Coated Cutting Tool Chlorine Multi-Layer Wear Oxidation
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Solution Overview
Problem
Existing cutting tools face challenges in achieving adequate wear resistance and oxidation resistance, especially during high-speed and dry cutting processes, as conventional coatings fail to provide sufficient hardness and stability at high temperatures.
Innovation Solution
A coated cutting tool with a substrate coated using a compound containing Al, Cr, and at least one element from carbon, nitrogen, oxygen, and boron, with chlorine inclusion, forming multiple layers to enhance wear resistance and oxidation resistance, including a first layer with Al and/or Cr, a second layer with group IVa, Va, or VIa elements, and optionally a third layer with chlorine, improving adhesion and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coatings such as TiAlN or AlTiSi-based films are used, then wear resistance is improved, but oxidation resistance is insufficient at high temperatures
Solution Approach 1:
The patent applies composite material principles by creating a multi-layer coating structure combining TiAlN, AlTiSiN, and TiSiN layers. Each layer contributes different properties: TiAlN provides hardness and wear resistance, AlTiSiN forms protective alumina oxidation barriers, and TiSiN provides oxidation resistance and prevents porous oxide formation. The composite structure synergistically combines these properties to simultaneously achieve both wear resistance and oxidation resistance at high temperatures.
Solution Approach 2:
The patent applies local quality principles by assigning different functional properties to different layers of the coating. The TiAlN layer is optimized for hardness and wear resistance, the AlTiSiN layer is optimized for forming protective oxidation barriers, and the TiSiN layer is optimized for oxidation resistance and preventing porous oxide formation. Each layer is locally optimized for its specific function, and the combination provides comprehensive protection.
2Productivity
If high-speed and dry cutting is performed, then productivity is improved, but temperature increases leading to reduced tool life
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and structure of the coating layers to withstand high temperatures generated during high-speed cutting. The specific composition ratios of Al, Ti, Si, and other elements are optimized to maintain coating stability, hardness, and oxidation resistance at elevated temperatures, thereby extending tool life while enabling high-speed cutting operations.
Solution Approach 2:
The multi-layer composite coating structure enables high-speed cutting by combining materials with complementary high-temperature properties. The AlTiSiN layer forms stable alumina oxidation barriers, the TiSiN layer prevents porous oxide formation, and the TiAlN layer maintains hardness. This composite structure allows the tool to withstand the thermal conditions of high-speed cutting while maintaining performance and extending tool life.
3Strength
If conventional TiAlN coating is used, then hardness is improved, but oxidation resistance is inadequate due to porous Ti oxide layer formation
Solution Approach 1:
The patent applies the intermediary principle by introducing AlTiSiN and TiSiN layers as intermediate protective barriers between the TiAlN coating and the oxidizing environment. The AlTiSiN layer forms stable alumina oxidation barriers, while the TiSiN layer acts as an intermediate layer that prevents porous Ti oxide formation. These intermediary layers protect the underlying TiAlN hardness-providing layer from oxidation while maintaining the overall coating's hardness and wear resistance.
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 presence of chlorine in the coating significantly enhances wear resistance and oxidation resistance, leading to improved tool performance and extended tool life during high-speed and dry cutting operations.
Implementation Method 1
an alumina layer formed through surface oxidation taking place during cutting acts as an oxidation protection film that prevents the inward diffusion of oxygen
Implementation Method 2
The coating includes: a compound formed from elements Al and/or Cr and at least one element selected from a group consisting of carbon, nitrogen, oxygen, and boron
Implementation Method 3
The coating includes: a compound formed from elements Al and/or Cr and at least one element selected from a group consisting of carbon, nitrogen, oxygen, and boron
Data Source
AI summary
The present invention relates to a coated cutting tool equipped with a substrate and a coating formed on the substrate. The coating includes: a compound formed from elements Al and/or Cr and at least one element selected from a group consisting of carbon, nitrogen, oxygen, and boron; and chlorine.