Tool of cemented carbide for cutting, punching and nibbling

Abstract: According to the invention there is provided a cemented carbide tool for punching, cutting and nibbling containing WC and with binder that comprises at least one of the metals Co, Ni and Fe. Moreover, it contsists of a core of eta-phase containing cemented carbide surrounded by an eta-phase free surface zone whose working surface comprises exposed eta-phase and a surrounding eta-phase free surface zone.

Description: The present invention relates to a cemented carbide tool for cutting, punching and nibbling which by means of a special way of manufacturing has given surprising properties of functioning in comparison to those of conventional tools. The manufacture of sheet metal parts is normally done by cutting and punching. By both of these methods the parting of the material occurs between two edges working against each other. The yield point of the material is exceeded at sufficiently a high cutting or punching force. Nibbling is used for the purpose of cutting contours in normally 3-10 mm thick sheet metal. Cylindrical punches of steel or cemented carbide are most frequently being used in a nibbling machine. They perforate the sheet metal by a movement perpendicular to the metal through a die used as a dolly. When nibbling and punching holes, different widths of the slot in the die are used, which are adjusted to suit the composition and sheet thickness of the material. When a so called "wide slot" is being used, the cutting, when nibbling is taking place, depends on both shear and tensile forces. Using a narrow slot, the cutting of the sheet takes place due to pure shear forces. The normal wear pattern of a steel nibbling punch is that material by abrasion is worn off and moved up along the punch. Because of the wear pattern, the punch turns conical which in turn finally causes an increased friction force that changes the cutting quality to an unacceptable level. When using cemented carbide punches, this wear process is considerably slower, but with the same result as obtained by the use of steel punches. Due to the brittleness of the cemented carbide the risk of fracture is great. As a result, cemented carbide punches are used only exceptionally. In EP 182759, there is disclosed a cemented carbide preferably for use in rock drilling but also for wear parts and other parts exposed to wear. It is characterized by a core containing eta-phase surrounded by cemented carbide free from eta-phase. Fig. 1 presents a die and a pressing tool in accordance with the invention where: 1 - die 2 - metal sheet 3 - punch 4 - cemented carbide containing eta-phase 5 - cobalt enriched surface zone 6 - cobalt depleted surface zone The object of the invention is to provide a cemented carbide tool for use in cutting, punching or nibbling operations with increased toughness, a method for making that tool and a method for using the tool. In one aspect of the invention there is provided a cemented carbide tool for cutting, punching or nibbling containing WC (α-phase) with a binder (β-phase) based on at least one of the metals Co, Ni or Fe and comprising a cemented carbide containing eta-phase surrounded by a surface zone free from eta-phase wherein the working surface of the tool comprises exposed eta-phase. In another aspect of the invention there is provided a method of manufacturing a cemented carbide tool for cutting, punching or nibbling by powder metallurgical methods as disclosed in claim 7. In a third aspect of the invention there is provided the use of a cemented carbide tool for cutting, punching or nibbling containing WC (α-phase) with a binder (β-phase) based on at least one of the metals Co, Ni or Fe, the improvement comprising using a cemented carbide having an eta-phase-containing cemented carbide core surrounded by an eta-phase-free surface zone, the working surface of the tool comprising exposed eta-phase. Punches for nibbling have been produced in accordance with EP 182759. When testing these, disasterous fractures appear after unacceptably short time. Fractures mostly take place along the working edge. After grinding at right angles to the longitudinal axis of the punch to remove the outer eta-phase-free zone of the end portion of the punch, the cutting performance surprisingly increased in a most dramatic way. The wear mecanism along the cutting edge is changed to a loss of material in the shape of very tiny and thin "flakes". Owing to this the sharpness of the edge is retained in spite of the fact that the edge slowly moves up along the punch. See figure 1. There is no formation of a conical shape. The desired cutting gap is not altered but kept essentially constant. The central portion of the punch is on the whole not changed at all due to the wear. When the cutting edge has moved upwards the punch to a distance corresponding to that of the formed cone in the case of the steel punch, also this type of cemented carbide punch must be reground. This happens after a number of punching cycles that by far exceeds the one obtained with steel punches. The limiting factor to the tool life has turned out to be the protruding flange at the top part of the punch that serves as a holding gadget, this probably depending on an unfavourable distribution of stresses. This is suitably remedied by special measures resulting in more favourable stress distribution. According to the invention a cemented carbide tool now is provided for cutting, punching and nibbling. It is made of cemented carbide mainly consisting of WC + a binder based on Co, Ni or Fe. The amount of binder should be 5 - 20% preferably 6 - 16%. The grain size of the WC used should be less than 5 µm preferably 0,4 - 3 µm. The cemented carbide may contain less than 3% preferably less than 1% carbides such as TiC, TaC, NbC, VC, Mo₂C and HfC. The core of the cemented carbide shall consist of eta-phase containing cemented carbide surrounded by cemented carbide free from eta-phase with the exception for the working surface of the punch where the eta-phase is exposed according to the invention. The eta-phase shall have a fine grain size of 0,5 - 10 µm preferably 1 - 5 µm and shall be evenly distributed within the matrix of the normal structure of WC and binder in the core. In the transition area towards the eta-phase-free cemented carbide the eta-phase may have a slightly coarser grain size than in the core otherwise. The content of eta-phase in the core is 2 - 60% preferably 10 - 35% by volume. The thickness of the eta-phase free cemented carbide shall be 0,3 - 10 mm, preferably 0,5 - 8 mm. For other cross-sections than circular the corners shall be shaped in order to shape radii of the corners to about the same radii dimensions as the thickness of the eta-phase free cemented carbide. In the inner part of the eta-phase free surface zone, situated close to the core, the amount of binder is greater than the nominal amount of binder in the cemented carbide body. The amount of binder in the surface zone increases towards the core up to at least 1,2 times preferably 1,4 - 2,5 times the nominal content of the binder-phase in the cemented carbide body. In the outermost part of the surface zone the content of the binder is lower, 0,2 - 0,8 times the nominal binder content. The width of the outermost binder depleted zone is 20 - 80% preferably 30 - 70% of the thickness of the zone free from eta-phase. The tool according to the invention is manufactured in accordance with powder metallurgical methods such as milling, pressing and sintering. By starting with a powder that is understoichiometric with regard to the carbon content an etaphase containing cemented carbide is obtained after sintering. This is heat treated in a carburizing atmosphere after the sintering which gives the desired structure to the cemented carbide. The working surface of the tool is obtained by cutting and/or grinding the carburized material and/or by during the carburizing step of the process protect the working surface by packing the material tightly together or covering it with material that protects it against reaction. Preferably also the surface of the opposite end of the tool is to be protected in a corresponding way to increase its impact resistance. An explanation to the good properties of the tool in accordance with the invention may be the reduction of the axial prestresses which are introduced by the carburizing treatment. This would cause the special wear pattern with wear of material in the shape of very thin "flakes". The invention refers to the use of the above described tool for cutting, punching and nibbling purpose. Example 1. From a powder containing 2 - 3 µm WC and 11 % Co with an understoichiometric carbon content (5,1 % instead of 5,4 %) blanks were pressed which, disregarding the dimensions of the holder, were shaped to a length of 84 mm and a diameter of 12,2 mm. The blanks were presintered in nitrogen for 1 hour at 900 o C and standard sintered at 1430 o C. They were then loosely packed in fine aluminium oxide powder in graphite boxes and thermally treated in a carburizing atmosphere for two hours at 1370 o C in a pusher furnace. Hereby a very thin zone of only α + β structure was formed in the surface of the blanks due to the carbon diffusion into the blanks and transformation of the eta-phase to α and β phases. After two hours treatment enough carbon had diffused into and transformed all eta-phase of the surface zone. The blanks manufactured in this way had after the treatment a 2 mm eta-phase free surface zone and a core with 5 mm diameter containing fine dispersed eta-phase. The part of the surface zone closest to the eta-phase containing core was enriched with cobalt. Thus, the outermost part of the surface zone was depleted of cobalt and consequently also harder. The working end parts of the punchblanks were cut 5 mm and ground. Example 2. A punch according to previous example was tested on the following conditions: Machine: Pullman Pullmatic Stroke: 30 mm turning point 1 mm below the sheet Motor speed: 200 r/min Slot width: 0,30 mm for 2 mm sheet metal 0,35 mm -"- 3 mm -"- -"- Material: Stainless steel SIS 2333 The cutting edge of the punch was examined at even intervals. After some 34 153 strokes only 12 very small and thin "flakes" had come off why the used sheet was replaced by a 3 mm thick sheet of the same material. After some 48 689 strokes the punch was examined again. Now one could see that 3 more small "flakes" had come off. The test carried on until the total amount of strokes was 64 000. The punch was then ground flat, the reduction in tool length was measured to be 0,25 mm. The test was then repeated with a conventional punch in steel (SIS 2260) under the same conditions as above. After 7 231 strokes the punch was conical to that extent it had to be reground. In this case the reduction in length was 5 mm. Due to the conical shape the quality of the hole successively turns to the worse. Even the used cutting force increases dramatically what may cause a stand still of the machine. In a third test, a punch manufactured in a cemented carbide of standard grade containg 11 % Co and with a grainsize of around 2 - 3 µm was used. Also this time the same type of material and conditions were applied. The result from this test was that the edge of the punch broke down after 15 strokes.

Claims: Cemented carbide tool for cutting, punching and nibbling containing WC (α phase) with a binder (β phase) based on at least one of the metals Co, Ni or Fe and comprising a cemented carbide containing eta-phase surrounded by a surface zone free from eta-phase characterized in that the working surface comprises exposed eta-phase and surrounding etaphase free surface zone. Cemented carbide tool in accordance with the previous claim characterized in that the width of the eta-phase free zone is 0,3 - 10 mm preferably 0,5 - 8 mm. Cemented carbide tool in accordance with any of the previous claims characterized in that the grain size of the eta-phase is 0,5 - 10 µm preferably 1- 5 µm and that the amount of eta-phase in the core is 2 - 60 % preferably 10 - 35 vol%. Cemented carbide tool in accordance with any of the previous claims characterized in that the amount of binder in the outermost binder depleted surface zone is 0,1 - 0,9 preferably 0,2 - 0,7 times the nominal content of binder. Cemented carbide tool in accordance with any of the previous claims characterized in that the width of the outermost binder depleted surface zone is 0,2 - 0,8 preferably 0,3 - 0,7 times the width of the eta-phase free zone. Cemented carbide tool in accordance with any of the previous claims characterized in that the inner part of the the surface zone free from eta-phase next to the eta-phase containing co re has a content of binder that is greater than the nominal and that this increases towards the core to at least 1,2 times, preferably 1,4 - 2,5 times compared to the nominal content of binder in the cemented carbide body. Method of manufacturing a cemented carbide tool for cutting, punching or nibbling by powder metallurgical methods as milling, pressing and sintering whereby an understoichiometric powder is sintered to an eta-phase containing cemented carbide blank that afterwards is partially carburized in a way that an eta-phase containing core surrounded by an eta-phase free surface zone is created characterized in that the eta-phase in the working surface is exposed by cutting and/or grinding and/or by protecting mentioned surface from carburization with adjoining material or with a coating of material protecting against reactions, to give a working surface comprising exposed eta-phase and a surrounding eta-phase free surface zone. Use of a cemented carbide tool for cutting, punching and nibbling containing WC (α-phase) with a binder (β-phase) based on at least one of the metals Co, Ni or Fe and consisting of an eta-phase containing cemented carbide surrounded by an eta-phase free surface zone characterized in that the working surface comprises exposed eta-phase and surrounding eta-phase free surface zone.

Inventors: DROUGGE LARS, DROUGGE, LARS
Applicants: SANDVIK AB, SANDVIK AKTIEBOLAG
Application year: 1991
Main classification: C22C29
IPC codes: C22C29