Cubic Crystal Coating Structure for Durable Cutting Tools
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Solution Overview
Problem
Existing coated tools for cutting processes lack optimal durability and wear resistance, particularly in maintaining high intensity and orientation of cubic crystal planes, which affects their performance in cutting tools.
Innovation Solution
A coated tool with a cubic crystal coating layer composed of elements from Groups 4, 5, and 6, Al, Si, B, Y, and Mn, and C, N, O, featuring a maximum peak in X-ray intensity distribution at 50° or more for the (111) plane and a wide peak width, ensuring high orientation and durability, along with a laminated structure of AlTiN and AlCrN layers for enhanced hardness and peeling load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard coating film made of metal compound is applied to improve wear resistance, then the coating provides basic protective function, but the durability and wear resistance are insufficient without optimal crystal plane orientation
Solution Approach 1:
The patent applies parameter changes by controlling the crystal plane orientation parameters of the coating film. Specifically, it regulates the tilt angle of the (111) plane and (200) plane relative to the tool base member surface, and controls the in-plane orientation angles to achieve optimal wear resistance and durability through precise parameter optimization during the coating process
Solution Approach 2:
The patent employs composite materials by using a metal compound coating film with specific cubic crystal structure containing elements from Groups 4, 5, and 6 of the periodic table. The coating combines multiple elements to form a composite structure that achieves both hardness and optimal crystal plane orientation for enhanced durability
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 coated tool exhibits improved durability, hardness, and peeling load, maintaining high intensity even at 90°, and balanced performance in scratch tests, leading to enhanced cutting tool stability and longevity.
Implementation Method 1
A maximum peak is located in a range of 50° or more in a distribution of X-ray intensity (111) indicated at α axis of a pole figure, the X-ray intensity regarding a (111) plane of the cubic crystal
Data Source
AI summary
A coated tool includes a base and a coating layer on the base. The coating layer includes a cubic crystal that includes one or more kinds of elements selected from Groups 4, 5 and 6 in the periodic table, Al, Si, B, Y and Mn, and one or more kinds of elements selected from C, N and O. A maximum peak is in a range of 50° or more in a distribution of X-ray intensity (111) at α axis of a pole figure, the X-ray intensity regarding a (111) plane of the cubic crystal. The intensity at the maximum peak is Imax, a peak width at 0.8 Imax of the maximum peak is 20° or more, and the intensity at 90° is 0.78 Imax or more. A cutting tool includes a holder which includes a pocket at an end, and the coated tool in the pocket.