cBN Sintered Material With Interfacial Phase for Stable Tool Life
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Solution Overview
Problem
Cubic boron nitride (cBN) cutting tools used for high-strength hardened steel experience unstable life due to rapid wear and defects caused by hard particles in the steel, leading to increased cutting resistance and premature failure.
Innovation Solution
A cBN sintered material with a specific composition comprising cubic boron nitride particles, a binding phase, and an interfacial phase containing aluminum, nitrogen, and oxygen, which enhances adhesion and stress absorption, preventing crack formation and particle detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cBN cutting tools are used for high-strength hardened steel, then cutting capability is improved, but tool life becomes unstable due to rapid wear and defects
Solution Approach 1:
An interfacial phase comprising aluminum nitride and aluminum boride is introduced between the cubic boron nitride particles and the binding phase. This interfacial phase acts as a mediator that improves adhesion at the particle-binder interface, prevents crack formation, and reduces particle detachment, thereby stabilizing tool life while maintaining cutting capability
Solution Approach 2:
The binding phase is designed as a composite material containing titanium nitride and aluminum compounds in specific proportions. This composite structure provides both strength and toughness, enabling the tool to withstand the mechanical stresses of cutting high-strength hardened steel while maintaining structural integrity over extended periods
2Productivity
If higher cutting speeds are used to improve productivity, then output increases, but wear and defects increase leading to premature failure
Solution Approach 1:
The interfacial phase and composite binding phase are designed beforehand to absorb and distribute mechanical stresses and thermal loads that occur during high-speed cutting. This pre-engineered cushioning structure prevents crack initiation and propagation, reducing wear and defects even at elevated cutting speeds
Solution Approach 2:
The chemical composition parameters of the binding phase and interfacial phase are optimized to achieve the right balance of hardness, toughness, and thermal stability. By adjusting the ratios of titanium nitride, aluminum compounds, aluminum nitride, and aluminum boride, the material properties are tuned to withstand high-speed cutting conditions while minimizing wear and defect formation
Data Source
AI summary
A cubic boron nitride sintered material comprises cubic boron nitride particles, a binding phase, and an interfacial phase. The interfacial phase intervenes between the cubic boron nitride particles and the binding phase. The interfacial phase includes aluminum, nitrogen, boron, and oxygen. A total of an average value of the atomic concentrations of aluminum included in the interfacial phase and an average value of the atomic concentrations of nitrogen included in the interfacial phase is 50.0 at % or more. A ratio of an average value of the atomic concentrations of nitrogen included in the interfacial phase to an average value of the atomic concentrations of boron included in the interfacial phase is more than 1.00.