obtained, and streaks are generated on the surface of the work material.
そこで、本発明は、上記問題点に鑑みて、耐摩耗性に優れ、被削材の面粗度の改善が可能なダイヤモンド焼結体工具を安価に提供することを課題とする。また、該ダイヤモンド焼結体工具を提供することにより、超精密切削加工を可能とすることを課題とする。 In view of the above problems, an object of the present invention is to provide a diamond sintered body tool that is excellent in wear resistance and can improve the surface roughness of a work material at a low cost. Another object of the present invention is to enable ultra-precision cutting by providing the diamond sintered body tool.
被削材を切削加工する場合、図3に示すように、横切れ刃境界部で被削材が大きく切り取られ、前切れ刃境界部により仕上げ面の形成が行われる。このため、被削材表面には前切れ刃境界部の形状が転写されることとなる。したがって、前切れ刃境界部の摩耗が進行して前切れ刃の表面粗さが悪くなると、被削材表面も粗くなり仕上がり状態が悪くなる。また、被削材表面に筋が発生し始めると境界摩耗が更に発達して前切れ刃境界部に溝が形成され、上記問題が一層顕著となり、短時間で加工表面粗さが悪化してしまう(図4参照)。 When cutting a work material, as shown in FIG. 3, the work material is largely cut off at the lateral cutting edge boundary portion, and a finished surface is formed by the front cutting edge boundary portion. For this reason, the shape of the front cutting edge boundary portion is transferred to the surface of the work material. Therefore, if the wear of the front cutting edge boundary progresses and the surface roughness of the front cutting edge deteriorates, the surface of the work material also becomes rough and the finished state deteriorates. In addition, when the streak begins to occur on the surface of the work material, boundary wear further develops and grooves are formed at the front cutting edge boundary, and the above problem becomes more prominent, and the machining surface roughness deteriorates in a short time. (See FIG. 4).
本発明者等は、工具刃先の前切れ刃境界部の摩耗が、なるべく平滑に進行するようにすることができれば、被削材の面粗さが悪化しにくく、長寿命で高精度加工が行えることを見出した。すなわち、少なくとも、切れ刃の切削時における前境界部分を、ダイヤモンド単結晶体にすることが有効であることを見出し、本発明を完成させた。なお、「平滑に摩耗する」とは、前切れ刃境界部の摩耗が抑制され、段差や溝(筋)の形成が押さえられて滑らかになる状態のことをいう。 If the wear of the front cutting edge boundary part of the tool edge can proceed as smoothly as possible, the present inventors can prevent the surface roughness of the work material from being deteriorated, and can perform high-precision machining with a long life. I found out. That is, it has been found that it is effective to make at least the front boundary portion at the time of cutting of the cutting edge a diamond single crystal, and the present invention has been completed. “Smoothly wear” refers to a state in which wear at the front cutting edge boundary portion is suppressed and formation of a step or a groove (streak) is suppressed to make it smooth.
本発明は以下の特徴を有する。
(1)本発明に係る超精密切削加工用ダイヤモンド焼結体工具は、ダイヤモンド粒子を含有する焼結体を切れ刃部分とする焼結体工具であって、該焼結体のダイヤモンド含有率が70−98体積%であり、被削材と接触する切れ刃部分において、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%が、送りと反対方向の切れ刃は切り込み量のy%がダイヤモンド単結晶体で形成され、xが10以上、80以下であり、yが10以上、80以下であり、かつ、残部の切れ刃部分がダイヤモンド多結晶体で形成されていることを特徴とする(図1)。
(2)上記(1)に記載のダイヤモンド焼結体工具であって、前記焼結体の結合相が少なくとも鉄族金属を有することを特徴とする。
(3)上記(2)に記載のダイヤモンド焼結体工具であって、前記鉄族金属として、Fe、Co、Ni、のいずれかを有することを特徴とする。
The present invention has the following features.
(1) A diamond sintered body tool for ultra-precise cutting according to the present invention is a sintered body tool having a sintered body containing diamond particles as a cutting edge part, and the diamond content of the sintered body is The cutting edge in the feed direction is 70% to 98% by volume, and the cutting edge in the feed direction is x% of the cutting edge in the feed direction, and the cutting amount in the direction opposite to the feed is from the point where the cutting becomes maximum at the cutting edge portion in contact with the work material. Y% is formed of a diamond single crystal, x is 10 or more and 80 or less, y is 10 or more and 80 or less , and the remaining cutting edge portion is formed of a diamond polycrystal. (Fig. 1).
(2) The diamond sintered body tool according to (1), wherein a binder phase of the sintered body includes at least an iron group metal.
(3) The diamond sintered body tool according to (2), wherein the iron group metal has any one of Fe, Co, and Ni.
(4)上記(1)〜(3)のいずれか一に記載のダイヤモンド焼結体工具であって、被削材と接触する切れ刃のうち、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%(10≦x)が、送りと反対方向の切れ刃は切り込み量のy%(10≦y)の切れ刃部分が、粒子径が100μm以上のダイヤモンド粒子からなることを特徴とする。
(5)上記(1)〜(3)のいずれか一に記載のダイヤモンド焼結体工具であって、被削材と接触する切れ刃のうち、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%(10≦x)が、送りと反対方向の切れ刃は切り込み量のy%(10≦y)の切れ刃部分が、粒子径が200μm以上のダイヤモンド粒子からなることを特徴とする。
(4) The diamond sintered body tool according to any one of the above (1) to (3), wherein the cutting in the feeding direction is cut from the point where the cutting becomes maximum among the cutting blades in contact with the work material. The cutting edge of the blade is x% (10 ≦ x), and the cutting edge in the direction opposite to the feed is y% (10 ≦ y) of the cutting amount is made of diamond particles having a particle diameter of 100 μm or more. Features.
(5) The diamond sintered body tool according to any one of the above (1) to (3), wherein the cutting in the feed direction is determined from the point where the cutting becomes maximum among the cutting blades in contact with the work material. The cutting edge of the blade is x% (10 ≦ x), and the cutting edge in the direction opposite to the feed is y% (10 ≦ y) of the cutting amount is made of diamond particles having a particle diameter of 200 μm or more. Features.
従来のダイヤモンド焼結体切削工具には様々なダイヤモンド粒径の焼結体が用いられているが、ダイヤモンド粒子の粒径が連続的に分布しており、かつ、切れ刃のダイヤモンド粒子の粒度分布が焼結体全体のダイヤモンド粒度分布に近い状態となっているため、切れ刃の任意の部分の機能は等しいものとなっている。このため、上述したような切れ刃の各部分の要求特性に対する最適な材料設計とはならず、性能に限度がある。
これに対し、本発明に係るダイヤモンド焼結体工具は上記のように、切れ刃の各部位の要求特性を満足する工具となっている。
Sintered bodies with various diamond particle sizes are used in conventional diamond sintered body cutting tools, but the diamond particle size is distributed continuously and the particle size distribution of the diamond particles at the cutting edge However, since it is in a state close to the diamond particle size distribution of the entire sintered body, the functions of arbitrary portions of the cutting edge are equal. For this reason, it does not become the optimal material design with respect to the required characteristic of each part of a cutting edge as mentioned above, and there exists a limit in performance.
In contrast, the diamond sintered body tool according to the present invention is a tool that satisfies the required characteristics of each part of the cutting edge as described above.
本発明に係る超精密切削加工用ダイヤモンド焼結体工具は、切削時における前切れ刃境界部となる部分を含む前切れ刃が、ダイヤモンド単結晶体により形成されているため、被削材表面の面粗度の悪化や、筋の発生を抑制することができる。更に、単結晶ダイヤモンド工具よりも安価に切削工具を提供することができる。 In the diamond sintered compact tool for ultra-precise cutting according to the present invention, the front cutting edge including a portion that becomes a front cutting edge boundary portion at the time of cutting is formed of a diamond single crystal, so that the surface of the work material is Deterioration of surface roughness and generation of streaks can be suppressed. Furthermore, a cutting tool can be provided at a lower cost than a single crystal diamond tool.
本発明に係る超精密切削加工用ダイヤモンド焼結体工具は、切削時に前切れ刃境界部となる部分を含む前切れ刃が、ダイヤモンド単結晶体により構成されていることを特徴とする。具体的には、被削材と接触する切れ刃部分において、少なくとも、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%(x≧10)が、送りと反対方向の切れ刃は切り込み量のy%(y≧10)がダイヤモンド単結晶体により構成されていることが好ましい(図1参照)。これにより前切れ刃境界部がダイヤモンド単結晶体により形成されることとなるため、ダイヤモンド多結晶体で切削した場合のような被削材表面の面粗度の悪化、筋の発生が抑制される。すなわち、前切れ刃境界部付近の刃先摩耗が凹凸なく平滑に進行し、被削材表面の面粗度が良好なものとなる。また、耐摩耗性にも優れた前切れ刃となるため、工具寿命も長くなる。 The diamond sintered compact tool for ultra-precise machining according to the present invention is characterized in that the front cutting edge including a portion that becomes a front cutting edge boundary portion at the time of cutting is composed of a diamond single crystal. Specifically, the cutting edge in the feed direction has a cutting edge in the opposite direction to the feed, since the cutting edge in the feeding direction has a maximum cutting depth at the cutting edge portion in contact with the work material. It is preferable that y% (y ≧ 10) of the cutting depth is constituted by a diamond single crystal (see FIG. 1). As a result, the front cutting edge boundary portion is formed by the diamond single crystal body, so that deterioration of the surface roughness of the work material surface and generation of streaks, as in the case of cutting with a diamond polycrystal body, are suppressed. . That is, the cutting edge wear near the front cutting edge boundary portion proceeds smoothly without unevenness, and the surface roughness of the work material surface becomes good. In addition, since the front cutting edge has excellent wear resistance, the tool life is extended.
一方、横切れ刃境界部分は、被削材を大きく切り取る部分であり、特に仕上げ面の面粗度に影響を与えることはない。このため、前記切り込み量が最大となる点から送り方向の切れ刃は切り込み量のx%(x≧10)、送りと反対方向の切れ刃は切り込み量のy%(y≧10)を超える部分をダイヤモンド多結晶体により形成すれば、ダイヤモンド単結晶体のみから工具を作製する場合に比べて低コストで提供することが可能となる。xとyは各々80を超えると、刃先の研磨コストが高くなるため、80以下が好ましい。 On the other hand, the horizontal cutting edge boundary portion is a portion where the work material is largely cut, and does not particularly affect the surface roughness of the finished surface. For this reason, the cutting edge in the feed direction from the point at which the cutting amount is maximized is x% (x ≧ 10) of the cutting amount, and the cutting edge in the direction opposite to the feeding is a portion exceeding y% (y ≧ 10) of the cutting amount. Can be provided at a lower cost than the case where a tool is produced from only a diamond single crystal. When x and y each exceed 80, the polishing cost of the cutting edge becomes high, so 80 or less is preferable.
このような切削工具を作製するためには、粗粒のダイヤモンド単結晶体と微粒のダイヤモンド単結晶体とを有するダイヤモンド焼結体から、前切れ刃部分がダイヤモンド単結晶体により、横切れ刃部分がダイヤモンド多結晶体により構成されるように切り出せばよい(図2参照)。このとき、切削時に被削材に接触する切れ刃のうち切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%(x≧10)が、送りと反対方向の切れ刃は切り込み量のy%(y≧10)が、粒子径が100μm以上のダイヤモンド粒子により構成されることが好ましい。該ダイヤモンド単結晶体の粒子径は、200μm以上であることがより好ましい。 In order to produce such a cutting tool, a diamond sintered body having a coarse-grained diamond single crystal body and a fine-grained diamond single crystal body is used. What is necessary is just to cut out so that it may be comprised with a diamond polycrystal (refer FIG. 2). At this time, the cutting edge in the feed direction has a cutting depth of x% (x ≧ 10), while the cutting edge in the opposite direction to the feed has a cutting depth, since the cutting depth of the cutting edge that comes into contact with the work material during cutting is maximum. The amount of y% (y ≧ 10) is preferably composed of diamond particles having a particle diameter of 100 μm or more. The particle size of the diamond single crystal is more preferably 200 μm or more.
上記ダイヤモンド焼結体は、ダイヤモンド含有率が70−98体積%であることを特徴とする。ダイヤモンドの含有率がこれらの範囲にあることにより、焼結体の強度と耐摩耗性を両立させることが可能となる。より好ましいダイヤモンド含有率の範囲は、80〜95体積%である。 The diamond sintered body has a diamond content of 70 to 98% by volume. When the content of diamond is within these ranges, it is possible to achieve both the strength and wear resistance of the sintered body. A more preferable range of the diamond content is 80 to 95% by volume.
更に、焼結体の結合相が、少なくとも鉄族金属を有することを特徴とする。該鉄族金属としては、Fe、Co、Niから選ばれるいずれか1種以上を有することが好ましい。これらの結合材成分により、ダイヤモンド焼結体の耐摩耗性及び強度を向上させることができる。当然、これらの成分以外にも不可避的に不純物が含まれていても構わない。 Furthermore, the binder phase of the sintered body has at least an iron group metal. The iron group metal preferably has at least one selected from Fe, Co, and Ni. With these binder components, the wear resistance and strength of the diamond sintered body can be improved. Of course, impurities other than these components may inevitably be contained.
被削材がアルミ合金や無酸素銅等である場合に、超精密切削加工を行うには、一般的に、切り込み量は0.01〜0.15mm、送り量は0.001〜0.2mm/revの条件で行われる。このような場合、摩耗の進展により刃先が後退するため、前記ダイヤモンド焼結体工具のノーズ先端部分から送り方向の切れ刃は切り込み量のx%が、送りと反対方向の切れ刃は切り込み量のy%がダイヤモンド単結晶体で形成され、x、yが10以上であることが望ましい。これにより、前切れ刃境界部分が、ダイヤモンド単結晶体で構成され、横切れ刃境界部分はダイヤモンド多結晶体で構成されることとなる。 When the work material is an aluminum alloy, oxygen-free copper or the like, in order to perform ultra-precise cutting, in general, the cut amount is 0.01 to 0.15 mm, and the feed amount is 0.001 to 0.2 mm. This is performed under the condition of / rev. In such a case, since the cutting edge moves backward due to the progress of wear, the cutting edge in the feed direction from the nose tip of the diamond sintered body tool has x% of the cutting amount, and the cutting edge in the direction opposite to the feeding has the cutting amount. It is desirable that y% is formed of a diamond single crystal, and x and y are 10 or more. As a result, the front cutting edge boundary portion is composed of a diamond single crystal, and the lateral cutting edge boundary portion is composed of a diamond polycrystal.
超硬合金製のポット及びボールを用いて、平均粒径200μmのダイヤモンド粒子と平均粒径2μmのダイヤモンド粒子及びCo、WC等の結合材材料を混合してから熱処理を施し、この粉末をCo板と共にMo製容器に充填し、圧力5.5GPa、温度1,450℃で20分焼結し、ダイヤモンド含有率が90%のダイヤモンド焼結体を得た。 Using cemented carbide pots and balls, diamond particles with an average particle diameter of 200 μm, diamond particles with an average particle diameter of 2 μm, and binder materials such as Co, WC, etc. are mixed and heat treated. At the same time, it was filled in a Mo container and sintered at a pressure of 5.5 GPa and a temperature of 1,450 ° C. for 20 minutes to obtain a diamond sintered body having a diamond content of 90%.
この焼結体を切断し、基材として超硬合金製の台金にロー材を用いて接合した後、研磨加工を実施し、切削加工用ダイヤモンド焼結体工具(TPGN110304)を作製した。このとき、工具の前切れ刃境界部に粗粒のダイヤモンド単結晶体が配置され、被削材と接触する切れ刃部分において、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%が、送りと反対方向の切れ刃は切り込み量のy%がダイヤモンド単結晶体で形成され、x、yが表1に記載された値となり、被削材と接触する他の切れ刃部分がダイヤモンド多結晶体で形成されるように焼結体中の粗粒ダイヤモンド単結晶粒子の位置を確認した後、切断、接合、研磨を実施した。 The sintered body was cut and bonded to a base metal made of cemented carbide using a brazing material as a base material, and then subjected to polishing to produce a diamond sintered body tool for cutting (TPGN110304). At this time, a coarse diamond single crystal body is arranged at the front cutting edge boundary portion of the tool, and the cutting edge in the feed direction has a cutting amount from the point where the cutting becomes the maximum at the cutting edge portion in contact with the work material. The cutting edge in the direction opposite to the feed direction with x% is formed by a single crystal of y% of the cutting amount, and x and y are the values described in Table 1, and other cutting edge portions that come into contact with the work material After confirming the position of the coarse-grained diamond single crystal particles in the sintered body so as to be formed of a polycrystalline diamond, cutting, bonding, and polishing were performed.
この切削加工用ダイヤモンド焼結体工具を用いて、被削材として無酸素銅を用い、切削速度500m/min、切り込み0.08mm、送り量0.02mm/rev、wetの条件で、工具前切れ刃を形成する粗粒ダイヤモンド単結晶体が切削時に被削材に接触する切れ刃のうち、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%、送りと反対方向の切れ刃は切り込み量のy%としたときに表1に記載の条件となるように設定し、切削試験を実施したところ、寿命判定基準をRzで0.5μmとして、表1に記載の工具寿命が得られた。 Using this diamond sintered body tool for cutting, oxygen-free copper is used as the work material, cutting speed is 500m / min, cutting is 0.08mm, feed amount is 0.02mm / rev, and wet before cutting. Of the cutting edges where the coarse diamond single crystal forming the blade contacts the work material during cutting, the cutting edge in the feed direction is x% of the cut amount, and the cutting direction is opposite to the feed direction. The blade was set to satisfy the conditions shown in Table 1 when the cutting depth was set to y%, and a cutting test was conducted. The tool life shown in Table 1 was determined with a life criterion of 0.5 μm Rz. Obtained.
超硬合金製のポット及びボールを用いて、ダイヤモンド粒子とCo、WC等の結合材材料を混合してから熱処理を施し、この粉末をCo板と共にMo製容器に充填し、圧力5.4GPa、温度1,430℃で20分焼結し、表2に記載のダイヤモンド焼結体を得た。 Using cemented carbide pots and balls, diamond particles and binder materials such as Co and WC are mixed and then heat treated, and this powder is filled into a Mo container together with a Co plate, with a pressure of 5.4 GPa, Sintering was performed at a temperature of 1,430 ° C. for 20 minutes to obtain a diamond sintered body shown in Table 2.
この焼結体を切断し、基材として超硬合金製の台金にロー材を用いて接合した後、研磨加工を実施し、切削加工用ダイヤモンド焼結体工具(TPGN110308)を作製した。このとき、工具の前切れ刃境界部に粗粒のダイヤモンド単結晶体が配置され、被削材と接触する切れ刃部分において、切込みが最大となる点から、送り方向の切れ刃は切り込み量の30%が、送りと反対方向の切れ刃は切り込み量の40%がダイヤモンド単結晶体で形成され、被削材と接触する他の切れ刃部分がダイヤモンド多結晶体で形成されるように焼結体中の粗粒ダイヤモンド単結晶粒子の位置を確認した後、切断、接合、研磨を実施した。 This sintered body was cut and bonded to a base metal made of cemented carbide using a brazing material as a base material, and then subjected to polishing to produce a diamond sintered body tool for cutting (TPGN110308). At this time, a coarse diamond single crystal body is arranged at the front cutting edge boundary portion of the tool, and the cutting edge in the feed direction has a cutting amount from the point where the cutting becomes the maximum at the cutting edge portion in contact with the work material. 30% of the cutting edge in the direction opposite to the feed is sintered so that 40% of the cutting depth is formed of a diamond single crystal, and the other cutting edge portion in contact with the work material is formed of a polycrystalline diamond. After confirming the position of the coarse diamond single crystal particles in the body, cutting, joining and polishing were performed.
この切削加工用ダイヤモンド焼結体工具を用いて、被削材としてアルミ合金(ADC12)を用い、表3に記載の条件で切削試験を実施したところ、寿命判定基準をRzで0.5μmとして、表3に記載の工具寿命が得られた。 Using this diamond sintered tool for cutting, an aluminum alloy (ADC12) was used as a work material, and a cutting test was carried out under the conditions shown in Table 3, the life criterion was 0.5 μm in Rz, The tool life shown in Table 3 was obtained.
Claims (5)
該焼結体のダイヤモンド含有率が70−98体積%であり、
被削材と接触する切れ刃部分において、切込みが最大となる点から、送り方向の切れ刃は切り込み量のx%が、送りと反対方向の切れ刃は切り込み量のy%がダイヤモンド単結晶体で形成され、
xが10以上、80以下であり、
yが10以上、80以下であり、
かつ、残りの切れ刃部分がダイヤモンド多結晶体で形成されている
ことを特徴とする超精密切削加工用ダイヤモンド焼結体工具。 A diamond sintered body tool for ultra-precise cutting with a sintered body containing diamond particles as a cutting edge part,
The diamond content of the sintered body is 70-98% by volume,
From the point of maximum cutting at the cutting edge part in contact with the work material, the cutting edge in the feed direction is x% of the cutting amount, and the cutting edge in the direction opposite to the feeding is y% of the cutting amount. Formed with
x is 10 or more and 80 or less ,
y is 10 or more and 80 or less ,
A diamond sintered body tool for ultraprecision cutting, wherein the remaining cutting edge portion is formed of a polycrystalline diamond.
粒子径が100μm以上のダイヤモンド粒子により構成されていることを特徴とする請求項1〜3のいずれか一に記載の超精密切削加工用ダイヤモンド焼結体工具。 Of the cutting edges that come into contact with the work material, the cutting edge in the feed direction is x% (10 ≦ x) of the cutting amount, and the cutting edge in the direction opposite to the feeding is y% of the cutting amount from the point of maximum cutting. The cutting edge part of (10 ≦ y) is
The diamond sintered compact tool for ultraprecision cutting according to any one of claims 1 to 3, wherein the diamond sintered body tool is constituted by diamond particles having a particle diameter of 100 µm or more.
粒子径が200μm以上のダイヤモンド粒子により構成されていることを特徴とする請求項1〜3のいずれか一に記載の超精密切削加工用ダイヤモンド焼結体工具。 Of the cutting edges that come into contact with the work material, the cutting edge in the feed direction is x% (10 ≦ x) of the cutting amount, and the cutting edge in the direction opposite to the feeding is y% of the cutting amount from the point of maximum cutting. The cutting edge part of (10 ≦ y) is
The diamond sintered compact tool for ultraprecision cutting according to any one of claims 1 to 3, wherein the diamond sintered body tool is constituted by diamond particles having a particle diameter of 200 µm or more.
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