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The metal cutting tool materials used today can be divided into nine types, from high-speed steel with the lowest cutting speed and the worst wear resistance to the most high-quality polycrystalline diamond tool. High-speed cutting also requires tool materials with good toughness, high impact resistance and good wear resistance.
In general, lower performance tools, such as high speed steel and uncoated cemented carbide, are widely used in general machining, but have high speed performance. High-performance tools, such as polycrystalline diamond tools, are the hardest of all tool materials, with very high wear resistance and speed capability. Cutting heat has little effect on it, and high-speed processing of non-ferrous and non-metallic materials. It fully reflects its superiority. However, its impact resistance is poor, and its thermal properties are poor when cutting steel and cast iron materials. Because of the high-speed cutting of ferrous metals, carbon atoms in the tool material will spread to the workpiece, causing increased tool wear.
Carbide tools are the most widely used, accounting for 80% of all tool sales. 90% of ordinary speed metal cutting uses carbide tools. Cemented carbide has better impact toughness, but high speed performance is not good. In addition, high-speed cutting tools also have extremely high thermohardness and chemical stability, and the hard alloys are not satisfactory.
CBN tools are extremely heat resistant and can cut hard materials at high temperatures, but they are expensive and cannot be processed with soft metal materials. The aluminum-based ceramic material with good chemical stability is just suitable for this kind of processing, but it lacks thermosetting properties and cannot be used for high-speed processing.
Focusing on the advantages of different characteristics of tool materials, the development of new tool materials, which have both impact resistance and high wear resistance, is one of the main problems to be solved in the research of high-speed cutting tools. On the tool base material with better impact toughness, surface coating is applied with materials with good thermosetting and wear resistance to produce new tools, often with the advantages of two materials. Has a large scope of application.
Under the guidance of this idea, new composite tools such as cemented carbide coated tools, CBN coated tools and PCD coated tools have appeared, which are suitable for high-speed cutting of different metal materials.
Coated carbide tools for high-speed cutting, due to the use of heat-resistant, high-hardness coating materials and multi-layer coating technology, the coating of cemented carbide tools has a large cutting range and long life, and its cutting The performance is much better than the non-coated cemented carbide. Therefore, coated cemented carbides have a tendency to replace ordinary non-coated cemented carbides.
Tool coating technology can not only be used on hard alloy tools, but also on other tool materials, such as cermets and ceramics.
Ceramic knives are also tools that can be used for high-speed cutting and are an important part of the research and development of tool materials in recent years. Whisker-reinforced ceramic tool is a special material tool. It is suitable for high-speed machining because of its good impact toughness and thermal shock resistance.
Another problem to be solved by high-speed cutting tools is to grind or press out a certain geometry of the chip breaker on the blade in order to achieve chip breaking and control chip direction, which is also an important technology to improve machining efficiency and improve tool durability.
High-speed cutting tools should have excellent impact toughness and thermal shock resistance, better heat resistance, wear resistance and chemical stability, as well as better chip breaking effect, and adapt to a larger metal cutting range.
Performance and application range of high speed cutting tool materials
From the research of high-speed cutting mechanism, we can see that with the increase of cutting speed, the metal removal rate is greatly improved, and the high strain rate of the material (about 1.67×105/s at cutting speed of 500m/min, cutting temperature) Up to 1400 ° C) makes the chip forming process and the various phenomena occurring on the interface between the tool and the workpiece different from those under the traditional cutting conditions. The hot hardness of the tool and the problem of tool wear are key. In order to achieve high-speed cutting, it must be supported by tool materials and tool manufacturing techniques suitable for high-speed cutting.