1、超硬刀具材料的发展与应用分析超硬刀具材料的发展与应用分析摘要随着材料工业及精密机械工业的发展，精密切削、超精密切削和难切削材料使用的增多，超硬刀具材料的应用日益广泛。本文通过分析超硬刀具材料的发展状况，对主要品种的应用进行探讨。abstract with the development of material industry, and precision machinery industry, precision cutting, the ultra precision cutting and difficult cutting material used on the rise, appl
2、ication of superhard cutting tool materials is becoming more and more widely. In this paper, by analyzing the development situation of superhard cutting tool material, the main varieties of application were discussed.关键词超硬刀具 刀具材料 金刚石key words diamond superhard cutting tool cutting tool materials一、超硬
3、刀具材料发展概况First, development general situation of superhard cutting tool materials超硬刀具材料是指天然金刚石及硬度、性能与之相近的人造金刚石和CBN(立方氮化硼)。由于天然金刚石价格比较昂贵，所以生产上大多采用人造聚晶金刚石(PCD)、聚晶立方氮化硼(PCBN)以及它们的复合材料。Refers to the natural diamond superhard cutting tool materials and hardness, the performance similar to the synthetic di
4、amond and CBN (cubic boron nitride). Because natural diamond price is expensive, so the production mostly adopts the synthetic polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) and their composite materials.早在20世纪50年代，美国就利用人造金刚石微粉和CBN微粉在高温、高压、触媒和结合剂的作用下烧结成尺寸较大的聚晶块作为刀具材料。之后
5、，南非戴比尔斯(DeBeem)公司、前苏联和日本也相继研制成功。20世纪70年代初又推出了金刚石或CBN和硬质合金的复合片，它们是在硬质合金基体上烧结或压制一层0.5mm1mm的PCD或PCBN而成，从而解决了超硬刀具材料抗弯强度低、镶焊困难等问题，使超硬刀具的应用进入实用阶段。In the early 1950 s, the United States have used artificial diamond micro powder and CBN powder at high temperature, high pressure, and the catalytic binder bur
6、n under the action of big size of polycrystalline block as the cutting tool material. DE beers, the South Africa (DeBeem) company, the former Soviet union and Japan have also successfully developed. Launched in the early 1970 s, the diamond or CBN and carbide composite films, they are sintered on ce
7、mented carbide substrates or suppress a layer of 0.5 mm to 1 mm between PCD and PCBN, low flexural strength so as to solve the superhard cutting tool materials, welding on difficult problems, the application of superhard cutting tool into the practical stage.我国超硬刀具材料的研究与应用开始于上个世纪70年代，并于1970年在贵阳建造了我国
8、第一座超硬材料及制品的专业生产厂第六砂轮厂，从19701990年整整20年中，超硬材料年产量从仅46万克拉增至3500万克拉。上个世纪90年代前后，不少超硬材料生产专业厂从国外引进成套的超硬材料合成设备及技术，使产量得以迅速提高，至1997年，我国人造金刚石年产量就已达到5亿克拉左右，CBN年产量达800万克拉，跃居世界超硬材料生产大国之首。Superhard cutting tool material research and application in our country began in the 70 s, and in 1970 built Chinas first in gui
9、yang superhard materials and products of the professional manufacturer for our 6, from 1970-1990 for 20 years, the annual production of superhard materials from only 460000 carats to 35 million carats. In the 90 s, before and after a lot of superhard materials production plants from abroad the intro
10、duction of complete sets of superhard materials synthesis equipment and technology, make the yield increase rapidly, to 1997, the synthetic diamond production in China has reached about 500 million carats, CBN annual output up to 8 million carats, become the worlds top producer of superhard material
11、s.金刚石具有极高的硬度和耐磨性，其显微硬度可达10000HV，是刀具材料中最硬的材料。同时它的摩擦系数小，与非铁金属无亲和力，切屑易流出，热导率高，切削时不易产生积屑瘤，加工表面质量好，能有效地加工非铁金属材料和非金属材料，如铜、铝等有色金属及其合金、陶瓷、末烧结的硬质合金、各种纤维和颗粒加强的复合材料、塑料、橡胶、石墨、玻璃和各种耐磨的木材(尤其是实心木和胶合板等复合材料)。Diamond has a very high hardness and wear resistance, the microhardness of up to 10000 hv, is the most hard m
12、aterials in the cutting tool material. At the same time, its friction coefficient is small, and no affinity of non-ferrous metal, scrap easy flow, high thermal conductivity, is not easy to produce the devolop tumor when cutting, machining surface quality is good, can effective processing of non-ferr
13、ous metal materials and nonmetal materials, such as copper, aluminum and other non-ferrous metals and their alloys, ceramics, at the end of the sintering of hard alloys, various kinds of fiber and particle reinforced composites, plastics, rubber, graphite, glass and all kinds of wear-resistant wood
14、(especially the composite materials such as solid wood and plywood).金刚石的缺点是韧性差，热稳定性低。700一800时容易碳化，故不适于加工钢铁材料。因为在高温下铁原子容易与碳原子作用而使其转化为石墨结构。此外，用它切削镍基合金时，同样也会迅速磨损。Diamond are the shortcomings of poor toughness, low thermal stability. 700 a 800 when the carbide easily, therefore not suitable for processi
15、ng steel materials. Because iron with carbon atoms under high temperature effect and make it into the graphite structure. In addition, cutting nickel-based alloy, with it will also wear quickly.二、超硬刀具的主要品种及应用Second, main varieties and application of superhard cutting tool目前，在世界上已经应用或正在试验中的超硬刀具材料的主要品
16、种有以下几种。At present, in the world has been used or are testing in the main varieties of superhard cutting tool materials are the following.1.天然和人工合成大单晶金刚石1. Natural and synthetic diamond single crystal单晶金刚石有天然金刚石(ND)和人工合成金刚石两种。单晶金刚石用于制作切削刀具必须是大颗粒的(质量大于0.1g，最小径长不得小于3mm)。ND是目前已知矿物中最硬的物质，其显微硬度可达10000HV，耐
17、磨性好，而且切削刃非常锋利，刃部粗糙度值小，摩擦因数低，抗黏结性好，热导率高，切削时不易黏刀及产生积屑瘤，加工表面质量好。天然金刚石的硬度、抗磨损与抗腐蚀性和化学稳定性保证了刀具的超长寿命，能保证持续长久的正常切削，并减少由于刀具磨损对被加工零件的影响；其较高的导热系数又可降低切削温度和零件的热变形。天然大单晶金刚石的优良特性可满足精密及超精密切削对刀具材料的大多数要求，虽然其价格昂贵却仍被公认为是理想的精密及超精密切削工具材料。可广泛地应用于加工原子核反应堆及其它高技术领域的各种反射镜、导弹和火箭中的地航陀螺、计算机硬盘基片，加速器电子枪的超精密加工以及传统手表零件、首饰、制笔、有色金属装饰
18、件的精密加工等。此外，还可以用于制造医用刀具。ND的缺点主要是与铁族元素接触时有化学反应， 在700800时将碳化(即石墨化)，一般不适于加工钢铁材料。Single crystal diamond is natural diamond (ND) and synthetic diamond. Single crystal diamond cutting tool must be used to make large particles (quality is greater than 0.1 g, the path length shall not be less than 3 mm). ND
19、is the most hard material of known mineral, the microhardness of up to 10000 hv, good abrasion resistance, and the cutting edges are very sharp, blade roughness value is small, low friction factor, good compressive resistance, high thermal conductivity, is not easy to stick a knife when cutting and
20、produce the devolop tumor, processing surface quality is good. Natural diamonds hardness, wear resistance and corrosion resistance and chemical stability, to ensure the long life of a tool, can guarantee the long time of normal cutting, and to reduce due to the influence of tool wear on machining pa
21、rts; Its high thermal conductivity and can reduce the cutting temperature and the thermal deformation of parts. Excellent characteristics of large natural single crystal diamond can meet the precision and ultra precision cutting for most of the requirements of the cutting tool material, although it
22、is expensive but still is acknowledged as the ideal for precision and ultra precision cutting tool material. Can be widely used in processing and nuclear reactor and other high technology in the field of various mirror, missiles and rockets in navigation gyroscope, computer hard disk substrate, elec
23、tron gun accelerator of ultra-precision processing and traditional parts, jewelry, watches, pens, non-ferrous metal precision machining, etc. In addition, can also be used in the manufacture of medical tools. ND the disadvantages of the main is in contact with the elements of iron group have chemica
24、l reaction, carbonized at 700 800 (graphitization), generally not suitable for processing steel materials.2.聚晶金刚石和聚晶金刚石复合刀片2. The polycrystalline diamond and polycrystalline diamond composite bladesPCD又称金刚石烧结体，它是在高温、高压下，通过钴等金属结合剂将许多金刚石单晶粉聚晶成的多晶体材料。虽其硬度稍低于天然单晶金刚石，但它是随机取向的金刚石晶粒的聚合，属各向同性，无解理面。因而它不像大单晶金
25、刚石那样在不同晶面上的强度、硬度及耐磨性有很大的差别，以及因解理面的存在而呈脆性。在切削时，切削刃对意外损坏不很敏感，抗磨损能力也较强，可长时间保持锋利的切削刃，加工时可采用很高的切削速度和较大的背吃刀量，使用寿命一般高于WC基硬质合金刀具1050倍，而且PCD原料来源丰富，其价格只有ND的几十分之一至十几分之一，PCD刀具具有极高的硬度及寿命、很低的摩擦系数、锋利的刀刃、优异的导热性和低膨胀系数等特点，现已成为传统WC基硬质合金刀具的高性能替代品。聚晶金刚石复合片(PDC)刀具材料是在PCD研究的基础上发展起来的。硬质合金作为PCD的基体材料既有好的韧性和一定的硬度，同时又具有可焊性以及与P
26、CD的某种兼容性。所以它既具有金刚石的硬度和耐磨性，又具有硬质合金的韧性和可焊性之优点。PCD is also called diamond sintered body, which is under the high temperature and high pressure, through cobalt and other metallic bond will be lot of polycrystalline diamond single crystal into polycrystalline material. The hardness was slightly lower tha
27、n natural single crystal diamond, but it is random orientation of polymerization of diamond grain, isotropic, no cleavage plane. So it is not like a large single crystal diamond strength, hardness and wear resistance in different directions, theres a big difference, and due to the cleavage plane exi
28、stence in brittleness. In cutting, the cutting edge is not sensitive to accidental damage, wear resistance is strong, can maintain sharp cutting edge for a long time, can use high cutting speed and processing when bigger back turning, life is generally higher than 10 50 times the WC based cemented c
29、arbide cutting tools, PCD and abundant raw material sources, its price is only a small percentage of ND to 10 a few minutes, one of the PCD cutting tool has a very high hardness and service life, low friction coefficient, sharp blade, good thermal conductivity and low coefficient of expansion and ot
30、her characteristics, has become a high performance alternative to traditional the WC based cemented carbide cutting tools. Polycrystalline diamond compact (PDC) cutter material is developed on the basis of the PCD research. Hard alloy as the matrix of PCD material with good toughness and hardness, a
31、nd weldability and some compatibility with PCD. So it has the hardness of diamond and wear resistance, but also has advantages of carbide toughness and weldability.3.CVD金刚石3. The CVD diamondCVD金刚石是在低压下制备的，它不同于大单晶金刚石，而PCD、PDC是在高温高压下合成的。CVD金刚石包括三类：第一种是在适当基体上沉积的CVD金刚石涂层(包括类金刚石DLC涂层)；第二种是沉积厚度达1mm的无支撑的CV
32、D金刚石厚膜；第三种是在金刚石晶种上外延生长的CVD金刚石单晶膜或准单晶膜。CVD金刚石由于是不含任何金属催化剂的纯金刚石，因此它的热稳定性接近天然金刚石。同高温高压人工合成聚晶金刚石一样，CVD聚晶金刚石晶粒也呈无序排列，无脆性解理面而呈各向同性。CVD涂层刀具与PCD、PDC刀具相比，具有刀具形状复杂、成本低、一片多刀刃等优点。然而，也存在金刚石涂层与基体之间结合强度低以及对有CVD金刚石涂层的刃口进行研磨处理时容易分层剥落的缺陷。CVD diamond is prepared under low pressure, it is different from single crystal diamond, but the PCD, PDC are synthesized under high temperature and high pressure. CVD diamond includes three types: the first is on the proper matrix deposition CVD diamond coating (including diamond-like DLC coating); The second is sedimentary thickness of 1 mm without sup
