cBN Cutting Insert Composition for Wear and Fracture Resistance
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Solution Overview
Problem
Cubic boron nitride (cBN) sintered compacts used in cutting tools face challenges with low fracture resistance due to imbalances in the composition of TiN, AlN, and Al2O3, affecting wear resistance and strength.
Innovation Solution
A cBN sintered compact with a specific composition where TiN (200) intensity exceeds cBN (111) intensity, and AlN (100) exceeds Al2O3 (104), along with controlled Al content, enhances the balance between wear resistance and fracture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the composition of TiN, AlN, and Al2O3 is not balanced in the cBN sintered compact, then wear resistance may be sufficient, but fracture resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of TiN, AlN, and Al2O3 in the cBN sintered compact. Specifically, it sets TiN content at 5-20 mass%, AlN at 3-15 mass%, and Al2O3 at 3-15 mass%, with the additional constraint that AlN intensity exceeds Al2O3 intensity in XRD analysis. These parameter adjustments optimize both fracture resistance and wear resistance simultaneously.
Solution Approach 2:
The patent employs composite materials by creating a multi-phase sintered compact containing cBN, TiN, AlN, and Al2O3. This composite structure allows each component to contribute its unique properties: cBN provides hardness and wear resistance, while the controlled amounts of TiN, AlN, and Al2O3 enhance fracture resistance and overall mechanical stability.
2Strength
If TiN content is increased to improve wear resistance, then fracture resistance may improve, but the balance with AlN and Al2O3 deteriorates
Solution Approach 1:
The patent applies parameter changes by setting specific content ranges for each component: TiN at 5-20 mass%, AlN at 3-15 mass%, and Al2O3 at 3-15 mass%. These parameter constraints ensure that no single component dominates, maintaining composition balance while achieving the desired mechanical properties.
Solution Approach 2:
The patent applies local quality by differentiating the functional roles of each component in the composite. TiN is optimized for wear resistance, while AlN and Al2O3 contribute to fracture resistance and structural stability. The specific constraint that AlN intensity exceeds Al2O3 intensity in XRD analysis creates a localized compositional optimization within the overall balanced structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved cBN sintered compact exhibits enhanced wear resistance and fracture resistance, extending tool life and maintaining mechanical stability during cutting operations.
Implementation Method 1
TiN (200) is higher than cBN (111), where the TiN (200) is an X-ray intensity on a (200) plane of the TiN and the cBN (111) is an X-ray intensity on a (111) plane of the cBN, obtained by X-ray diffraction on the cBN sintered compact
Data Source
AI summary
An insert of the present disclosure includes a cBN sintered compact containing cBN and TiN. The cBN occupies 60% or more of the cross-sectional area of the cBN sintered compact observed. TiN (200) is higher than cBN (111), where the TiN (200) is an X-ray intensity on a (200) plane of the TiN and the cBN (111) is an X-ray intensity on a (111) plane of the cBN, obtained by X-ray diffraction on the cBN sintered compact.