CBN Sintered Compact Composition for Wear and Breakage Resistance
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Solution Overview
Problem
Existing cubic boron nitride sintered materials do not provide sufficient tool life during high-efficiency machining of high-hardness steels, necessitating improved abrasion and breakage resistance.
Innovation Solution
A cubic boron nitride sintered material comprising specific volume content of cBN particles, a binder phase with selected elements and compounds, and a first phase containing cobalt and tungsten, with enhanced contact between binder phase particles, improving binding force and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the content of cubic boron nitride particles is increased to improve hardness, then abrasion resistance is improved, but toughness and breakage resistance deteriorate
Solution Approach 1:
The patent optimizes the volume content of cubic boron nitride particles within a specific range (25-80%) rather than maximizing it to 100%. This parameter optimization balances hardness and toughness, preventing excessive brittleness while maintaining sufficient abrasion resistance for high-hardness steel machining.
Solution Approach 2:
The patent creates a composite structure with multiple phases: cubic boron nitride particles (for hardness), binder phase particles (for binding), and first phase particles containing cobalt and tungsten (for toughness and breakage resistance). This multi-phase composite material combines the advantages of different materials to achieve both high hardness and sufficient toughness.
2Reliability
If the content of binder phase is increased to improve toughness, then breakage resistance is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent limits the binder phase content to 10-30% by volume, optimizing it to provide sufficient binding and toughness without excessive softness that would reduce abrasion resistance. This controlled parameter range balances the conflicting requirements.
Solution Approach 2:
The patent enhances local quality by forming a first phase containing cobalt and tungsten that selectively contacts the binder phase particles. This first phase is concentrated at the interfaces between binder phase particles, providing localized reinforcement and improvement of breakage resistance specifically where needed, without compromising overall abrasion resistance.
3Stability of the object's composition
If conventional binder phases are used to maintain chemical stability, then heat stability is maintained, but abrasion resistance in high-hardness steel machining deteriorates
Solution Approach 1:
The patent creates a composite binder system combining conventional binder phases (for chemical stability) with a first phase containing cobalt and tungsten (for improved abrasion resistance). This composite binder phase maintains the chemical stability needed for high-hardness steel machining while adding the wear resistance required for prolonged tool life.
Solution Approach 2:
The first phase containing cobalt and tungsten is selectively formed to contact the binder phase particles, creating localized regions of enhanced wear resistance at the critical interfaces. This local enhancement of properties allows the bulk material to maintain chemical stability while specific regions provide improved abrasion resistance.
Data Source
AI summary
Cubic boron nitride sintered material, including cubic boron nitride particles; a binder phase; and a first phase, wherein the content of the cubic boron nitride particles in the cubic boron nitride sintered material is 25% by volume or more and 80% by volume or less, the binder phase contains either or both of one or more first compounds consisting of at least one element selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, aluminum, and silicon, and at least one element selected from the group consisting of nitrogen, carbon, boron, and oxygen, and a solid solution derived from the first compound, the first phase contains cobalt, tungsten, and at least one first element selected from the group consisting of the elements contained in the binder phase, the total content of cobalt and tungsten in the cubic boron nitride sintered material is 1.0% by mass or more and 6.0% by mass or less, the binder phase consists of multiple binder phase particles, the multiple binder phase particles contain 50% or more of first binder phase particles on a number basis, surfaces of the first binder phase particles include 50% by area or more of a first region, and the first region is in contact with the first phase.