CBN Sintered Binder Composition for Longer Cutting Tool Life
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Solution Overview
Problem
Existing cutting tools using cubic boron nitride sintered materials face challenges in achieving both high-efficiency processing and extended tool life, particularly when processing high-hardness hardened steel and other difficult-to-cut materials.
Innovation Solution
A sintered material comprising 3% to 80% cubic boron nitride grains and a binder containing specific metallic elements like Li, Ca, and their nitrides, along with controlled oxygen and carbon content, which enhances the tool's wear resistance and fracture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cubic boron nitride sintered material is used for high-efficiency processing, then productivity is improved, but tool life deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by incorporating specific metallic elements (Li, Ca, Na, Sr, Ba, or Be) at controlled concentrations (0.001-0.5 mass%). This parameter modification enhances the binder's bonding strength and fracture resistance, thereby extending tool life while preserving high-efficiency cutting capabilities
Solution Approach 2:
The invention creates a composite binder system combining traditional binder materials with trace metallic elements. This composite structure leverages the synergistic effects between the binder and metallic additives to simultaneously improve bonding force, wear resistance, and fracture toughness, resolving the contradiction between productivity and tool life
2Duration of action of moving object
If binder composition is optimized for bonding force, then tool life is improved, but manufacturing complexity increases
Solution Approach 1:
The invention applies local quality by introducing trace amounts (0.001-0.5 mass%) of specific metallic elements at precise locations within the binder matrix. This localized addition of functional elements enhances bonding force without requiring comprehensive reformulation of the entire binder system, thus limiting complexity increase
Solution Approach 2:
The invention uses partial action by adding only trace quantities of metallic elements rather than bulk amounts. This minimal addition is sufficient to achieve the desired bonding enhancement and tool life extension while avoiding the complexity associated with major compositional changes
Data Source
AI summary
A sintered material has 3% by volume or more and 80% by volume or less of cubic boron nitride grains and a binder. The binder contains: one or more types selected from the group consisting of one or more compounds composed of one or more first elements selected from the group consisting of a group 4 element, a group 5 element, a group 6 element, Al and Si and one or more second elements selected from the group consisting of C, N, O and B, and a solid solution of these compounds; and one or more metallic elements selected from the group consisting of Li, Ca, Na, Sr, Ba and Be. The binder contains the one or more metallic elements of 0.001% by mass or more and 0.5% by mass or less in total, and oxygen of 0.1% by mass or more and 10.0% by mass or less.