Coated tool and cutting tool

Abstract

This coated tool comprises a substrate having a first surface, and a coating layer positioned on the first surface. The coating layer includes a first layer and a second layer positioned between the first layer and the substrate. Each of the first layer and the second layer contains polycrystals which include: metal components including Ti and Al; and at least one element selected from the group consisting of carbon, nitrogen, and oxygen. When the angle of inclination of a (111) plane of the polycrystals contained in the first layer with respect to a direction perpendicular to the first surface is defined as the first inclination angle, the distribution of the first inclination angles in a range of 0° to 60° inclusive has a primary peak of the first inclination angle in a range of 50° to 60° inclusive. The ratio of the number of polycrystals having the first inclination angle in the range of 50° to 60° inclusive to the total number of the polycrystals included in the first layer is 50% or less.

Description

Coated and cutting tools

[0001] The present disclosure relates to coated tools and cutting tools.

[0002] As a tool used in cutting processes such as turning or milling, a coated tool having a substrate made of cemented carbide, cermet, ceramic, or the like coated with a coating layer is known. Coating with a coating layer can improve the wear resistance and other properties of the tool.

[0003] International Publication No. 2016 / 017790

[0004] A coated tool according to one embodiment of the present disclosure includes a substrate having a first surface and a coating layer positioned on the first surface. The coating layer includes a first layer and a second layer positioned between the first layer and the substrate. Each of the first layer and the second layer includes polycrystals containing a metal component including Ti and Al and at least one element selected from the group consisting of carbon, nitrogen, and oxygen. When the inclination angle of the (111) plane of the polycrystals included in the first layer with respect to a direction perpendicular to the first surface is defined as the first inclination angle, the distribution of the first inclination angles within a range of 0° to 60° has a primary peak within a range of 50° to 60°. The ratio of the number of polycrystals having a first inclination angle within the range of 50° to 60° to the total number of polycrystals included in the first layer is 50% or less.

[0005] FIG. 1 is a perspective view showing an example of a coated tool according to an embodiment. FIG. 2 is a side cross-sectional view showing an example of a coated tool according to an embodiment. FIG. 3 is a schematic enlarged view of a corner portion of a tip body according to a reference example. FIG. 4 is a cross-sectional view showing an example of a coating layer according to an embodiment. FIG. 5 is a diagram illustrating the distribution of the inclination angle of the (111) plane of polycrystals included in the wear-resistant layer according to an embodiment. FIG. 6 is a diagram illustrating the distribution of the inclination angle of the (100) plane of polycrystals included in the wear-resistant layer according to an embodiment. FIG. 7 is a diagram illustrating the distribution of the inclination angle of the (111) plane of polycrystals included in the intermediate layer according to an embodiment. FIG. 8 is a diagram illustrating the distribution of the inclination angle of the (100) plane of polycrystals included in the intermediate layer according to an embodiment. FIG. 9 is a front view showing an example of a cutting tool according to an embodiment. FIG. 10 is a graph showing the distribution of the first inclination angle according to an example. FIG. 11 is a graph showing the distribution of the second inclination angle according to an example. FIG. 12 is a graph showing the distribution of the third inclination angle according to an example. FIG. 13 is a graph showing the distribution of the fourth inclination angle according to an example. Fig. 14 is a graph showing the distribution of the first inclination angle according to the comparative example. Fig. 15 is a graph showing the distribution of the second inclination angle according to the comparative example. Fig. 16 is a graph showing the distribution of the third inclination angle according to the comparative example. Fig. 17 is a graph showing the distribution of the fourth inclination angle according to the comparative example. Fig. 18 is a graph showing the correlation between cutting time and abrasive wear amount. Fig. 19 is an image showing the cutting edge condition of the coated tool according to the example after a cutting test. Fig. 20 is an image showing the cutting edge condition of the coated tool according to the comparative example after a cutting test.

[0006] Hereinafter, modes for carrying out a coated tool and a cutting tool according to the present disclosure (hereinafter referred to as "embodiments") will be described in detail with reference to the drawings. The coated tool and the cutting tool according to the present disclosure are not limited to these embodiments. The respective embodiments can be appropriately combined within the scope of not causing contradictions in the content. In the following embodiments, the same components are designated by the same reference numerals, and redundant explanations will be omitted.

[0007] As a tool used in cutting processes such as turning or milling, a coated tool having a substrate made of cemented carbide, cermet, ceramic, or the like coated with a coating layer is known. Coating with a coating layer can improve the wear resistance and other properties of the tool.

[0008] The above-mentioned conventional techniques have room for further improvement in terms of improving durability.

[0009] Therefore, there is a need for a technology that can overcome the above-mentioned problems and improve durability.

[0010] <Coated tool> Fig. 1 is a perspective view showing an example of a coated tool according to an embodiment. Fig. 2 is a side cross-sectional view showing an example of a coated tool according to an embodiment. As shown in Fig. 1, the coated tool 1 according to the embodiment has a tip body 2.

[0011] (Chip Body 2) The chip body 2 has, for example, a hexahedral shape in which the upper and lower surfaces (surfaces intersecting with the Z axis shown in FIG. 1) are parallelogram-shaped.

[0012] One corner portion 201 of the insert body 2 functions as a cutting edge portion. The cutting edge portion has a first surface (for example, an upper surface) and a second surface (for example, a side surface) that is connected to the first surface. In the embodiment, the first surface functions as a "rake surface" that scoops up chips generated by cutting, and the second surface functions as a "flank surface." A cutting edge is located on at least a portion of the ridge where the first surface and the second surface intersect, and the coated tool 1 cuts the workpiece by applying this cutting edge to the workpiece.

[0013] A through-hole 5 that passes through the tip body 2 from top to bottom is located in the center of the tip body 2. A screw 75 is inserted into the through-hole 5 to attach the coated tool 1 to a holder 70 (described later) (see FIG. 9).

[0014] 1 is merely an example and does not limit the shape of the coated tool according to the present disclosure. The coated tool according to the present disclosure may, for example, have a rod-shaped body having a rotation axis and extending from a first end to a second end, a cutting edge located at the first end of the body, and a groove extending spirally from the cutting edge toward the second end of the body.

[0015] As shown in FIG. 2, the chip body 2 has a base 10 and a coating layer 20 .

[0016] (Base 10) The base 10 has a surface referred to as a first surface. The first surface of the base 10 may be, for example, the upper surface of the base 10.

[0017] The substrate 10 is formed, for example, from a cemented carbide. The cemented carbide contains a hard phase containing at least W (tungsten), specifically WC (tungsten carbide). The cemented carbide may contain a binder phase containing at least one iron group element such as Ni (nickel) and Co (cobalt). As an example, the substrate 10 is made of a WC-based cemented carbide having hard particles made of WC as the hard phase component and Co as the main component of the binder phase. When the substrate 10 is formed from a cemented carbide, the substrate 10 has better heat resistance properties.

[0018] The substrate 10 may be formed of a cermet. The cermet contains, for example, Ti (titanium), specifically, TiC (titanium carbide) or TiN (titanium nitride). The cermet may also contain Ni or Co.

[0019] The substrate 10 may be formed of a cubic boron nitride sintered body containing cubic boron nitride (cBN) particles. The substrate 10 is not limited to cubic boron nitride (cBN) particles, but may also contain particles of hexagonal boron nitride (hBN), rhombohedral boron nitride (rBN), wurtzite boron nitride (wBN), or the like.

[0020] The substrate 10 may be made of ceramic, such as Al. ２ O ３ (aluminum oxide), for example, κ-Al ２ O ３ and α-Al ２ O ３ The ceramic may contain other elements in addition to aluminum oxide. For example, the ceramic may contain, in addition to aluminum oxide, at least one of magnesium (Mg), calcium (Ca), strontium (Sr), silicon (Si), and an element from Group 3 of the periodic table.

[0021] (Coating layer 20) The coating layer 20 coats the substrate 10, for example, for the purpose of improving the abrasion resistance, heat resistance, etc. of the substrate 10. In the example of FIG. 2, the coating layer 20 coats the entire substrate 10. The arrangement of the coating layer 20 on the substrate 10 is not particularly limited as long as the coating layer 20 is located at least on the surface of the substrate 10. The coating layer 20 is located, for example, on the first surface (here, the upper surface) of the substrate 10. When the coating layer 20 is located on the first surface of the substrate 10, the abrasion resistance and heat resistance of the first surface are high. When the coating layer 20 is located on the second surface (here, the side surface) of the substrate 10, the abrasion resistance and heat resistance of the second surface are high.

[0022] (Damage to the Chip Body) Damage to the chip body will now be described with reference to Fig. 3. Fig. 3 is a schematic enlarged view of a corner portion 201X of a chip body 2X according to a reference example.

[0023] 3, the insert body 2X may undergo wear such as primary boundary wear D1, secondary boundary wear D2, abrasive wear D3, and crater wear D4. The primary boundary wear D1, secondary boundary wear D2, and abrasive wear D3 occur on the flank face, and the crater wear D4 occurs on the rake face.

[0024] Abrasive wear D3 is a wear phenomenon in which the surface of the tip body 2X is scraped away by foreign matter interposed between the tip body 2X and the workpiece. Abrasive wear D3 may cause an increase in cutting resistance and cutting heat.

[0025] Primary boundary wear D1 and secondary boundary wear D2 are wear that occurs at both ends of abrasive wear D3, i.e., at the cutting boundary. The primary boundary is the boundary that contacts the cutting surface of the workpiece, and the secondary boundary is the boundary that contacts the finished surface of the workpiece. Primary boundary wear D1 may cause burrs to form on the workpiece. Secondary boundary wear D2 may deteriorate the finished surface of the workpiece or change the dimensions of the workpiece.

[0026] Crater wear D4 occurs when the insert body 2X is heated to a high temperature, oxidizing the surface and generating relatively soft oxides. Crater wear D4 may deteriorate chip disposal.

[0027] The coated tool 1 according to the embodiment can reduce such damage by devising the configuration of the coating layer 20 that coats the tip body 2 .

[0028] (Configuration of Covering Layer 20) Here, an example of the configuration of the covering layer 20 according to the embodiment will be described with reference to Fig. 4. Fig. 4 is a cross-sectional view showing an example of the covering layer 20 according to the embodiment.

[0029] 4 , the coating layer 20 includes a first layer 21, a second layer 22, and a third layer 23. The first layer 21 is located on the outer side of the coating layer 20 compared to the second layer 22 and the third layer 23. The second layer 22 is located between the first layer 21 and the substrate 10. The third layer 23 is located between the second layer 22 and the substrate 10. That is, the second layer 22 is located between the first layer 21 and the third layer 23.

[0030] The first layer 21 may be located as the outermost layer of the coating layer 20. In such a case, the first layer 21 is generally called a wear-resistant layer because it comes into contact with the workpiece. Therefore, hereinafter, the first layer 21 will be appropriately referred to as the wear-resistant layer 21.

[0031] As described above, the second layer 22 is located between the first layer 21 and the third layer 23, and may therefore be referred to as an intermediate layer 22. The second layer 22, which is located inside the coating layer 20 with respect to the first layer 21, may be in contact with the first layer 21, as in the example shown in FIG.

[0032] The third layer 23 may be located at the innermost portion of the coating layer 20. In such a case, the third layer 23 is positioned as a region that contacts the substrate 10 and enhances the adhesion of the coating layer 20 to the substrate 10. Therefore, the third layer 23 is generally referred to as an adhesion layer. Hereinafter, the third layer 23 will be appropriately referred to as the adhesion layer 23. The adhesion layer 23 may be in contact with the intermediate layer 22, as in the example shown in FIG. 4. Another layer may be located between the intermediate layer 22 and the adhesion layer 23, and the adhesion layer 23 may be separated from the intermediate layer 22. In the example shown in FIG. 4, the adhesion layer 23, the intermediate layer 22, and the wear-resistant layer 21 are stacked in this order from the front surface or first surface side of the substrate 10.

[0033] The wear-resistant layer 21 includes polycrystals. The polycrystals contained in the wear-resistant layer 21 are mainly cubic. The polycrystals contained in the wear-resistant layer 21 include metal components including Ti and Al, and at least one element selected from the group consisting of carbon, nitrogen, and oxygen. However, the composition of the polycrystals contained in the wear-resistant layer 21 is different from the composition of the polycrystals contained in the intermediate layer 22. For example, the polycrystals contained in the wear-resistant layer 21 may include Ti as a metal component. ｇ Al ｈ Cr ｉ M ｊ The composition of the polycrystal contained in the wear-resistant layer 21 is defined as a first composition. M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table (excluding Cr) and Si. g, h, i, and j are all atomic ratios, satisfying the following conditions: 15≦g≦40, 50≦h≦70, 5≦i≦20, and g+h+i+j=100. As an example, the composition of the polycrystal contained in the wear-resistant layer 21 may be TiAlCrWNbSiN. The polycrystal contained in the wear-resistant layer 21 does not necessarily need to contain M. In this case, the composition of the polycrystal contained in the wear-resistant layer 21 may be, for example, TiAlCrN. The wear-resistant layer 21 is a layer that comes into contact with the workpiece when cutting the workpiece with the coated tool 1, and can reduce the occurrence of primary boundary wear D1, secondary boundary wear D2, and abrasive wear D3 in the tip body 2.

[0034] The intermediate layer 22 includes polycrystals. The polycrystals included in the intermediate layer 22 are mainly cubic. The polycrystals included in the intermediate layer 22 include metal components including Ti and Al, and at least one element selected from the group consisting of carbon, nitrogen, and oxygen. For example, the composition of the polycrystals included in the intermediate layer 22 includes Ti as a metal component. ｄ Al ｅ M ｆ The composition of the polycrystal contained in the intermediate layer 22 is defined as a second composition. M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table (excluding Cr) and Si. d, e, and f are all atomic ratios, where 0≦d≦55, 40≦e≦80, and d+e+f=100. As an example, the composition of the polycrystal contained in the intermediate layer 22 may be TiAlWNbSiN. The polycrystal contained in the intermediate layer 22 does not necessarily need to contain M. In this case, the composition of the polycrystal contained in the intermediate layer 22 may be, for example, TiAlN. The intermediate layer 22 has high oxidation resistance. As a result, the intermediate layer 22 can reduce the occurrence of crater wear D4 in the tip body 2.

[0035] The adhesion layer 23 includes polycrystals. The polycrystals included in the adhesion layer 23 are mainly cubic crystals. The polycrystals included in the adhesion layer 23 include Ti and Al. For example, the composition of the polycrystals included in the adhesion layer 23 is Ti, ａ Al ｂ M ｃ M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table and Si. The composition of the polycrystal contained in the adhesion layer 23 is defined as a third composition. a, b, and c are all atomic ratios, and satisfy the following: 40≦a≦80, 0≦b≦55, and a+b+c=100. As an example, the composition of the polycrystal contained in the adhesion layer 23 may be TiAlWNbSi. The polycrystal contained in the adhesion layer 23 does not necessarily need to contain M. In this case, the composition of the polycrystal contained in the adhesion layer 23 may be, for example, TiAl. The adhesion layer 23 improves the adhesion of the coating layer 20 to the substrate 10. This reduces peeling of the coating layer 20 from the substrate 10.

[0036] The proportion of metal components in the polycrystals contained in the adhesion layer 23, the intermediate layer 22, and the wear-resistant layer 21 can be determined, for example, by analysis using an EDS (energy dispersive X-ray spectrometer) attached to an STEM (scanning transmission electron microscope).

[0037] The thickness of the coating layer 20 may be 2.5 μm or more and 10 μm or less. When the thickness of the coating layer 20 is 2.5 μm or more, wear resistance (particularly resistance to abrasive wear D3) can be more easily ensured. On the other hand, when the thickness of the coating layer 20 is 10 μm or less, chipping of the coating layer 20 can be more easily reduced. Therefore, when the thickness of the coating layer 20 is 2.5 μm or more and 10 μm or less, the wear resistance and chipping resistance of the coating layer 20 can be improved.

[0038] The thickness of the wear-resistant layer 21 may be 1.5 μm or more and 7 μm or less. When the thickness of the wear-resistant layer 21 is 1.5 μm or more, the occurrence of primary boundary wear D1, secondary boundary wear D2, and abrasive wear D3 in the tip body 2 can be more easily reduced. On the other hand, when the thickness of the wear-resistant layer 21 is 7 μm or less, the effect of the intermediate layer 22 in reducing the occurrence of crater wear D4 in the tip body 2 can be more easily ensured. Therefore, when the thickness of the wear-resistant layer 21 is 1.5 μm or more and 7 μm or less, damage to the tip body 2 can be more easily reduced.

[0039] The thickness of the intermediate layer 22 may be smaller than the thickness of the wear-resistant layer 21. For example, the thickness of the intermediate layer 22 may be 0.5 μm or more and 3 μm or less. When the thickness of the intermediate layer 22 is 0.5 μm or more, the occurrence of crater wear D4 in the tip body 2 can be more easily reduced. On the other hand, when the thickness of the intermediate layer 22 is 3 μm or less, the effect of the wear-resistant layer 21 in reducing the occurrence of primary boundary wear D1, secondary boundary wear D2, and abrasive wear D3 in the tip body 2 can be more easily ensured. Therefore, when the thickness of the intermediate layer 22 is 0.5 μm or more and 3 μm or less, damage to the tip body 2 can be more easily reduced.

[0040] The thickness of the adhesion layer 23 may be 2 nm or more and 8 nm or less. When the thickness of the adhesion layer 23 is 2 nm or more, the adhesion of the coating layer 20 to the substrate 10 can be more easily improved. The occurrence of primary boundary wear D1 and secondary boundary wear D2 in the chip body 2 can also be more easily reduced. On the other hand, when the thickness of the adhesion layer 23 is 8 nm or less, the plastic deformation of the relatively soft adhesion layer 23 can be reduced, thereby more easily reducing the destruction of the coating layer 20. Therefore, when the thickness of the adhesion layer 23 is 2 nm or more and 8 nm or less, the occurrence of primary boundary wear D1 and secondary boundary wear D2 in the chip body 2 and the destruction of the coating layer 20 can be reduced.

[0041] Here, an example has been shown in which the coating layer 20 is composed of the adhesion layer 23, the intermediate layer 22, and the wear-resistant layer 21, but the coating layer 20 does not necessarily need to include the adhesion layer 23. For example, when the adhesion of the intermediate layer 22 to the substrate 10 is high and / or when the coated tool 1 is intended for a workpiece material that is less susceptible to primary boundary wear D1 and secondary boundary wear D2, the coated tool 1 may have the coating layer 20 composed of the intermediate layer 22 located on the surface or first surface of the substrate 10 and the wear-resistant layer 21 located on the surface of the intermediate layer 22.

[0042] (Details of Wear-Resistant Layer 21) Next, an example of details of the wear-resistant layer 21 included in the coating layer 20 according to the embodiment will be described with reference to Figs. 5 and 6. Fig. 5 is a diagram illustrating the distribution of inclination angles of the (111) plane of the polycrystals included in the wear-resistant layer 21 according to the embodiment. Fig. 6 is a diagram illustrating the distribution of inclination angles of the (100) plane of the polycrystals included in the wear-resistant layer 21 according to the embodiment. The distribution of inclination angles of the (111) plane and the (100) plane of the polycrystals included in the wear-resistant layer 21 can be evaluated by analyzing the crystal orientation using a TEM electron diffraction mapping method, for example, as shown in the examples described below.

[0043] For the wear-resistant layer 21 according to the embodiment, the inclination angle of the (111) plane of the polycrystal contained in the wear-resistant layer 21 relative to the direction perpendicular to the surface or first surface of the substrate 10 is defined as the first inclination angle. Here, the inclination angle of the (111) plane of the polycrystal refers to the angle of the normal direction of the (111) plane of the polycrystal relative to the direction perpendicular to the surface or first surface of the substrate 10. FIG. 5 shows the distribution of first inclination angles. In FIG. 5, the horizontal axis represents the first inclination angle (°). In FIG. 5, the vertical axis represents the ratio of the number of polycrystals having a certain first inclination angle to the total number of polycrystals contained in the wear-resistant layer 21.

[0044] Here, the "number of polycrystals" may be evaluated by the following procedure: (1) Measure the first tilt angle of each polycrystal included in the measurement range; (2) Among the polycrystals whose first tilt angles are measured in (1) above, the number of polycrystals whose first tilt angles are in the range of 0° to 60° is defined as the total number of polycrystals; (3) Divide the first tilt angles into a predetermined range δθ; (4) Count the number of polycrystals for each division set in (3) above according to the value of the first tilt angle measured in (2) above.

[0045] The section with the largest number of counted polycrystals among the sections in the first tilt angle is the primary peak. The median of each section is then defined as the first tilt angle where the primary peak exists. For example, if the first tilt angle is θ1 and the predetermined range δθ is 2°, the first tilt angles are divided into 0°≦θ1<2°, 2°≦θ1<4°, ..., 56°≦θ1<58°, and 58°≦θ1≦60°. If the measurement of the first tilt angle of one of the polycrystals reveals that θ1=57°, the number of polycrystals present in the section 56°≦θ1<58° is counted as 1. If the measurement of the first tilt angle of the polycrystals included in the measurement range reveals that the section 56°≦θ1<58° has the largest number of polycrystals, the distribution of first tilt angles within the range of 0° to 60° is evaluated as having a primary peak at 57°.

[0046] 5 , in the wear-resistant layer 21 according to the embodiment, the distribution of the first inclination angles in the range of 0° to 60° has a primary peak of the first inclination angles in the range of 50° to 60°. In other words, in the distribution of the first inclination angles in the range of 0° to 60°, the primary peak of the first inclination angles exists in the range of 50° to 60°. Here, the primary peak of the first inclination angle refers to the peak with the largest number ratio in the distribution of the first inclination angles in the range of 0° to 60°.

[0047] Here, polycrystals having a (111) plane with an inclination angle in the range of 50° to 60° are considered to be cubic crystals aligned generally along the surface or first surface of the substrate 10. Therefore, the presence of the primary peak of the first inclination angle in the range of 50° to 60° means that the proportion of cubic crystals aligned generally along the surface or first surface of the substrate 10 is high among the polycrystals contained in the wear-resistant layer 21.

[0048] In this way, when the first tilt angle has a primary peak at a specific angle (division) within the range of 50° to 60°, it can be said that there is a high proportion of cubic crystals aligned at a specific angle along the surface or first face of the base 10. Since the cutting load can be distributed among the cubic crystals aligned at this specific angle, durability against wear such as abrasive wear is improved.

[0049] If the primary peak of the first tilt angle is simply in the range of 50° to 60°, the ratio of the number of polycrystals having the first tilt angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer 21 is likely to be large. That is, the tilt angle of the (111) plane of the polycrystals is likely to be excessively concentrated in the range of 50° to 60°.

[0050] However, in the wear-resistant layer 21 according to the embodiment, the ratio of the number of polycrystals having the first tilt angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer 21 is 50% or less. As described above, the first tilt angle is the tilt angle of the (111) plane of the polycrystals, so it can be said that the ratio of the number of polycrystals having the (111) plane tilt angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer 21 is 50% or less.

[0051] Thus, since the ratio of the number of polycrystals having a first tilt angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer 21 is 50% or less, it can be said that the tilt angles of the (111) planes of the polycrystals are not excessively concentrated in the range of 50° to 60°. In other words, it can be said that the distribution of the orientation directions of the polycrystals with respect to the surface or first surface of the substrate 10 is not excessively concentrated in a particular direction but is a moderately dispersed distribution.

[0052] As described above, in the wear-resistant layer 21 according to the embodiment, the proportion of the number of polycrystals having a (111) plane with an inclination angle in the range of 50° to 60° is the highest but is 50% or less. As a result, although the proportion of the orientation direction of the polycrystals relative to the surface or first surface of the substrate 10 is highest in a specific direction, the distribution of the orientation directions of the polycrystals relative to the surface or first surface of the substrate 10 is not concentrated in a specific direction but is a moderately dispersed distribution.

[0053] When a load is applied to the wear-resistant layer 21 according to this embodiment, the load is dispersed by the polycrystals having a moderately dispersed distribution of orientation directions. As a result, even when loads are applied to the wear-resistant layer 21 according to this embodiment from various directions, it is possible to reduce, for example, the frequency of cracks occurring in the wear-resistant layer 21 and / or peeling of the wear-resistant layer 21. Alternatively, it is possible to reduce, for example, the rate at which cracks and / or peeling of the wear-resistant layer 21 progress.

[0054] That is, not only can the wear resistance of the coating layer 20 be improved, but also the durability of the coating layer 20 against loads in various directions can be improved, thereby improving the durability of the coated tool 1. As a result, the tool life of the coated tool 1 can be extended.

[0055] As shown in FIG. 5 , the distribution of first tilt angles within the range of 0° to 60° may have a secondary peak of the first tilt angle at a lower angle than the primary peak of the first tilt angle. In other words, in the distribution of first tilt angles within the range of 0° to 60°, the secondary peak of the first tilt angle may be located at a lower angle than the primary peak of the first tilt angle within the range of 50° to 60°. Here, the secondary peak of the first tilt angle refers to the peak with the second highest numerical ratio in the distribution of first tilt angles within the range of 0° to 60°. The orientation of the polycrystal that provides the secondary peak of the first tilt angle is considered to be different from the orientation of the polycrystal that provides the primary peak of the first tilt angle, i.e., the polycrystal having a first tilt angle within the range of 50° to 60°.

[0056] In this case, since the secondary peak of the first tilt angle is located at a lower angle than the primary peak of the first tilt angle, it is possible to more reliably achieve a ratio of 50% or less of the number of polycrystals having a first tilt angle in the range of 50° to 60°. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation direction of the polycrystals relative to the surface or first face of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0057] 5, the distribution of the first tilt angles in the range of 0° to 60° may have a secondary peak of the first tilt angles in the range of 20° to 30°. In other words, in the distribution of the first tilt angles in the range of 0° to 60°, the secondary peak of the first tilt angles may be present in the range of 20° to 30°.

[0058] In this case, since the secondary peak of the first tilt angle is in the range of 20° to 30°, it is possible to more reliably achieve a ratio of the number of polycrystals having a first tilt angle in the range of 50° to 60° being 50% or less. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation direction of the polycrystals relative to the surface or first face of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0059] 5, the value of the secondary peak at the first tilt angle may be 30% to 70% of the value of the primary peak at the first tilt angle. For example, the value of the primary peak at the first tilt angle and the value of the secondary peak at the first tilt angle are the proportion of the number of polycrystals that give the primary peak at the first tilt angle and the proportion of the number of polycrystals that give the secondary peak at the first tilt angle, respectively.

[0060] In this case, the value of the secondary peak at the first tilt angle is 30% to 70% of the value of the primary peak at the first tilt angle, allowing for a suitable adjustment of the ratio of the number of polycrystals exhibiting the secondary peak at the first tilt angle to the number of polycrystals exhibiting the primary peak at the first tilt angle. Accordingly, it is possible to more reliably achieve a maximum ratio of polycrystals exhibiting a first tilt angle in the range of 50° to 60°, but still below 50%. In other words, it is possible to more reliably achieve a suitably dispersed distribution of the orientation direction of the polycrystals relative to the surface or first face of the substrate 10. This can therefore more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0061] 5, the distribution of the first tilt angle within the range of 0° to 60° may have a tertiary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle and higher than the secondary peak of the first tilt angle. In other words, in the distribution of the first tilt angle within the range of 0° to 60°, the tertiary peak of the first tilt angle may be located at an angle lower than the primary peak of the first tilt angle and higher than the secondary peak of the first tilt angle.

[0062] Here, the secondary peak of the first tilt angle refers to the peak with the third largest numerical proportion in the distribution of the first tilt angle in the range of 0° to 60°. The orientation of the polycrystal that gives the tertiary peak of the first tilt angle is considered to be different from the orientation of the polycrystal that gives the primary peak of the first tilt angle, i.e., the polycrystal having the first tilt angle in the range of 50° to 60°.

[0063] In this case, since the tertiary peak of the first tilt angle is located at a lower angle than the primary peak of the first tilt angle and at a higher angle than the secondary peak of the first tilt angle, it is possible to more reliably achieve a ratio of 50% or less of the number of polycrystals having a first tilt angle in the range of 50° to 60°. In other words, it is possible to more reliably achieve a moderately dispersed distribution of the orientation direction of the polycrystals relative to the surface or first face of the substrate 10. This makes it possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0064] For the wear-resistant layer 21 according to the embodiment, the inclination angle of the (100) plane of the polycrystal contained in the wear-resistant layer 21 relative to the direction perpendicular to the surface or first face of the substrate 10 is defined as the second inclination angle. Here, the inclination angle of the (100) plane of the polycrystal refers to the angle of the normal direction of the (100) plane of the polycrystal relative to the direction perpendicular to the surface or first face of the substrate 10. FIG. 6 shows the distribution of second inclination angles. In FIG. 6, the horizontal axis represents the second inclination angle (°). In FIG. 6, the vertical axis represents the ratio of the number of polycrystals having a certain second inclination angle to the total number of polycrystals contained in the wear-resistant layer 21.

[0065] As shown in Fig. 6, in the wear-resistant layer 21 according to the embodiment, the distribution of the second inclination angles in the range of 0° to 60° may have a primary peak of the second inclination angles in the range of 20° to 30°. In other words, in the distribution of the second inclination angles in the range of 0° to 60°, the primary peak of the second inclination angles may be in the range of 20° to 30°. Here, the primary peak of the second inclination angle refers to the peak with the largest number proportion in the distribution of the second inclination angles in the range of 0° to 60°.

[0066] Therefore, the presence of the primary peak of the second tilt angle in the range of 20° to 30° means that the ratio of the number of polycrystals having a (100) plane with a tilt angle in the range of 20° to 30° is the highest relative to the total number of polycrystals contained in the wear-resistant layer 21. Here, the polycrystals having a (100) plane with a tilt angle in the range of 20° to 30° are considered to be cubic crystals that are not generally aligned along the surface or the first face of the substrate 10.

[0067] That is, the orientation of a polycrystal having a (100) plane with a tilt angle in the range of 20° to 30° is considered to be different from the orientation of a polycrystal having a (111) plane with a tilt angle in the range of 50° to 60°. In other words, the orientation of a polycrystal that provides a primary peak at the second tilt angle is considered to be different from the orientation of a polycrystal that provides a primary peak at the first tilt angle, i.e., a polycrystal with a first tilt angle in the range of 50° to 60°.

[0068] In this case, since the primary peak of the second tilt angle is in the range of 20° to 30°, it is possible to more reliably achieve a ratio of the number of polycrystals having a first tilt angle in the range of 50° to 60° of 50% or less. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or first face of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0069] As shown in FIG. 6 , the distribution of second tilt angles within the range of 0° to 60° may have a secondary peak of the second tilt angle at a higher angle than the primary peak of the second tilt angle. In other words, in the distribution of second tilt angles within the range of 0° to 60°, the primary peak of the second tilt angle may be located at a higher angle than the primary peak of the second tilt angle within the range of 20° to 30°. Here, the secondary peak of the second tilt angle refers to the peak with the second highest numerical ratio in the distribution of second tilt angles within the range of 0° to 60°. The orientation of the polycrystal that provides the secondary peak of the second tilt angle is considered to be different from the orientation of the polycrystal that provides the primary peak of the first tilt angle, i.e., the polycrystal having a first tilt angle within the range of 50° to 60°.

[0070] In this case, since the secondary peak of the second tilt angle is located at a higher angle than the primary peak of the second tilt angle, it is possible to more reliably achieve a ratio of 50% or less of the number of polycrystals having a first tilt angle in the range of 50° to 60°. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or first face of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0071] As shown in Fig. 6, the distribution of the second tilt angles in the range of 0° to 60° may have a secondary peak of the second tilt angles in the range of 40° to 60°. In other words, in the distribution of the second tilt angles in the range of 0° to 60°, the secondary peak of the second tilt angles may be present in the range of 40° to 60°.

[0072] In this case, since the secondary peak of the second tilt angle is in the range of 40° to 60°, it is possible to more reliably achieve a ratio of the number of polycrystals having a first tilt angle in the range of 50° to 60° being 50% or less. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or first face of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0073] As shown in Fig. 6, the value of the secondary peak at the second tilt angle may be 70% to 90% of the value of the primary peak at the second tilt angle. For example, the value of the primary peak at the second tilt angle and the value of the secondary peak at the second tilt angle are the proportion of the number of polycrystals that give the primary peak at the second tilt angle and the proportion of the number of polycrystals that give the secondary peak at the second tilt angle, respectively.

[0074] In this case, the value of the secondary peak at the second tilt angle is 70% to 90% of the value of the primary peak at the second tilt angle, allowing for a suitable adjustment of the ratio of the number of polycrystals exhibiting the secondary peak at the second tilt angle to the number of polycrystals exhibiting the primary peak at the second tilt angle. Accordingly, it is possible to more reliably achieve a ratio of 50% or less of the number of polycrystals having a first tilt angle in the range of 50° to 60°. In other words, it is possible to more reliably achieve a suitably dispersed distribution of the orientation direction of the polycrystals relative to the surface or first face of the substrate 10. This can therefore more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0075] As shown in Fig. 6, the distribution of second tilt angles within the range of 0° to 60° may have a tertiary peak of the second tilt angles at a lower angle than the primary peak of the second tilt angles. In other words, in the distribution of second tilt angles within the range of 0° to 60°, the tertiary peak of the second tilt angles may be located at a lower angle than the primary peak of the second tilt angles. Here, the tertiary peak of the second tilt angles refers to the peak with the third largest proportion in number in the distribution of second tilt angles within the range of 0° to 60°.

[0076] In this case, since the tertiary peak of the second tilt angle is located at a lower angle than the primary peak of the second tilt angle, it is possible to more reliably achieve the highest proportion of polycrystals having a first tilt angle in the range of 50° to 60°, but still below 50%. In other words, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or first face of the substrate 10. This makes it possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0077] (Details of Intermediate Layer 22) Next, an example of the details of the intermediate layer 22 included in the coating layer 20 according to the embodiment will be described with reference to Figs. 7 and 8. Fig. 7 is a diagram illustrating the distribution of inclination angles of the (111) plane of the polycrystals included in the intermediate layer 22 according to the embodiment. Fig. 8 is a diagram illustrating the distribution of inclination angles of the (100) plane of the polycrystals included in the intermediate layer 22 according to the embodiment. The distribution of inclination angles of the (111) plane and the (100) plane of the polycrystals included in the intermediate layer 22 can be evaluated by analyzing the crystal orientation using a TEM electron diffraction mapping method, for example, in the same manner as the analysis of the wear-resistant layer 21.

[0078] For the intermediate layer 22 according to the embodiment, the inclination angle of the (111) plane of the polycrystal contained in the intermediate layer 22 relative to the direction perpendicular to the surface or first face of the substrate 10 is defined as a third inclination angle. Here, the inclination angle of the (111) plane of the polycrystal refers to the angle of the normal direction of the (111) plane of the polycrystal relative to the direction perpendicular to the surface or first face of the substrate 10. FIG. 7 shows the distribution of third inclination angles. In FIG. 7, the horizontal axis represents the third inclination angle (°). In FIG. 7, the vertical axis represents the ratio of the number of polycrystals having a certain third inclination angle to the total number of polycrystals contained in the intermediate layer 22.

[0079] 7 , in the intermediate layer 22 according to the embodiment, the distribution of the third tilt angles in the range of 0° to 60° has a primary peak of the third tilt angles in the range of 50° to 60°. In other words, in the distribution of the third tilt angles in the range of 0° to 60°, the primary peak of the third tilt angles exists in the range of 50° to 60°. Here, the primary peak of the third tilt angle refers to the peak at which the proportion of the number is greatest in the distribution of the third tilt angles in the range of 0° to 60°.

[0080] Therefore, the presence of the primary peak of the third tilt angle in the range of 50° to 60° means that the ratio of the number of polycrystals having a (111) plane with a tilt angle in the range of 50° to 60° is the highest relative to the total number of polycrystals contained in the intermediate layer 22. Here, the polycrystals having a (111) plane with a tilt angle in the range of 50° to 60° are considered to be cubic crystals arranged generally along the surface or the first surface of the substrate 10.

[0081] In this case, since the primary peak of the third inclination angle is in the range of 50° or more and 60° or less, not only in the wear-resistant layer 21 according to the embodiment, but also in the intermediate layer 22 according to the embodiment, the proportion of polycrystals having a (111) plane with an inclination angle in the range of 50° or more and 60° or less is the highest.

[0082] Accordingly, it is possible to more reliably achieve the highest proportion of polycrystals having (111) planes with inclination angles in the range of 50° to 60° in the wear-resistant layer 21. Therefore, it is possible to more reliably achieve the highest proportion of polycrystals with a first inclination angle in the range of 50° to 60°, but not exceeding 50%. In other words, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or first surface of the substrate 10. Therefore, it is possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0083] For the intermediate layer 22 according to the embodiment, the inclination angle of the (100) plane of the polycrystal contained in the intermediate layer 22 relative to the direction perpendicular to the surface or first face of the substrate 10 is defined as a fourth inclination angle. Here, the inclination angle of the (100) plane of the polycrystal refers to the angle of the normal direction of the (100) plane of the polycrystal relative to the direction perpendicular to the surface or first face of the substrate 10. FIG. 8 shows the distribution of the fourth inclination angles. In FIG. 8, the horizontal axis represents the fourth inclination angle (°). In FIG. 8, the vertical axis represents the ratio of the number of polycrystals having a certain fourth inclination angle to the total number of polycrystals contained in the intermediate layer 22.

[0084] 8 , in the intermediate layer 22 according to the embodiment, the distribution of the fourth tilt angles within the range of 0° to 60° may have a primary peak of the fourth tilt angles within the range of 10° to 20°. In other words, in the distribution of the fourth tilt angles within the range of 0° to 60°, the primary peak of the fourth tilt angles may be within the range of 10° to 20°. Here, the primary peak of the fourth tilt angles refers to the peak at which the proportion of the number is greatest in the distribution of the fourth tilt angles within the range of 0° to 60°.

[0085] Therefore, the presence of the primary peak of the fourth tilt angle in the range of 10° to 20° means that the ratio of the number of polycrystals having a (100) plane with a tilt angle in the range of 10° to 20° is the highest relative to the total number of polycrystals contained in the intermediate layer 22. Here, the polycrystals having a (100) plane with a tilt angle in the range of 10° to 20° are considered to be cubic crystals that are not generally aligned along the surface or the first plane of the substrate 10.

[0086] In this case, since the primary peak of the fourth inclination angle is in the range of 10° or more and 20° or less, it is possible to more reliably achieve that the proportion of polycrystals having an inclination angle in the range of 50° or more and 60° or less is 50% or less not only in the wear-resistant layer 21 of the embodiment but also in the intermediate layer 22 of the embodiment.

[0087] Accordingly, it is possible to more reliably achieve that the proportion of polycrystals having a first inclination angle in the range of 50° to 60° in the wear-resistant layer 21 is 50% or less. That is, it is possible to more reliably achieve a moderately dispersed distribution of the orientation directions of the polycrystals relative to the surface or the first face of the base 10. This makes it possible to more reliably improve the durability of the coated tool 1. As a result, it is possible to more reliably extend the tool life of the coated tool 1.

[0088] In the above, a "peak" in the distribution of tilt angles is defined as having a value less than half of the peak maximum value on both the lower and higher angle sides relative to the tilt angle corresponding to the peak maximum. However, if the lower angle includes 0°, a "peak" in the distribution of tilt angles is defined as having a value less than half of the peak maximum value on the higher angle side relative to the tilt angle corresponding to the peak maximum. If the higher angle includes 60°, a "peak" in the distribution of tilt angles is defined as having a value less than half of the peak maximum value on the lower angle side relative to the tilt angle corresponding to the peak maximum.

[0089] The distribution of the first tilt angle, the distribution of the second tilt angle, the distribution of the third tilt angle, and the distribution of the fourth tilt angle as described above can be obtained, for example, by analysis using a transmission electron microscope (TEM) electron diffraction mapping method.

[0090] More specifically, a crystal orientation map for the (111) plane of the polycrystal contained in the wear-resistant layer 21 in the direction perpendicular to the surface or first surface of the substrate 10, a crystal orientation map for the (100) plane of the polycrystal contained in the wear-resistant layer 21 in the direction perpendicular to the surface or first surface of the substrate 10, a crystal orientation map for the (111) plane of the polycrystal contained in the intermediate layer 22 in the direction perpendicular to the surface or first surface of the substrate 10, and a crystal orientation map for the (100) plane of the polycrystal contained in the intermediate layer 22 in the direction perpendicular to the surface or first surface of the substrate 10 are obtained.

[0091] By analyzing these crystal orientation maps, the distribution of the first tilt angle, the distribution of the second tilt angle, the distribution of the third tilt angle, and the distribution of the fourth tilt angle can be obtained. The ratio of the number of polycrystals having a first tilt angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer 21 can be obtained, for example, by summing the ratios of the number of polycrystals in the first tilt angle range of 50° to 60°.

[0092] (Method for manufacturing the coating layer 20) Next, an example of a method for manufacturing the coating layer 20 according to this embodiment will be described. The method for manufacturing the coating layer 20 according to this embodiment is not limited to the following manufacturing method.

[0093] The coating layer 20 may be formed by, for example, a physical vapor deposition (PVD) method. For example, when the coating layer 20 is formed by utilizing the physical vapor deposition method while the base body 10 is held on the inner peripheral surface of the through hole 5, the coating layer 20 can be formed so as to cover the entire surface of the base body 10 except for the inner peripheral surface of the through hole 5.

[0094] Examples of physical vapor deposition methods include ion plating methods such as arc ion plating (AIP) and sputtering. Arc ion plating is a method of evaporating a target metal in a vacuum atmosphere by using arc discharge, and optionally N ２ This is a method for forming a film of a metal or metal nitride by bonding with a gas, etc. Here, the bias voltage applied to the substrate 10, which is the object to be coated, may be −30 V or less.

[0095] As an example, when the coating layer 20 is produced by the arc ion plating method, the coating layer 20 can be produced by the following method.

[0096] First, a description will be given of an example of a method for manufacturing the adhesion layer 23. As an example, a metal target, a composite alloy target, or a sintered target of Ti, Al, and M (where M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table, and Si) is prepared.

[0097] Next, the target, which is the metal source, is evaporated and ionized by arc discharge, glow discharge, or the like, and the ionized metal is vapor-deposited onto the surface or the first surface of the substrate 10. By the above procedure, the adhesion layer 23 can be formed.

[0098] The composition of the adhesion layer 23 can be adjusted by independently controlling the voltage and current values ​​applied to the various metal targets during arc discharge or glow discharge for each target. The composition of the adhesion layer 23 can also be adjusted by controlling the composition of the metal target, the coating time, or the atmospheric gas pressure. The thickness of the adhesion layer 23 can be adjusted, for example, by controlling the coating time.

[0099] Next, a description will be given of an example of a method for manufacturing the intermediate layer 22. As an example, a metal target, a composite alloy target, or a sintered target of Ti, Al, and M (where M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table (excluding Cr) and Si) is prepared.

[0100] Next, the target, which is the metal source, is evaporated and ionized by arc discharge or glow discharge. The ionized metal is then evaporated with nitrogen (N ２ ) gas and is deposited on the surface or first surface of the substrate 10, or on the surface of the adhesive layer 23. The intermediate layer 22 can be formed by the above procedure.

[0101] The composition of the intermediate layer 22 can be adjusted by controlling the composition of the metal target. The grain size of the intermediate layer 22 can be adjusted by controlling the current value during arc discharge or glow discharge or by controlling the atmospheric gas pressure. The thickness of the intermediate layer 22 can be adjusted, for example, by controlling the coating time.

[0102] Next, a description will be given of a method for manufacturing the wear-resistant layer 21. As an example, a metal target, a composite alloy target, or a sintered target of Ti, Al, Cr, and M (where M is at least one metal selected from Groups 4a, 5a, and 6a of the periodic table (excluding Cr) and Si) is prepared.

[0103] Next, the target, which is the metal source, is evaporated and ionized by arc discharge or glow discharge. The ionized metal is then evaporated with nitrogen (N ２ ) gas and is deposited on the surface of the intermediate layer 22. The abrasion-resistant layer 21 can be formed by the above procedure.

[0104] The composition of the wear-resistant layer 21 can be adjusted by controlling the composition of the metal target. The grain size of the wear-resistant layer 21 can be adjusted by controlling the voltage and current values ​​during arc discharge or glow discharge, or by controlling the atmospheric gas pressure. The thickness of the wear-resistant layer 21 can be adjusted, for example, by controlling the coating time.

[0105] <Cutting Tool> Next, the configuration of a cutting tool including the coated tool 1 described above will be described with reference to Fig. 9. Fig. 9 is a front view showing an example of a cutting tool according to an embodiment.

[0106] As shown in FIG. 9 , a cutting tool 100 according to the embodiment includes a coated tool 1 and a holder 70 for fixing the coated tool 1 .

[0107] The holder 70 is a rod-shaped member extending from a first end (the upper end in FIG. 7 ) to a second end (the lower end in FIG. 7 ). The holder 70 is made of, for example, steel or cast iron. For example, steel, which has high toughness among these materials, may be used.

[0108] The holder 70 has a pocket 73 at the end on the first end side. The pocket 73 is a portion where the coated tool 1 is attached, and has a seating surface that intersects with the rotation direction of the workpiece and a restraining side surface that is inclined relative to the seating surface. The seating surface is provided with a screw hole into which a screw 75, which will be described later, is threaded.

[0109] The coated tool 1 is positioned in a pocket 73 of the holder 70 and attached to the holder 70 by a screw 75. That is, the screw 75 is inserted into the through hole 5 of the coated tool 1, and the tip of the screw 75 is inserted into a threaded hole formed in the seating surface of the pocket 73 to screw the threaded portions together. In this way, the coated tool 1 is attached to the holder 70 so that the cutting edge portion protrudes outward from the holder 70.

[0110] In the embodiment, a cutting tool 100 used for so-called turning is exemplified. Examples of turning include internal diameter machining, external diameter machining, and grooving. The cutting tool is not limited to that used for turning. For example, the coated tool 1 may be used as a cutting tool used for milling. Examples of cutting tools used for milling include milling cutters such as flat milling cutters, face milling cutters, side milling cutters, and groove milling cutters, and end mills such as single-blade end mills, multi-blade end mills, tapered-blade end mills, and ball end mills.

[0111] Examples of the present disclosure will be specifically described below, but the present disclosure is not limited to the examples shown below.

[0112] (Example) A coated tool including a substrate and a coating layer consisting of an adhesion layer, an intermediate layer, and a wear-resistant layer was fabricated by sequentially laminating an adhesion layer, an intermediate layer, and a wear-resistant layer on the surface of the substrate using an arc ion plating method. The substrate was a WC-based cemented carbide. The compositions and thicknesses of the adhesion layer, intermediate layer, and wear-resistant layer formed on the surface of the substrate are shown in Table 1.

[0113]

[0114] Next, the cutting edge of the coated tool produced as an example was subjected to crystal orientation analysis using a TEM electron diffraction mapping method. Specifically, crystal orientation maps were obtained for the (111) and (100) planes of the polycrystals contained in the wear-resistant layer and the intermediate layer in the direction perpendicular to the surface of the substrate. The crystal orientation map was obtained under the following conditions. <Crystal orientation map acquisition conditions> Transmission electron microscope: JEM-ARM200F manufactured by JEOL Crystal orientation analysis system: ASTAR manufactured by NanoMegas Measurement conditions Acceleration voltage: 200 kV Measurement area of ​​wear-resistant layer: 200 nm × 200 nm Measurement area of ​​intermediate layer: 1.5 μm × 1.5 μm

[0115] By analyzing the obtained crystal orientation map, the distribution of the inclination angle (first inclination angle) of the (111) plane of the polycrystal contained in the wear-resistant layer relative to the direction perpendicular to the surface of the substrate, the distribution of the inclination angle (second inclination angle) of the (100) plane of the polycrystal contained in the wear-resistant layer relative to the direction perpendicular to the surface of the substrate, the distribution of the inclination angle (third inclination angle) of the (111) plane of the polycrystal contained in the intermediate layer relative to the direction perpendicular to the surface of the substrate, and the distribution of the inclination angle (fourth inclination angle) of the (111) plane of the polycrystal contained in the intermediate layer relative to the direction perpendicular to the surface of the substrate were obtained.

[0116] Fig. 10 is a graph showing the distribution of first inclination angles according to an example. Fig. 11 is a graph showing the distribution of second inclination angles according to an example. Fig. 12 is a graph showing the distribution of third inclination angles according to an example. Fig. 13 is a graph showing the distribution of fourth inclination angles according to an example. The ratios of numbers in each of Fig. 10, Fig. 11, Fig. 12, and Fig. 13 are relative values.

[0117] As shown in Figure 10, it was confirmed that the distribution of the first tilt angle within the range of 0° or more and 60° or less has a primary peak of the first tilt angle within the range of 50° or more and 60° or less, a secondary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle, a secondary peak of the first tilt angle within the range of 20° or more and 30° or less, the value of the secondary peak of the first tilt angle (0.1) is 30% or more and 70% or less of the value of the primary peak of the first tilt angle (0.2), and a tertiary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle and higher than the secondary peak of the first tilt angle.

[0118] From the graph shown in Figure 10, it was confirmed that the ratio of the number of polycrystals having a first inclination angle in the range of 50° or more and 60° or less to the total number of polycrystals contained in the wear-resistant layer was 39%.

[0119] As shown in Figure 11, it was confirmed that the distribution of the second tilt angle within the range of 0° or more and 60° or less has a primary peak of the second tilt angle within the range of 20° or more and 30° or less, a secondary peak of the second tilt angle at a higher angle than the primary peak of the second tilt angle, a secondary peak of the second tilt angle within the range of 40° or more and 60° or less, the value of the secondary peak of the second tilt angle (0.07) is 70% or more and 90% or less of the value of the primary peak of the second tilt angle (0.1), and a tertiary peak of the second tilt angle at a lower angle than the primary peak of the second tilt angle.

[0120] As shown in FIG. 12, it was confirmed that the distribution of the third tilt angle in the range of 0° to 60° has a primary peak of the third tilt angle in the range of 50° to 60°.

[0121] As shown in FIG. 13, it was confirmed that the distribution of the fourth tilt angle in the range of 0° to 60° has a primary peak of the fourth tilt angle in the range of 10° to 20°.

[0122] Similarly, the cutting edge of a conventional coated tool as a comparative example was also analyzed for crystal orientation using the TEM electron diffraction mapping method. Specifically, crystal orientation maps were obtained for the (111) and (100) planes of the polycrystals contained in the wear-resistant layer and intermediate layer in the direction perpendicular to the surface of the substrate. The crystal orientation map was obtained under the following conditions: <Crystal orientation map acquisition conditions> Transmission electron microscope: JEM-ARM200F manufactured by JEOL Ltd. Crystal orientation analysis system: ASTAR manufactured by NanoMegas Corporation Measurement conditions: Acceleration voltage: 200 kV Measurement area of ​​the wear-resistant layer and intermediate layer: 400 nm x 400 nm

[0123] By analyzing the obtained crystal orientation map, the distribution of the first tilt angle, the distribution of the second tilt angle, the distribution of the third tilt angle, and the distribution of the fourth tilt angle were obtained. Fig. 14 is a graph showing the distribution of the first tilt angle according to the comparative example. Fig. 15 is a graph showing the distribution of the second tilt angle according to the comparative example. Fig. 16 is a graph showing the distribution of the third tilt angle according to the comparative example. Fig. 17 is a graph showing the distribution of the fourth tilt angle according to the comparative example. The ratios of numbers in each of Figs. 14, 15, 16, and 17 are relative values.

[0124] As shown in Fig. 14 , the distribution of the first tilt angles within the range of 0° to 60° had a primary peak of the first tilt angle within the range of 50° to 60°. However, as shown in Fig. 14 , the distribution of the first tilt angles within the range of 0° to 60° did not have a secondary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle. Accordingly, the distribution of the first tilt angles within the range of 0° to 60° did not have a secondary peak of the first tilt angle within the range of 20° to 30°, the value of the secondary peak of the first tilt angle was not 30% to 70% of the value of the primary peak of the first tilt angle, and the distribution did not have a tertiary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle and higher than the secondary peak of the first tilt angle.

[0125] From the graph shown in FIG. 14, the ratio of the number of polycrystals having a first inclination angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer was 61%.

[0126] 15 , the distribution of the second tilt angles within the range of 0° to 60° did not have a primary peak of the second tilt angles within the range of 20° to 30°. Accordingly, the distribution of the second tilt angles within the range of 0° to 60° did not have a secondary peak of the second tilt angles at an angle higher than the primary peak of the second tilt angles, did not have a secondary peak of the second tilt angles within the range of 40° to 60°, did not have a value of the secondary peak of the second tilt angles that was 70% to 90% of the value of the primary peak of the second tilt angles, and did not have a tertiary peak of the second tilt angles at an angle lower than the primary peak of the second tilt angles.

[0127] As shown in FIG. 16, the distribution of the third tilt angles in the range of 0° to 60° did not have a primary peak of the third tilt angles in the range of 50° to 60°.

[0128] As shown in FIG. 17, the distribution of the fourth tilt angle in the range of 0° to 60° did not have a primary peak of the fourth tilt angle in the range of 10° to 20°.

[0129] Next, the peel loads were measured for the coated tools according to the Examples and the Comparative Examples. Specifically, the coating layer of each of the coated tools according to the Examples and the Comparative Examples was scratched in a direction parallel to the surface of the substrate. The load applied to the coating layer was changed from 1 N to 25 N at a rate of change of 0.23 N / sec. The minimum load that caused peeling of the intermediate layer and the wear-resistant layer in the coating layer was measured as the peel load. The peel load for the coated tool according to the Examples was 18 N. The peel load for the coated tool according to the Comparative Example was 12 N. Thus, it was confirmed that the peel load for the coated tool according to the Examples was greater than that for the coated tool according to the Comparative Example.

[0130] Therefore, it was confirmed that when the distribution of first inclination angles within the range of 0° or more and 60° or less has a primary peak of first inclination angles within the range of 50° or more and 60° or less, and the ratio of the number of polycrystals having first inclination angles within the range of 50° or more and 60° or less to the total number of polycrystals contained in the wear-resistant layer is 50% or less, peeling of the intermediate layer and the wear-resistant layer in the coating layer is reduced.

[0131] On the other hand, it was confirmed that when the distribution of first inclination angles within the range of 0° to 60° has a primary peak at first inclination angles within the range of 50° to 60°, but the ratio of the number of polycrystals having a first inclination angle within the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer exceeds 50%, peeling of the intermediate layer and the wear-resistant layer in the coating layer is not reduced. Thus, when the ratio of the number of polycrystals having a first inclination angle within the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer exceeds 50%, the distribution of the orientation direction of the polycrystals relative to the surface of the substrate is concentrated in a specific direction. When a load is applied to such a wear-resistant layer, the load applied to the wear-resistant layer is thought to be concentrated in a specific direction. As a result, it is thought that the frequency of peeling of the wear-resistant layer is not reduced.

[0132] Next, cutting tests were carried out on the coated tools according to the examples and the comparative examples under the following conditions.

[0133] <Cutting test conditions> Workpiece: Inconel (registered trademark) 718 Cutting speed (Vc): 30 m / min Feed (f): 0.1 mm / rev Depth of cut (ap): 0.5 mm Cutting condition: Wet Tool used: CNMG120408SG

[0134] The length of abrasive wear in the thickness direction of the coating layer of the coated tool according to the example (hereinafter referred to as "abrasive wear amount") was measured using an image showing the cutting edge condition of the coated tool according to the example after the cutting test. The cutting times in the cutting test were 7.4 minutes, 14.8 minutes, 19.8 minutes, 24.7 minutes, 29.7 minutes, and 34.6 minutes.

[0135] Similarly, the amount of abrasive wear in the thickness direction of the coating layer of the coated tool according to the comparative example was measured using an image showing the cutting edge condition of the coated tool according to the comparative example after the cutting test. The cutting times in the cutting test were 7.4 minutes and 14.8 minutes.

[0136] Fig. 18 is a graph showing the correlation between cutting time and abrasive wear amount. The horizontal axis of the graph shown in Fig. 18 represents cutting time (minutes). The vertical axis of the graph shown in Fig. 18 represents abrasive wear amount (mm). In the graph shown in Fig. 18, open circles represent measured values ​​for the coated tool according to the example. Closed circles represent measured values ​​for the coated tool according to the comparative example.

[0137] 18 , it was confirmed that the abrasive wear amount of the coated tool according to the example was smaller than the abrasive wear amount of the coated tool according to the comparative example at a certain cutting time. In other words, it was confirmed that the cutting time of the coated tool according to the example was longer than the cutting time of the coated tool according to the comparative example at a certain abrasive wear amount.

[0138] Using images showing the cutting edge condition of the coated tool according to the example after the cutting test, the time until the abrasive wear amount of the coated tool according to the example reached 0.2 mm was calculated. The time until the abrasive wear amount of the coated tool according to the example reached 0.2 mm was more than 34.6 minutes. Similarly, using images showing the cutting edge condition of the coated tool according to the comparative example after the cutting test, the time until the abrasive wear amount of the coated tool according to the comparative example reached 0.2 mm was calculated. The time until the abrasive wear amount of the coated tool according to the comparative example reached 0.2 mm was 14.8 minutes. It was confirmed that at a certain abrasive wear amount, the cutting time of the coated tool according to the example was longer than the cutting time of the coated tool according to the comparative example.

[0139] As described above, it was confirmed that the wear resistance of the coated tool can be improved when the distribution of first inclination angles within the range of 0° to 60° has a primary peak at first inclination angles within the range of 50° to 60° and the ratio of the number of polycrystals having first inclination angles within the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer is 50% or less. That is, it was confirmed that the durability of the coated tool can be improved. In other words, it was confirmed that the tool life of the coated tool can be extended.

[0140] The cutting edge condition of the coated tool after 7.4 minutes of cutting under the above cutting conditions is shown in Figures 19 and 20. Figure 19 is an image showing the cutting edge condition of the coated tool according to the example after the cutting test. Figure 20 is an image showing the cutting edge condition of the coated tool according to the comparative example after the cutting test. In each of Figures 19 and 20, the portion of the cutting edge of the coated tool where the coating layer has been scraped away by abrasive wear D3 and the substrate is exposed is indicated by a dotted white circle.

[0141] 19 and 20 , it was confirmed that the abrasive wear D3 of the coated tool according to the example was reduced compared to the abrasive wear D3 of the coated tool according to the comparative example. Therefore, it was confirmed that the wear resistance of the coated tool can be improved when the distribution of the first inclination angles in the range of 0° to 60° has a primary peak at first inclination angles in the range of 50° to 60° and the ratio of the number of polycrystals having a first inclination angle in the range of 50° to 60° to the total number of polycrystals contained in the wear-resistant layer is 50% or less. In other words, it was confirmed that the durability of the coated tool can be improved.

[0142] <Notes> Note (1): A coated tool comprising: a base having a first surface; and a coating layer located on the first surface, wherein the coating layer includes: a first layer; and a second layer located between the first layer and the base, wherein each of the first layer and the second layer includes polycrystals containing a metal component including Ti and Al, and at least one element selected from the group consisting of carbon, nitrogen, and oxygen, wherein, when an inclination angle of a (111) plane of the polycrystals included in the first layer with respect to a direction perpendicular to the first surface is defined as a first inclination angle, a distribution of the first inclination angles within a range of 0° to 60° has a primary peak of the first inclination angles within a range of 50° to 60°, and a ratio of the number of the polycrystals having the first inclination angle within a range of 50° to 60° to a total number of the polycrystals included in the first layer is 50% or less. Appendix (2): The coated tool according to Appendix (1), wherein the distribution of the first inclination angle within the range of 0° to 60° has a secondary peak of the first inclination angle at an angle lower than the primary peak of the first inclination angle. Appendix (3): The coated tool according to Appendix (2), wherein the distribution of the first inclination angle within the range of 0° to 60° has a secondary peak of the first inclination angle within the range of 20° to 30°. Appendix (4): The coated tool according to Appendix (2) or (3), wherein the value of the secondary peak of the first inclination angle is 30% to 70% of the value of the primary peak of the first inclination angle. Appendix (5): The coated tool according to any one of Appendixes (2) to (4), wherein the distribution of the first inclination angle within the range of 0° to 60° has a tertiary peak of the first inclination angle at an angle lower than the primary peak of the first inclination angle and higher than the secondary peak of the first inclination angle. Supplementary Note (6): The coated tool according to any one of Supplementary Notes (1) to (5), wherein, when the inclination angle of the (100) plane of the polycrystal included in the first layer with respect to a direction perpendicular to the first surface is defined as a second inclination angle, the distribution of the second inclination angles within a range of 0° to 60° has a primary peak of the second inclination angles within a range of 20° to 30°.Appendix (7): The coated tool according to Appendix (6), wherein the distribution of the second inclination angle within the range of 0° to 60° has a secondary peak of the second inclination angle at a higher angle than the primary peak of the second inclination angle. Appendix (8): The coated tool according to Appendix (7), wherein the distribution of the second inclination angle within the range of 0° to 60° has a secondary peak of the second inclination angle within the range of 40° to 60°. Appendix (9): The coated tool according to Appendix (7) or (8), wherein the value of the secondary peak of the second inclination angle is 70% to 90% of the value of the primary peak of the second inclination angle. Appendix (10): The coated tool according to any one of Appendixes (7) to (9), wherein the distribution of the second inclination angle within the range of 0° to 60° has a tertiary peak of the second inclination angle at a lower angle than the primary peak of the second inclination angle. Appendix (11): The coated tool according to any one of Appendixes (1) to (10), wherein, when an inclination angle of a (111) plane of the polycrystal included in the second layer with respect to a direction perpendicular to the first surface is defined as a third inclination angle, a distribution of the third inclination angle within a range of 0° to 60° has a primary peak of the third inclination angle within a range of 50° to 60°. Appendix (12): The coated tool according to any one of Appendixes (1) to (11), wherein, when an inclination angle of a (100) plane of the polycrystal included in the second layer with respect to a direction perpendicular to the first surface is defined as a fourth inclination angle, a distribution of the fourth inclination angle within a range of 0° to 60° has a primary peak of the fourth inclination angle within a range of 10° to 20°. Appendix (13): A cutting tool comprising: a rod-shaped holder having a pocket at an end; and the coated tool according to any one of Appendixes (1) to (12) positioned in the pocket.

[0143] Further advantages and / or modifications may readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described above. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.

[0144] REFERENCE SIGNS LIST 1 coated tool 2 tip body 5 through hole 10 substrate 20 coating layer 21 first layer (wear-resistant layer) 22 second layer (intermediate layer) 23 third layer (adhesion layer) 70 holder 73 pocket 75 screw 100 cutting tool 201 corner portion

Claims

1. a substrate having a first surface; a coating layer overlying the first surface; Equipped with The coating layer is The first layer, a second layer positioned between the first layer and the substrate; Including, each of the first layer and the second layer includes a polycrystal containing a metal component including Ti and Al and at least one element selected from the group consisting of carbon, nitrogen, and oxygen; When the inclination angle of the (111) plane of the polycrystal included in the first layer with respect to the direction perpendicular to the first surface is defined as a first inclination angle, the distribution of the first tilt angle in the range of 0° to 60° has a primary peak of the first tilt angle in the range of 50° to 60°, a ratio of the number of the polycrystals having the first tilt angle in the range of 50° to 60° to the total number of the polycrystals included in the first layer is 50% or less; Coated tools.

2. The distribution of the first tilt angle within the range of 0° to 60° has a secondary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle. The coated tool according to claim 1 .

3. The distribution of the first tilt angle in the range of 0° to 60° has a secondary peak of the first tilt angle in the range of 20° to 30°. The coated tool according to claim 2 .

4. a secondary peak value of the first tilt angle is 30% or more and 70% or less of a primary peak value of the first tilt angle; The coated tool according to claim 2 .

5. The distribution of the first tilt angle within the range of 0° to 60° has a tertiary peak of the first tilt angle at an angle lower than the primary peak of the first tilt angle and at an angle higher than the secondary peak of the first tilt angle. The coated tool according to claim 2 .

6. When the inclination angle of the (100) plane of the polycrystal included in the first layer with respect to the direction perpendicular to the first surface is defined as a second inclination angle, The distribution of the second tilt angle in the range of 0° to 60° has a primary peak of the second tilt angle in the range of 20° to 30°. The coated tool according to claim 1 .

7. The distribution of the second tilt angle within the range of 0° to 60° has a secondary peak of the second tilt angle at a higher angle side than the primary peak of the second tilt angle. The coated tool according to claim 6.

8. The distribution of the second tilt angle in the range of 0° to 60° has a secondary peak of the second tilt angle in the range of 40° to 60°. The coated tool according to claim 7.

9. a secondary peak value of the second tilt angle is 70% or more and 90% or less of a primary peak value of the second tilt angle; The coated tool according to claim 7.

10. The distribution of the second tilt angle within the range of 0° to 60° has a tertiary peak of the second tilt angle at an angle lower than the primary peak of the second tilt angle. The coated tool according to claim 7.

11. When the inclination angle of the (111) plane of the polycrystal included in the second layer with respect to the direction perpendicular to the first surface is defined as a third inclination angle, The distribution of the third tilt angle in the range of 0° to 60° has a primary peak of the third tilt angle in the range of 50° to 60°. The coated tool according to claim 1 .

12. When the inclination angle of the (100) plane of the polycrystal included in the second layer with respect to the direction perpendicular to the first surface is defined as a fourth inclination angle, The distribution of the fourth tilt angle in the range of 0° to 60° has a primary peak of the fourth tilt angle in the range of 10° to 20°. The coated tool according to claim 1 .

13. a rod-shaped holder having a pocket at an end; The coated tool according to any one of claims 1 to 12, which is located in the pocket; A cutting tool comprising: