Cermet Insert With CTiW Interlayer For Wear And Chipping Resistance
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Solution Overview
Problem
Cermets with titanium as a main component face challenges in achieving optimal wear resistance and chipping resistance, particularly in cutting tools, due to limitations in binder phase composition and coating layer structure.
Innovation Solution
A cermet insert with a TiCN-based base and a multilayer coating system, including TiN, TiCN, and Al2O3 layers, where a CTiW compound with a specific composition is positioned between the base and the coating layer, enhancing wear and chipping resistance through controlled thermal expansion coefficients and compressive stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a drill bit is used to create hole portions in the workpiece, then hole formation is achieved, but burrs are generated on the inner surfaces of the hole portions
Solution Approach 1:
The cutting tool is divided into multiple cutting portions (first cutting portion and second cutting portion) that operate at different stages. The first cutting portion creates the hole with burrs, while the second cutting portion removes the burrs and finishes the inner surface, achieving both efficiency and quality through functional segmentation.
Solution Approach 2:
The cutting tool performs continuous useful action by integrating hole creation and burr removal in a single operation. The multiple cutting portions work sequentially without requiring the workpiece to be removed or repositioned, maintaining continuous material removal and surface finishing.
2Manufacturing precision
If a reamer is used to process hole portions, then inner surface quality is improved, but the processing time increases
Solution Approach 1:
The functions of hole creation and surface finishing are merged into a single cutting tool with multiple cutting portions. This eliminates the need for separate drilling and reaming operations, reducing processing time while maintaining high inner surface quality through the integrated cutting and finishing actions.
3Manufacturing precision
If multiple separate tools are used for hole creation and surface finishing, then processing quality is maintained, but the number of steps increases
Solution Approach 1:
The cutting tool is designed with multi-functionality, incorporating both roughing and finishing cutting portions in a single tool. This universal tool can perform hole creation, burr removal, and surface finishing operations, eliminating the need for multiple specialized tools and simplifying the processing sequence.
Data Source
Figure 1~2
Figure 3
AI summary
An insert of the present disclosure includes a base and a coating layer covering a surface of the base. The base includes a hard phase containing a carbonitride including Ti and a binder phase containing Co. A CTiW compound that contains C, Ti, and W and satisfies the relation of C > Ti > W is positioned between the base and the coating layer. A cutting tool of the present disclosure includes a holder extending from a first end to a second end and having a pocket on the first end side, and the insert positioned in the pocket positioned in the pocket.