LARSSON TOMMY (SE)
ALM OSCAR (SE)
ANDERSSON JON (SE)
JOHANSSON MATS (SE)
LARSSON TOMMY (SE)
ALM OSCAR (SE)
ANDERSSON JON (SE)
| US3967035A | 1976-06-29 | |||
| US3836392A | 1974-09-17 | |||
| US3837896A | 1974-09-24 | |||
| US4619866A | 1986-10-28 | |||
| US5968595A | 1999-10-19 | |||
| US5162147A | 1992-11-10 | |||
| US5700569A | 1997-12-23 | |||
| US6015614A | 2000-01-18 | |||
| US6632514B1 | 2003-10-14 | |||
| US7470296B2 | 2008-12-30 | |||
| US6855413B2 | 2005-02-15 | |||
| US6572991B1 | 2003-06-03 | |||
| US6689450B2 | 2004-02-10 | |||
| US7094447B2 | 2006-08-22 | |||
| US7442431B2 | 2008-10-28 | |||
| US7455900B2 | 2008-11-25 | |||
| US7442432B2 | 2008-10-28 | |||
| US20070104945A1 | 2007-05-10 | |||
| US20080187774A1 | 2008-08-07 | |||
| US6333103B1 | 2001-12-25 | |||
| US5654035A | 1997-08-05 | |||
| US5766782A | 1998-06-16 | |||
| US7011867B2 | 2006-03-14 | |||
| US5980988A | 1999-11-09 | |||
| US5702808A | 1997-12-30 | |||
| USRE41111E | 2010-02-09 |
| Cutting tool insert for machining by chip removal comprising a body of a hard alloy of cemented carbide, cermet, ceramics or cubic boron nitride based material onto which a hard and wear resistant coating is deposited by CVD comprising at least one OC-AI2O3 layer characterised in that said layer with a thickness between 0.5 μιη and 30 μιη, preferably between 0.5 μιη and 20 μηι, having an ODF texture index >1, and at least two dominant texture components with 2 < ODF density < 100 coexisting within the layer. Cutting tool insert according to claim Icharacterisedin that 1 < ODF texture index < 50. Cutting tool insert according to claim Icharacterisedin that 1 < ODF texture index < 10. Cutting tool insert according to any of the preceding claims characterised in that 2 < ODF density < 50. Cutting tool insert according to any of the claims lto3characterised in that 3 < ODF density < 25. Cutting tool insert according to any of the preceding claims characterised in that said layer is fibre textured. Cutting tool insert according to any of the preceding claims characterised in that said layer has a columnar grain structure with an average column width between 0.1 μιη and 5 μιη, preferably between 0.1 μιη Cutting tool insert according to any of the preceding claims characterised in that said layer has a surface roughness Ra < 1.0 μιη, preferably between 0.2 μιη and 0.5 μιη. Cutting tool insert according to any of the preceding claims characterised in that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°. 10. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°. 11. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100° Cutting tool insert according to any of claims ItoScharacterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ2 < 75°, preferably 50° < φ2 < 70°, and/or - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ2 < 120°, preferably 110° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ2 < 75°, preferably 50° < φ2 < 70°, and/or - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ2 < 120°, preferably 110° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ2 < 75°, preferably 50° < φ2 < 70°, and/or - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ2 < 120°, preferably 110° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ2 < 75°, preferably 50° < φ2 < 70°, and/or - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ2 < 120°, preferably 110° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ2 < 75°, preferably 50° < φ2 < 70°, and/or - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ2 < 120°, preferably 110° < φ2 < 120°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°. Cutting tool insert according to any of claims l to 8 c h a r a c t e r i s e d in that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°, - and - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°. Cutting tool insert according to any of claims lto8characterisedin that said layer comprises texture components with Euler angles - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ2 < 59°, preferably 10° < φ2 < 50°, and/or - 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ2 < 119°, preferably 70° < φ2 < 110°, - and - 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ2 < 120°, - and - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ2 < 48°, preferably 24° < φ2 < 36°, and/or - 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ2 < 108°, preferably 78° < φ2 < 102°, - and - 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ2 < 45°, preferably 20° < φ2 < 40°, and 75° < φ2 < 105°, preferably 80° < φ2 < 100°. Cutting tool insert according to claim lcharacterisedin that said coating comprises of an inner single- and/or multilayers of, e.g. TiN, TiC or Ti(C,0,N) or other A1203 polymorphs, preferably Ti(C,0,N), and/or an outer single- and/or multilayers of, e.g. TiN, TiC, Ti(C,0,N) or other A1203 polymorphs, preferably TiN and/or Ti(C,0,N), to a total thickness 0.5 to 40 μπι, preferably 0.5 to 30 μιη. Method of making a cutting tool insert comprising a body of cemented carbide, cermet, ceramics or cubic boron nitride based material onto which a hard and wear resistant coating is deposited comprising at least one oc-Al203 layer by chemical vapour deposition at a temperature between 950°C and 1050°C in mixed H2, C02, CO, H2S, HCl and A1C13 at a gas pressure between 50 and 150 mbar characterised in periodically varying the C02/CO gas flow ratio, upwards and downward, continuously or stepwise between at least two gas flow ratios chosen within the interval 0.3 < (C02/CO) < 6 and with a difference of at least 0.1. The time between the starting points for the chosen gas flow ratios is between 1 and 60 minutes, preferably between 2 and 30 minutes. 27. Use of a cutting tool insert according to claims 1 to 24 for machining by chip removal at cutting speeds between 75 and 600 m/min, preferably between 150 and 600 m/min, with an average feed, per tooth in the case of milling, between 0.08 and 0.8 mm, preferably between 0.1 and 0.6 mm, depending on cutting speed and insert geometry. |
BACKGROUND OF THE INVENTION
The present invention relates to a coated cutting tool comprising a body coated combining a multi textured alpha-alumina (0C-AI 2 O 3 ) layer, the method of making and use the same. The layer is grown by chemical vapour deposition (CVD) and the invention provides an oxide layer with improved wear properties and good chip forming machining properties.
Typically, CVD alumina based coatings comprise an inner layer of titanium carbonitride and an outer layer of AI 2 O 3 . The development and use comprise different Α1 2 0 3 polymorphs, e.g., oc-Al 2 0 3 , K-A1 2 0 3 and γ-Α1 2 0 3 as well as multilayer structures thereof.
US 3967035 discloses an oc-Al 2 0 3 coated cutting tool insert where the layer is bonded to the insert through a thin intermediate layer of an iron group metal aluminate. US 3836392 discloses an oc-Al 2 0 3 coated cutting tool insert where the layer is deposited directly onto the insert.
US 3837896 discloses an oc-Al 2 0 3 coated cutting tool insert where an intermediate carbide or nitride layer is deposited prior to the oxide layer.
US 4619866 discloses an oc-Al 2 0 3 coated cutting tool insert where the oxide is deposited utilizing a dopant selected from the group consisting of sulphur, selenium, tellurium, phosphorous, arsenic, antimony, bismuth and mixtures thereof, dramatically increasing the growth rate of the layer.
US 5968595 discloses a cutting tool insert coated with single- or multilayers, comprising at least one layer of a {210} textured K-A1 2 0 3 . US 5162147 discloses a cutting tool insert coated with an inner oc-Al 2 0 3 layer and an outer K-A1 2 0 3 layer.
US 5700569 discloses a multilayer oxide coated cutting tool insert comprising layers of either -Α1 2 0 3 or K-A1 2 0 3 . US 6015614 discloses a cutting tool insert coated with a multilayer structure of TiN/TiC on a thick layer of a single and/or bi-layer of OC-AI 2 O 3 and K-AI 2 O 3 .
US 6632514 discloses a cutting tool insert coated with a multilayer of K-AI 2 O 3 and TiN or Ti(C,N) layers.
US 7470296 discloses a cutting tool insert coated with a multilayer comprising layers of Ti(C,N) and AI 2 O 3 , preferably K-AI 2 O 3 .
US 6855413 discloses a cutting tool insert coated multilayer comprising layers of TiN and K-Al 2 0 3 .
US 6572991 discloses an oxide coated cutting tool insert with an outer layer a layer of γ-Α1 2 03.
US 6689450 discloses a coated cutting tool insert having a multilayer of κ- AI 2 O 3 and or γ-Α1 2 03 or TiN.
Further enhancement of the oxide layers has recently been achieved through the control of crystallographic orientation, texture, especially for the OC-AI 2 O 3 polymorph. This has been achieved by the development of new synthesis routes comprising the use of nucleation and growth sequences, bonding layers, sequencing of the reactant gases, addition of texture modifying agents and/or by using alumina conversion layers. Commonly, the texture is evaluated by the use of X-ray diffraction (XRD) techniques and the concept of texture coefficients.
Textured alumina layer synthesis using various bonding/ nucleation layers and growth sequences
US 7094447 discloses a method to produce textured OC-AI 2 O 3 layers with improved wear resistance and toughness. The OC-AI 2 O 3 layer is formed on a
(Ti,Al)(C,0,N) bonding layer using a nucleation sequence composed of aluminizing and oxidization steps. The layer is characterized by a {012} growth texture as determined by XRD.
US 7442431 discloses a method to produce textured OC-AI 2 O 3 layers on a (Ti,Al)(C,0,N) bonding layer using a nucleation sequence composed of short pulses and purges of Ti-containing pulses and oxidizing pulses. The layer is characterized by a { 110} growth texture as determined by XRD. US 7455900 discloses a method to produce textured OC-AI 2 O 3 layers on a (Ti,Al)(C,0,N) bonding layer using a nucleation sequence composed of short pulses and purges consisting of Ti + Al pulses and oxidizing pulses. The layer is
characterized by a { 116} growth texture as determined by XRD. US 7442432 discloses a method to produce textured OC-AI 2 O 3 layers on a
(Ti,Al)(C,0,N) bonding layer with a modified but similar technique as disclosed in US 7455900. The layer is characterized by a { 104} growth texture as determined by XRD.
US 2007104945 discloses a textured -Α1 2 0 3 coated cutting tool insert for which a nucleation controlled -Αΐ 2 θ 3 layer texture is obtained. The layer is characterized by a {006} growth texture as determined by XRD.
US 2008187774 discloses a texture-hardened a- Al 2 0 3 coated cutting tool insert with a {006} growth texture as determined by XRD.
US 6333103 discloses a textured -Αΐ 2 θ 3 layer grown on a Ti(C,0) bonding layer characterized by a { 10(10)} growth texture as determined by XRD.
Textured alumina layer synthesis using sequencing of reactant gases
US 5654035 discloses a body coated with refractory single- or multilayers, wherein specific layers are characterized by a controlled micro structure and phase composition with crystal planes grown in a preferential direction with respect to the surface of the coated body (growth texture). The textured -Αΐ 2 θ 3 layer is obtained by sequencing of the reactant gases in the following order: CO 2 , CO and A1C1 3 . The layer is characterized by a {012} growth texture as determined by XRD.
US 5766782 discloses a cutting tool coated with refractory single- or multilayers including -Αΐ 2 θ 3 , wherein specific layers are characterized by a controlled growth texture with respect to the surface of the coated body. The textured -Αΐ 2 θ 3 layer is obtained by sequencing of the reactant gases such that first CO 2 and CO are supplied to the reactor in an N 2 and/or Ar atmosphere followed by supplying ¾ and A1C1 3 to the reactor. The layer is characterized by a { 104} growth texture as determined by XRD. Textured alumina layer synthesis using texture modifying agents
US 7011867 discloses a coated cutting tool comprising one or more layers of refractory compounds out of which at least one layer is an OC-AI 2 O 3 layer having a columnar grain-structure and a {300} growth texture as determined by XRD. The micro structure and texture is obtained by adding ZrCl 4 as a texture modifying agent to the reaction gas during growth.
US 5980988 discloses a { 110} textured -Α1 2 0 3 layer as obtained by using SF 6 as a texture modifying agent during growth. The texture is determined by XRD.
US 5702808 discloses a { 110} textured oc-Al 2 0 3 layer as obtained sequencing SF 6 and H 2 S during growth. The texture is determined by XRD.
Textured alumina layer synthesis using conversion layers
US RE41111 discloses a {0001 } textured oc-Al 2 0 3 layer as obtained using an initial heat treated alumina core layer (conversion layer) with a thickness of 20 - 200 nm. The texture is determined by electron back scattering diffraction (EBSD).
An explanation of EBSD and the analysis for texture evaluation by using pole figures, pole plots, orientation distribution functions (ODFs) and texture indexes can for instance be found in Introduction to Texture Analysis: Macrotexture,
Microtexture, and Orientation Mapping, Valerie Randle and Olaf Engler, (ISBN 90- 5699-224-4) pp. 13 - 40.
Typically, the evaluation of texture may comprise
i) construction of the ODF, ii) identifying the components Euler angles φι, Φ and φ 2 (cf. Fig 5) and their corresponding ODF densities and crystallographic indices, iii) construction of pole figure(s) of relevant texture components, and/or iv) construction of pole plot(s) of the relevant texture components.
It is an object of the present invention to provide a multitexture controlled oc- A1 2 0 3 layer deposited by CVD with improved wear properties and chip forming cutting performance. It is also an object of the present invention to provide a method of producing the same.
Surprisingly, it has been found that the control of a multitextured OC-AI 2 O 3 layer is obtained solely by the growth conditions resulting in tailorable OC-AI 2 O 3 layers with improved metal cutting properties.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig 1. Examples of the deposition of OC-AI 2 O 3 varying between the process conditions A, B, etc. periodically/aperiodically, upwards/downwards and/or continuously/stepwise.
Fig 2. SEM micrographs of fractured cross sections of (a) a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer (II) and Ti(C,N) layer (I) according to the invention and (b) a single textured {0001 } oc-Al 2 0 3 layer (II) and Ti(C,N) layer (I) according to prior art.
Fig 3. X-ray diffraction (XRD) pattern from a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer according to the invention.
Fig 4. Back scattered SEM micrographs of polished plan views of (a) a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer according to the invention and (b) a single textured {0001 } oc-Al 2 0 3 layer according to prior art.
Fig 5. Definition of the Euler angles φι, Φ, and φ 2 used in the ODF
representation with respect to the cry stallo graphic orientations.
Fig 6. ODF contouring charts (Euler angles and densities) of (a) a
multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer, denoted as A, A', B and B ' respectively, according to the invention with its {01-15}, { 10-15}, {01- 12}, and { 10-12} solutions and (b) a single textured {0001 } oc-Al 2 0 3 layer according to prior art.
Fig 7. EBSD pole figures of (a) {01-12}, {01-15}, { 10-12}, and { 10-15} texture components and (b) {0001 } textured oc-Al 2 0 3 layer according to prior art.
Fig 8. EBSD pole plots of (a) {01-15} texture component, (b) { 10-15} texture component, (c) {01-12} texture component, (d) { 10-12} texture component of a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer and (e) a single textured {0001 } OC-AI 2 O 3 layer according to prior art. χ is the angle from the centre (X=0) to the rim (χ=90) of the pole figures (cf. Fig 7). MUD is the multiples of unit distribution.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, there is provided a cutting tool insert for machining by chip removal comprising a body of a hard alloy of cemented carbide, cermet, ceramic, cubic boron nitride based material onto which a hard and wear resistant coating is deposited by CVD comprising at least one OC-AI 2 O 3 layer, herein defined as a multitextured OC-AI 2 O 3 layer, with an ODF texture index >1, preferably 1 < ODF texture index < 50, most preferably 1 < ODF texture index < 10, and
at least two dominant texture components, i.e., the highest ODF densities, each of which having 2 < ODF density < 100, preferably 2 < ODF density < 50, most preferably 3 < ODF density < 25, coexisting within the layer.
Preferably said multitextured OC-AI 2 O 3 layer has a rotational symmetry, fibre texture, relative to the surface normal of the coated body.
The texture is evaluated using pole figures, pole plots, orientation distribution functions (ODFs) and texture indexes from, e.g., EBSD or XRD data.
Said multitextured OC-AI 2 O 3 layer has a thickness between 0.5 μηι and 30 μιη, preferably between 0.5 μηι and 20 μηι, most preferably between 1 μηι and 10 μηι, with a columnar grain structure with an average column width between 0.1 μηι and 5 μπι, preferably between 0.1 μηι and 2.5 μιτι and an untreated (as-deposited) surface roughness of Ra < 1.0 μηι over a length of 10 μηι, preferably between 0.2 μηι and 0.5 μηι using a stylus profilometer. The column width is determined from back scattered SEM micrographs of polished plan views (top surface of the coating) and evaluated using, e.g., the EBSD Channel 5 program package.
In one preferred embodiment, said texture components have the highest ODF densities for {01-15}, { 10-15}, {01-12}, and { 10-12} satisfying one or both of the {01-15} or { 10-15} solutions and one or both of {01-12} or { 10-12} solutions with Euler angles: - {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, and {0001 } satisfying one or both of the {01-15} or { 10-15} solutions and the {0001 } solution with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, and { 10-10} satisfying one or both of the {01- 15} or { 10-15} solutions and the { 10-10} solution with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°, and - { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, { 11-20}, and {-1-120} satisfying one or both of the {01-15} or { 10-15} solutions and one or both of { 11-20} or {-1-120} solutions with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and
- { 11-20}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ 2 < 75°, preferably 50° < φ 2 < 70°, and/or
- {-1-120}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ 2 < 120°, preferably 110° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-12}, { 10-12} and {0001 } satisfying one or both of the { 01- 12} or { 10-12} solutions and the {0001 } solution with Euler angles:
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°, and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {0001 }, { 11-20}, and {-1-120} satisfying the {0001 } solution and one or both of the { 11-20} or {-1-120} solutions with Euler angles: - {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°,
and
- { 11-20}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ 2 < 75°, preferably 50° < φ 2 < 70°, and/or
- {-1-120}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ 2 < 120°, preferably 110° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {0001 } and { 10-10} satisfying the {0001 } solution and the { 10-10} solution with Euler angles:
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and
0° < φ 2 < 120°, and
- { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-12}, { 10-12}, { 11-20}, and {-1-120} satisfying one or both of the {01-12} or { 10-12} solutions and one or both of the { 11-20} or {-1-120} solutions with Euler angles:
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°, and
- { 11-20}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ 2 < 75°, preferably 50° < φ 2 < 70°, and/or
- {-1-120}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ 2 < 120°, preferably 110° < φ 2 < 120°. In another preferred embodiment, said texture components have the highest ODF densities for {01-12}, { 10-12}, and { 10-10} satisfying one or both of the {01-12} or { 10-12} solutions and the { 10-10} solution with Euler angles:
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°, and
- { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°.
In another preferred embodiment, said texture components have the highest ODF densities for { 10-10} , { 11-20}, and {-1-120} satisfying the { 10-10} solution and one or both of the { 11-20} or {-1-120} solutions with Euler angles: - { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and
15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°,
and
- { 11-20}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ 2 < 75°, preferably 50° < φ 2 < 70°, and/or
- {-1-120}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ 2 < 120°, preferably 110° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, {0001 }, and { 10-10} satisfying one or both of the { 10-15} or {01-15} solutions and the {0001 } solution and the { 10-10} solution with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or - { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°,
and
- { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-12}, { 10-12}, {0001 }, and { 10-10} satisfying one or both of the {01-12} or { 10-12} solutions and the {0001 } solution and the { 10-10} solution with Euler angles:
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°, and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°,
and
- { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, {0001 }, { 11-20}, and {-1-120} satisfying one or both of the { 10-15} or {01-15} solutions and the {0001 } solution and one or both of the { 11-20} or {-1-120} solutions with Euler angles: - {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°,
and
- { 11-20}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 45° < φ 2 < 75°, preferably 50° < φ 2 < 70°, and/or
- {-1-120}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 105° < φ 2 < 120°, preferably 110° < φ 2 < 120°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15 }, { 10-15}, {01-12}, { 10-12}, and {0001 } satisfying one or both of the { 10-15} or {01-15} solutions and one or both of the {01-12} or { 10-12} solutions and the {0001 } solution with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°, and
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°, and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°. In another preferred embodiment, said texture components have the highest ODF densities for {01-15}, {10-15}, {10-10}, {01-12}, and { 10-12} satisfying one or both of the {10-15} or {01-15} solutions and the {0001 } solution and one or both of the {01-12} or {10-12} solutions with Euler angles: - {01-15}: 0°<φι< 90°, 17° <Φ<47°, preferably 22° < Φ < 42°, and
1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or
- { 10-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 61° < φ 2 < 119°, preferably 70° < φ 2 < 110°,
and - { 10-10}: 0°<φι< 90°, 75° <Φ< 90°, preferably 80° <Φ< 90°, and
15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°,
and
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°.
In another preferred embodiment, said texture components have the highest ODF densities for {01-15}, {10-15}, {10-10}, {01-12}, {10-12}, and {0001} satisfying one or both of the { 10-15} or {01-15} solutions and { 10-10} solution and one or both of the {01-12} or {10-12} solutions and the {0001 } solution with Euler angles:
- {01-15}: 0° < φι < 90°, 17° < Φ < 47°, preferably 22° < Φ < 42°, and 1° < φ 2 < 59°, preferably 10° < φ 2 < 50°, and/or - { 10- 15 }: 0°<φι< 90°, 17° <Φ<47°, preferably 22° < Φ < 42°, and
61° < φ 2 < 119°, preferably 70° < φ 2 < 110°, and - { 10-10}: 0° < φι < 90°, 75° < Φ < 90°, preferably 80° < Φ < 90°, and 15° < φ 2 < 45°, preferably 20° < φ 2 < 40°, and 75° < φ 2 < 105°, preferably 80° < φ 2 < 100°,
and
- {01-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 12° < φ 2 < 48°, preferably 24° < φ 2 < 36°, and/or
- { 10-12}: 0° < φι < 90°, 43° < Φ < 73°, preferably 48° < Φ < 68°, and 72° < φ 2 < 108°, preferably 78° < φ 2 < 102°,
and
- {0001 }: 0° < φι < 90°, 0° < Φ < 15°, preferably 0° < Φ < 10°, and 0° < φ 2 < 120°.
Said coating may comprise of an inner single- and/or multilayers of, e.g. TiN, TiC or Ti(C,0,N) or other A1 2 0 3 polymorphs, preferably Ti(C,0,N), and/or an outer single- and/or multilayers of, e.g. TiN, TiC, Ti(C,0,N) or other A1 2 0 3 polymorphs, preferably TiN and/or Ti(C,0,N), to a total thickness 0.5 to 40 μιη, preferably 0.5 to 30 μηι, and most preferably 1 to 20 μιη, according to prior art.
Optionally, said coated body is post treated with, e.g., wet blasting, brushing operation, etc. such that the desired surface quality is obtained.
According to the invention, the deposition method for the multitextured oc- A1 2 0 3 layer of the present invention is based on chemical vapour deposition at a temperature between 950 C and 1050 C in mixed H 2 , C0 2 , CO, H 2 S, HC1 and A1C1 3 at a gas pressure between 50 and 150 mbar as known in the art. During deposition, the C0 2 /CO gas flow ratio is periodically or aperiodically varied, upwards and downwards, continuously or stepwise between at least two gas flow ratios chosen within the interval 0.3 < (C0 2 /CO) < 6 and with a difference of at least 0.1. The time between the starting points for the chosen gas flow ratios is between 1 and 60 minutes, preferably between 2 and 30 minutes. It is within the purview of the skilled artisan to determine the detailed process conditions in accordance with the present description. This invention also relates to the use of cutting tool inserts according to the above for machining by chip removal at cutting speeds between 75 and 600 m/min, preferably between 150 and 600 m/min, with an average feed, per tooth in the case of milling, between 0.08 and 0.5 mm, preferably between 0.1 and 0.4 mm depending on cutting speed and insert geometry.
Example 1
Cemented carbide inserts with the composition 5.5 wt% Co, 8 wt% cubic carbides and balance WC, were initially coated with a 6 μιη thick layer of MTCVD Ti (C,N). In subsequent process steps and during the same coating cycle, a 5 μιη thick layer of a multitextured OC-AI 2 O 3 was deposited with the general process conditions given in table 1 and the specific process conditions, indexed with A, B, C and D, given in table 2. The OC-AI 2 O 3 layer was deposited with a periodical and continuous change between process conditions A, B, C and D, and in time steps set by the process time ratios t^- t B : tc: t D where ti, i = A, B, C, D, is the time between two consecutive process conditions. The period time is t A + t B + tc + t D .
Table 1.
General process conditions
C0 2 + CO / % 7.5
AlCl 3 / % 2
H 2 S / % 0.3
HCl / % 2
H 2 / % Balance
Pressure / mbar 70
Temperature / °C 1000
Table 2.
Example 2
Example 1 was repeated with a single textured OC-AI 2 O 3 layer using a constant CO 2 /CO gas flow ratio of 2.0.
Example 3
OC-AI 2 O 3 layers from example 1 and 2 were characterized by SEM and EBSD using a LEO Ultra 55 scanning electron microscope operated at 15 kV and equipped with a HKL Nordlys II EBSD detector. The texture was evaluated from the EBSD data by constructing ODF's with series expansion having a resolution of 32x32x32 points and a Gaussian half width of 5° and L max =34 clustering data of 5° over a representative area of a polished top surface of the OC-AI 2 O 3 layers. The commercial Channel 5 software version 5.0.9.0 was used for data collection and also for data analyses: calculations of ODFs, i.e. the Euler angles and densities as well as texture indexes, pole figures, and pole plots.
Fig 2 shows back scattered SEM micrographs of polished cross sections of the OC-AI 2 O 3 layers, marked with II in the images, for (a) insert 2 in example 1
(invention) and (b) example 2 (reference). Both layers exhibit a columnar grain structure. The invention layers show a strong reduction of the surface roughness.
The surface roughness of insert 2 in example 1 was Ra = 0.35 μιη as measured by a stylus profilometer over a length of ΙΟμιη.
Fig 3 shows X-ray diffraction (XRD) patterns from insert 2 in example 1 demonstrating a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer.
Fig 4 shows back scattered SEM micrographs of polished plan views of (a) a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} α-Α1 2 0 3 layer of insert 2 in example 1 and (b) a single textured {0001 } oc-Al 2 0 3 layer of example 2. The invention layers show reduced column width, in average between 0.1 μιη and 2.5 μιη as determined from back scattered SEM micrographs of polished plan views (top surface of the coating) and evaluated using, e.g., the EBSD Channel 5 program package.
Fig 6 shows ODF contour charts (ODF Euler angles and densities) as deduced from the EBSD data of (a) a multitextured {01-15} + { 10-15} + {01-12} + { 10-12} -Α1 2 0 3 layer from insert 2 in example 1 (table 2) with the {01-15}, { 10-15}, {01- 12} and { 10-12} solutions and an ODF texture index of 4.06, and (b) of a single textured {0001 } oc-Al 2 0 3 layer of example 2 with an ODF texture index of 5.5. The Euler angles φι, Φ and φ 2 for the {01-15}, { 10-15}, {01-12} and { 10-12} solutions of the {01-15}, { 10-15}, {01-12}, and { 10-12} texture components are centred (highest ODF density) at about
- {01-15}: 0° < φι < 90°, Φ = 32° and φ 2 = 30°, - { 10-15}: 0° < φι < 90°, Φ = 32° and φ 2 = 90°,
- {01-12}: 0° < φι < 90°, Φ = 58° and φ 2 = 30°, and
- { 10-12}: 0° < φι < 90°, Φ = 58° and φ 2 = 90°.
From the Channel 5 software, the ODF density values for the {01-15} and {01-12} texture components were deduced as 17.7 and 6.2, respectively. The results demonstrate a multitextured {01-15} + {01-12} fibre texture.
The texture index and texture components with its corresponding ODF densities for the inserts in example 1 are shown in table 3.
Table 3.
Insert # Texture index Dominant texture component/ODF density
1 3.98 {01-15}/16.5 {01-12J/6.1
2 4.06 {01-15}/17.7 {01-12J/6.2
3 4.22 {01-15J/17.3 {01-12J/5.9
4 3.94 {01-15J/10.3 {01-12J/12.4
5 4.14 {01-15}/8.2 {01-12J/19.2
6 3.81 {01-15}/12.0 {0001J/4.2
7 2.54 {01-15}/6.9 {0001J/6.3
8 4.44 {01-15}/5.1 {0001J/15.2
9 4.91 {01-12J/15.9 {0001J/3.1
10 2.79 {01-12J/5.7 {0001J/7.1
11 4.91 {01-12J/3.2 {0001J/13.9
12 4.83 {01-12J/3.3 {0001J/14.4
13 5.56 {01-12J/19.4 {10-10J/6.0
14 4.67 {01-12J/13.2 {10-10J/21.0
15 5.93 {01-12J/7.6 {10-10J/24.0
16 3.25 {0001J/14.0 {10-10J/4.3
17 2.95 {0001 }/5.9 {10-10J/13.4
18 3.85 {0001J/3.1 {10-10J/14.7
19 2.72 {01-15J/9.6 {01-12J/3.5 {0001 }/5.2
20 3.48 {01-15J/15.5 {01-12J/5.0 {10-10J/7.7
21 3.34 {01-15J/14.9 {01-12J/4.9 {10-10J/7.5
22 2.79 {01-15J/10.0 {0001 }/5.4 {10-10J/5.0
23 2.36 {0001J/6.6 {01-12J/4.2 {10-10J/6.4
24 1.78 {01-15J/5.9 {01-12J/4.7 {0001J/4.5 {10-10J/5.2 In addition, pole figures and pole plots of the fibre textures were plotted.
Fig 7 shows pole figures of (a) {01-15}, { 10-15}, {01-12}, and { 10-12} texture components of insert 2 in example 1 and (b) {0001 } textured OC-AI 2 O 3 layer of example 2.
Fig 8 shows pole plots of (a) {01-15} texture component, (b) { 10-15} texture component, (c) {01-12} texture component, (d) { 10-12} texture component of insert 2 in example 1 and (e) a single textured {0001 } OC-AI 2 O 3 layer of example 2. χ is the angle from the centre (χ=0) to the rim (χ=90) of the pole figures (cf. Fig 4). MUD is the multiples of unit distribution.
Example 4:
Coated inserts from example 1 and example 2 together with competitor grades were tested in a continuous turning application at the following cutting conditions.
Work piece: Cylindrical bar
Material: SS 1672
Insert type: CNMG120408
Cutting speed 300 m/min
Feed: 0.35 mm/rev
Depth of cut: 2.5 mm
Remarks: dry
Life time for crater wear was used as criterion.
Table 4.
Insert Time / minutes
Example 1: Insert 1 15
Example 1: Insert 2 14
Example 1: Insert 3 14
Example 1: Insert 4 13.5
Example 2 13
Competitor X 13
Competitor Y Break down
Competitor Z 11 Example 5:
Coated inserts from example 1 and example 2 together with a competitor grade were tested in a continuous turning application at the following cutting conditions.
Work piece: Cylindrical bar
Material: SS2258
Insert type: CNMG120408
Cutting speed: 220 m/min
Feed: 0.35 mm/rev
Depth of cut: 2.5 mm
Remarks: dry
Life time for crater wear was used as criterion.
Table 5.
Insert Time / minutes
Example 1: insert 2 12
Examplel: insert 12 12
Example 1: insert 19 13
Example 2 11
Competitor X 10
Example 6:
Coated inserts from example 1 and example 2 together with a competitor grade were tested in a continuous turning application at the following cutting conditions.
Work piece: Cylindrical bar
Material: SS2348
Insert type: CNMG120408
Cutting speed: 180 m/min
Feed: 0.35 mm/rev
Depth of cut: 2.5 mm
Remarks: dry
Life time for crater wear was used as criterion.
Table 6.
Insert Time / minutes
Example 1: insert 1 17
Example 1: insert 5 18
Example 2 16
Competitor X 16