cBN Sintered Material Composition for Tough, Wear-Resistant Cutting Tools
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Solution Overview
Problem
Conventional sintered materials with high ZrO2 concentrations exhibit decreased hardness and wear resistance, while requiring improved flexural strength and life for cutting tools, particularly when cutting difficult-to-cut materials at high speeds.
Innovation Solution
A sintered material comprising cubic boron nitride, zirconium-containing oxide, zirconium-containing nitride, and aluminum-containing oxide, where the zirconium-containing nitride includes ZrN or ZrON, and the aluminum-containing oxide is α-type Al2O3, with specific particle size and content ratios to enhance flexural strength and life, and a cutting tool incorporating this material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high concentration of ZrO2 is used to increase toughness, then toughness is improved, but hardness decreases
Solution Approach 1:
The patent employs a composite binder system containing ZrO2 (5-20 mass%), ZrN (5-30 mass%), and Al2O3 (10-40 mass%). This composite approach allows the material to simultaneously achieve high toughness from ZrO2 and high hardness from ZrN and Al2O3, resolving the contradiction between toughness and hardness that occurs when using high concentrations of single-binder ZrO2.
2Strength
If high concentration of ZrO2 is used to increase toughness, then toughness is improved, but wear resistance decreases
Solution Approach 1:
The composite binder system combines ZrO2 for toughness with ZrN and Al2O3 for wear resistance. The ZrN phase specifically provides excellent wear resistance while maintaining the toughness benefits of ZrO2, thus resolving the contradiction between toughness and wear resistance.
Solution Approach 2:
The patent creates different phases with different properties within the binder: ZrO2 provides toughness, while ZrN and Al2O3 provide wear resistance. This local differentiation of material properties within the composite binder allows simultaneous achievement of toughness and wear resistance.
3Ease of manufacture
If conventional sintered material composition is used, then manufacturing simplicity is maintained, but flexural strength and life are insufficient
Solution Approach 1:
The patent modifies the chemical composition parameters of the binder by introducing specific ranges of ZrN (5-30 mass%) and Al2O3 (10-40 mass%) alongside ZrO2. These parameter changes enhance flexural strength and tool life while maintaining compatibility with conventional sintering processes, thus resolving the contradiction between manufacturing simplicity and improved mechanical properties.
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 sintered material achieves excellent flexural strength and life, preventing zirconia particle cracking and wear, and maintaining performance by controlling the content ratio of ZrN, ZrON, and Al2O3 with respect to cBN, thereby improving the cutting tool's durability and longevity.
Implementation Method 1
a sintered material obtained by sintering the cubic boron nitride together with a binder
Data Source
AI summary
A sintered material includes a cubic boron nitride, a zirconium-containing oxide, a zirconium-containing nitride, and an aluminum-containing oxide, wherein the zirconium-containing nitride includes both or one of ZrN and ZrON, and the aluminum-containing oxide includes a type Al2O3.