Coated Tool Protrusion Design for Wear and Fracture Resistance
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Solution Overview
Problem
Coated tools with titanium carbonitride and aluminum oxide layers face challenges in wear resistance and fracture resistance, especially under severe cutting conditions where chipping and peeling occur due to high impact.
Innovation Solution
A coated tool design featuring a substrate with a laminated coating layer structure, including a first titanium carbonitride layer with protrusions, a second titanium carbonitride layer with a higher number of protrusions, and an aluminum oxide layer, enhancing the joining properties and durability through specific layer thicknesses and compositions, and film-forming conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a coating layer with high wear resistance is used, then wear resistance is improved, but fracture resistance deteriorates under high impact conditions
Solution Approach 1:
The coating layer is divided into multiple sub-layers (first titanium carbonitride layer, second titanium carbonitride layer, aluminum oxide layer) with different functions. The first titanium carbonitride layer provides wear resistance, while the second titanium carbonitride layer with protrusions and aluminum oxide layer provide fracture resistance through impact absorption and stress distribution.
Solution Approach 2:
The invention uses a composite coating structure combining different materials (titanium carbonitride and aluminum oxide) with distinct properties. The titanium carbonitride layers provide hardness and wear resistance, while the aluminum oxide layer provides thermal stability and fracture toughness, creating a synergistic effect that resolves the contradiction between wear resistance and fracture resistance.
Data Source
AI summary
A coated tool may include a substrate and a coating layer located on a surface of the substrate. The coating layer includes: a first titanium carbonitride layer located on the substrate; a second titanium carbonitride layer located on the first titanium carbonitride layer; and an aluminum oxide layer located on the second titanium carbonitride layer. The first titanium carbonitride layer includes a plurality of first protrusions protruding toward a side of the aluminum oxide layer. The second titanium carbonitride layer includes a plurality of second protrusions protruding toward a side of the aluminum oxide layer. A number of second protrusions is greater than that of the first protrusions.