Cubic Boron Nitride Sintered Material Binder Phase Design
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Solution Overview
Problem
Cubic boron nitride (cBN) sintered materials used in cutting tools experience significant wear and chipping due to cBN particles detaching during cutting operations, and existing binder phases with high mechanical and thermal properties are insufficient in preventing this wear and chipping.
Innovation Solution
A cBN sintered material with a binder phase containing a carbide and a nitride of specific metal elements from groups 4, 5, and 6 of the periodic table, which coexist to enhance bonding strength and wear resistance, and a fiber-like structure with alternating carbide and nitride binder phases for improved chipping resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of binder phase is added to bind cBN particles, then wear resistance is improved, but chipping resistance deteriorates due to lower mechanical properties of the binder phase
Solution Approach 1:
The invention uses a composite binder phase consisting of two or more different binder materials (such as TiCN, TiC, TiN, WC, NbC, TaC, HfC, Co, Ni, Cu, Al, or their combinations) in specific proportion ranges. This composite structure allows the binder phase to simultaneously provide strong bonding (improving wear resistance) and adequate mechanical properties (improving chipping resistance) that single-material binders cannot achieve alone.
Solution Approach 2:
The invention specifies precise proportion ranges for each binder material component (e.g., TiCN: 1-50 vol%, TiC: 1-40 vol%, Co: 1-30 vol%) to optimize the balance between wear resistance and chipping resistance. By controlling the composition parameters within these ranges, the binder phase achieves both high bonding strength and sufficient mechanical integrity to prevent chipping.
2Reliability
If binder phase with high mechanical and thermal properties is used, then wear resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The invention defines specific proportion ranges for multiple binder materials that can be systematically adjusted to achieve desired performance. By providing clear parameter ranges (e.g., TiCN: 1-50 vol%, TiC: 1-40 vol%, Co: 1-30 vol%), the complexity of selecting and formulating the binder phase is reduced, making it easier to manufacture while maintaining high 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 cBN sintered material exhibits high wear resistance and chipping resistance, allowing for extended tool life and efficient cutting of hard-to-cut materials like hardened steel, with reduced binder phase wear and cBN particle detachment.
Implementation Method 1
cBN particles that are bound by a binder phase, wherein the binder phase contains a carbide of at least one kind of metal element selected from among a group consisting of groups 4, 5 and 6 of the periodic table and a nitride of at least one kind of metal element selected from among a group consisting of groups 4, 5 and 6 of the periodic table coexisting therein
Implementation Method 2
the cBN sintered material having such a constitution is capable of suppressing the cBN particles from coming off and the binder phase from wearing and coming off at the same time, thus exhibiting high wear resistance and, especially, excellent chipping resistance
Data Source
AI summary
A cubic boron nitride sintered material where wear resistance is suppressed from decreasing having excellent chipping resistance and a cutting tool made thereof are provided. The sintered material is constituted from cubic boron nitride particles that are bound by a binder phase, while the binder phase contains a carbide of at least one kind of metal element selected from among metals of groups 4, 5 and 6 of the periodic table and a nitride of at least one kind of metal element selected from among metals of groups 4, 5 and 6 of the periodic table coexisting therein, and therefore the particles can be suppressed from coming off and the binder phase can be suppressed from wearing and coming off at the same time, thereby making the sintered material having high wear resistance and particularly excellent chipping resistance.