Coating layer with microstructure serrated edge

• US 9,649,746 B2
• Filed: 05/29/2012
• Issued: 05/16/2017
• Est. Priority Date: 05/27/2011
• Status: Active Grant

• Current Assignee: P&S Global Holdings, LLC
• Original Assignee: NanoMech, Inc.
• Inventors: Malshe, Ajay P., Jiang, Wenping
• Primary Examiner(s): Turner, Archene
• Application Number:
  US14/119,785
• Publication Number:
  US 20140212232A1
• Time in Patent Office: 1,813 Days
• Field of Search: 51307, 51309, 428325, 428336, 428697, 428698, 428699
• CPC Class Codes: B23B 2200/081 with projections chip breaking projections in general B23B2200/321
• CPC Class Codes: B23B 2200/087 for chip breaking chip breaking depressions in general B23B2200/323, multiple chip breaking grooves B23B2200/325
• CPC Class Codes: B23B 2200/204 with discontinuous cutting edge
• CPC Class Codes: B23B 2200/205 with cutting edge having a wave form
• CPC Class Codes: B23B 2228/10 Coatings
• CPC Class Codes: B23B 27/141 Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness with specially shaped plate-like exchangeable cutting inserts, e.g. chip-breaking groove, B23B27/1603; with removable plate-like milling cutting inserts of special shape B23C5/202
• CPC Class Codes: B23B 27/143 characterised by having chip-breakers
• CPC Class Codes: B23B 27/148 Composition of the cutting inserts
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3843 Titanium carbides
• CPC Class Codes: C04B 2235/3856 Carbonitrides, e.g. titanium carbonitride, zirconium carbonitride
• CPC Class Codes: C04B 2235/3886 Refractory metal nitrides, e.g. vanadium nitride, tungsten nitride
• CPC Class Codes: C04B 2235/604 Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/665 Local sintering, e.g. laser sintering
• CPC Class Codes: C04B 2235/667 Sintering using wave energy, e.g. microwave sintering
• CPC Class Codes: C04B 35/5831 based on cubic boron nitrides or Wurtzitic boron nitrides, including crystal structure transformation of powder
• CPC Class Codes: C23C 28/044 coatings specially adapted for cutting tools or wear applications
• CPC Class Codes: C23C 30/005 : on hard metal substrates
• CPC Class Codes: Y10T 407/24 : with chip breaker, guide or deflector
• CPC Class Codes: Y10T 407/27 : comprising tool of specific chemical composition
• CPC Class Codes: Y10T 428/265 : 1 mil or less

Abstract

A cutting tool formed by a coating layer on a substrate has cutting edges that feature serrations. The linear dimensions of the serrations may vary from a few nanometers up to 10 microns. The serrations result in a smoother cut edge on the workpiece, particularly when the workpiece is formed of certain materials that are seen as particularly difficult to cut, such as hardened steels.

Claims

1. A cutting tool, comprising:

a. a substrate, wherein the substrate comprises a material selected from the set consisting of carbides, nitrides, carbonitrides, polycrystalline cubic boron nitride (PCBN), PCBN tip-brazed material, cermets, and steels; and

b. a coating on the substrate, wherein the coating comprises a first material selected from the set consisting of carbides, nitrides, oxides, and carbon, wherein the first material is one of continuous and discontinuous, further wherein the coating is infiltrated with a second material selected from the set consisting of titanium nitride, hafnium nitride, zirconia nitride, titanium carbide, hafnium carbide, titanium carbonitride, and hafnium carbonitride, further wherein the coating comprises at least one cutting edge having a plurality of microfluidic channels, wherein the at least one cutting edge comprises an aperiodic plurality of serrations, the aperiodic plurality of serrations comprising a plurality of protrusions and a plurality of valleys, wherein at least a subset of the aperiodic plurality of serrations are aperiodic in a first linear dimension, and further wherein the subset of the plurality of serrations are aperiodic in at least one aperiodic scale.

2. The tool of claim 1, wherein the first linear dimension is no greater than 5 microns.

3. The tool of claim 2, wherein the first linear dimension in the range of 1 to 3 microns.

4. The tool of claim 3, wherein the at least one cutting edge comprises a plurality of periodic serrations that are periodic in a periodic scale that is one of larger or smaller than the aperiodic scale.

5. The tool of claim 3, wherein the at least one cutting edge comprises a plurality of periodic serrations that are periodic in a second linear dimension that is different from the first linear dimension.

6. The tool of claim 3, wherein the at least one cutting edge comprises a first plurality of aperiodic serrations and a second plurality of aperiodic serrations, wherein the first plurality of aperiodic serrations and the second plurality of aperiodic serrations are of a different scale.

7. The tool of claim 3, wherein the at least one cutting edge comprises a first plurality of aperiodic serrations and a second plurality of aperiodic serrations, wherein the first plurality of aperiodic serrations are aperiodic in a first linear dimension, and the second plurality of aperiodic serrations are linear in a second linear dimension.

8. The tool of claim 7, wherein at least one of the first and second plurality of aperiodic serrations are chipbreakers.