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High-speed machining toolRelated Patent Categories: Stock Material Or Miscellaneous Articles, All Metal Or With Adjacent MetalsHigh-speed machining tool description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070054146, High-speed machining tool. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] This invention relates to a component which is excellent in wear resistance, lubricating properties, and fracture resistance, and can be used for high speed machining applications. The invention also relates to a machining tool including the component, and a high speed machining method, especially, a dry cutting method, using the tool. BACKGROUND ART [0002] In recent years, a high machining speed has been demanded from the viewpoint of increased productivity, and high speed cutting has been desired, for example, in the field of cutting. The range of targets for high speed cutting has been expanded, and there has been a demand for the application of high speed cutting to high hardness materials such as hot forging dies after hardening by heat treatment, and die casting molds. [0003] With conventional cutting methods, cutting oils were used for promoting a lubricating action and cooling a cutting edge, and cutting oils were needed, particularly, in high speed cutting. However, the use of a cutting oil may aggravate a work environment because of a foreign odor, dirt, and greasy fumes. In addition, treatment of a waste oil may pose the problem of environmental pollution, and cause the corrosion of tools. Thus, dry cutting using no cutting oil is desired and, for this purpose, there is need for the development of a cutting tool having wear resistance, fracture resistance, lubricating properties, and heat resistance. Such a cutting tool should desirably have the above-mentioned characteristics even in a high speed region. [0004] As tools for dry cutting, there are reports on tools having high hardness coatings formed on hard materials for improved durability. Their examples include a high speed tool steel having a Ti--Al--N--C-based coating (see Japanese Patent Application Laid-Open No. 1999-300518), and cemented carbides having coating layers comprising constituents such as TiCN, TiAlN, SiC and Al.sub.2O.sub.3 (see Japanese Application Laid-Open No. 2000-336489 and Japanese Patent Application Laid-Open No. 2001-293611). Methods such as CVD and PVD are used for the formation of these coating layers. An attempt has also been made to perform ion implantation of elements such as Cl and S into tungsten carbide for increased wear resistance (see U.S. Pat. No. 5,038,645). [0005] With the conventional methods of applying coatings to base materials, however, a coating layer, which comprises a different material from the base material, is deposited, so that peeling is apt to occur between the coating layer and the base material. To enhance adhesion, a method of forming a plurality of layers has been attempted, but involves a complicated process. Furthermore, even when a coating layer of high hardness is formed, its toughness may be low and, depending on a material to be cut (namely, a work material), fracture may occur, resulting in an insufficient tool life. In addition, when the work material is cut with the high hardness coating layer, swarf deposits on the coating layer, thus presenting the problem that cutting resistance in a high speed region is not fully decreased. With ion implantation of tungsten carbide, wear resistance is improved in a medium speed region (for example, a cutting speed of up to 91 m/minute), but performance obtained is inferior to that of coated tools. [0006] Because of the above-described problems, the cutting speed of the current steels is often set at a maximum of 150 to 200 m/min even with the use of a cutting oil, and is often set at 100 /min or less in dry cutting. Thus, dry cutting in a high speed region is difficult. DISCLOSURE OF THE INVENTION [0007] The present invention has been accomplished in light of the above-described circumstances. It is an object of the invention to provide a machining component, especially, a high speed cutting tool, improved in wear resistance, fracture resistance, lubricating properties, cutting resistance, and heat resistance in a high speed region. It is another object of the invention to provide a high speed machining method, especially a high speed dry cutting method, using the machining component of the present invention. [0008] The present inventors have diligently conducted studies, and found that when a halogen element is added to a surface layer of a machining component, and a workpiece is brought into contact with the so treated machining component at a high speed, characteristics, such as wear resistance and lubricating properties, are improved in accordance with the oxidation promoting effect of the halogen element. This finding has led to the accomplishment of the present invention. According to the present invention, the machining component and the workpiece are subjected to friction at a high speed to cause an interface reaction, whereby the surface of the machining tool according to the present invention, because of its excellent lubricating properties, enables high speed machining without using a lubricating oil. [0009] The above advantages of the present invention are presumed to be ascribed to a self-lubricating layer containing a Ti oxide phase and/or a Ti-containing compound oxide phase (however, the valence of Ti is greater than 2, but less than 4). The present invention is also characterized in that the self-lubricating film can be formed and regenerated in process during a machining process in a high speed region. [0010] That is, the gist of the present invention lies in a high speed machining component having a hard material as a base material, and containing at least one element selected from the group consisting of fluorine, chlorine, bromine and iodine, the concentration of the element being in the range of 0.2 mol % to 10 mol % within 1 .mu.m from the surface of the base material. The gist of the present invention also lies in such a high speed machining component that if the high speed machining component has a coating layer containing Ti and C and/or N on the outside of the base material, the high speed machining component contains at least one element selected from the group consisting of fluorine, chlorine, bromine and iodine, the concentration of the element being in the range of 0.2 mol % to 10 mol % within 1 .mu.m from the surface of the coating layer. The at least one element selected from the group consisting of fluorine, chlorine, bromine and iodine, can be added by ion implantation. The machining component of the present invention is brought into contact with a workpiece at a speed of 150 m/min or higher, whereby the high speed machining component can be produced. [0011] Further, the gist of the present invention also lies in the above high speed machining component treated in such a manner as to be brought into contact with a workpiece at a speed of 150 m/min or higher. [0012] The gist of the present invention also lies in the above high speed machining component further having a self-lubricating film on a surface in contact with the workpiece. The self-lubricating film is formed by bringing the high speed machining component into contact with the workpiece at a speed of 150 m/min or higher. A material containing Ti on a surface layer is named as the workpiece used for formation of the self-lubricating film. The self-lubricating film contains a Ti oxide and/or a Ti-containing compound oxide, the average valence of Ti in the oxide and/or the compound oxide is greater than 2, but less than 4, and if the amount of Ti in the self-lubricating film is calculated as TiO.sub.2, the mass ratio expressed as (mass of the calculated TiO.sub.2/mass of the self-lubricating film) is 5% or more. [0013] The gist of the present invention also lies in a high speed machining method using the above-mentioned machining component. It also lies in a high speed cutting tool including the above machining component. With the high speed cutting tool of the present invention, the wear width V.sub.B of a tool blank after cutting is performed under conditions including a depth of cut of 1.0 mm, a feed rate of 0.1 mm/rev, a cutting speed of 400 m/min, and a cutting length of 500 m can be set at 70 .mu.m or less. Moreover, cutting can be carried out at a cutting speed of 150 m/min or higher without the use of a cutting oil. BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 shows a model drawing of a cutting step. [0015] FIG. 2 shows the cutting speed dependence of a cutting resistance resultant force in connection with an ion-implanted P10 tool, a TiN-coated P10 tool, and an untreated P30 tool. [0016] FIG. 3 shows the cutting speed dependence of a feed force in connection with the ion-implanted P10 tool, the TiN-coated P10 tool, and the untreated P30 tool. [0017] FIG. 4 shows the cutting speed dependence of a coefficient of friction in connections with the ion-implanted P10 tool. [0018] FIG. 5 shows the results of a wear test of the ion-implanted P10 tool. [0019] FIG. 6 shows the results of observation of sections of the ion-implanted P10 tool used in cutting of a Ti-deoxidized steel. [0020] FIGS. 7(a) to 7(d) show the results of elemental analysis, by XMA, of sections of the ion-implanted P10 tool used in cutting of the Ti-deoxidized steel. Continue reading about High-speed machining tool... Full patent description for High-speed machining tool Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this High-speed machining tool patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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