Coated inserts for rough milling

Abstract

Coated milling insert has a WC-Co cemented carbide with a low content of cubic carbides and a highly W-alloyed binder phase and a coating including an inner layer of TiC x N y with columnar grains followed by a layer of κ-Al 2 O 3 and a top layer of TiN. The coated milling insert is particularly useful for milling of grey cast iron with or without cast skin under wet conditions at low and moderate cutting speeds and milling of nodular cast iron and compacted graphite iron with or without cast skin under wet conditions at moderate cutting speeds.

1. A cutting tool insert for milling of grey cast iron with or without cast skin under wet conditions at low and moderate cutting speeds and milling of nodular cast iron and compacted graphite iron under wet conditions at moderate cutting speeds, comprising:
 a cemented carbide body comprising WC, 7.3-7.9 wt. % Co, 1.0-1.8 wt. % cubic carbides of Ta and Nb, and a highly W-alloyed binder phase with a CW-ratio of 0.86-0.94;  
 a coating comprising a first, innermost layer of TiC x N y O z  with x+y+z= 1, y<x  y>x  and z<0.2 having an equiaxed grain structure with a size <0.5 μm and a total thickness of 0.1-1.5 μm;  
 a layer of TiC x N y  with x+y= 1, x<0.3  x>0.3  and y< 0 . 3   y> 0 . 3  with a thickness of 1-4 μm having a columnar grain structure with an average diameter of <5 μm;  
 a layer of a smooth, fine-grained, 0.5-2 μm κ-Al 2 O 3  with a thickness of 1-2.5 μm; and  
 an outer layer of TiN with a thickness of 0.5-1.0 μm.  
 
     
     
       2. The cutting tool insert according to  claim 1 , wherein the cemented carbide contains 1.4-1.7 wt. % carbides of Ta and Nb. 
     
     
       3. The cutting tool insert according to  claim 1 , wherein the outer layer of TiN is removed along a cutting edge. 
     
     
       4. The cutting tool insert according to  claim 1 , wherein the first, innermost layer of TiC x N y O z  has y< 0 . 8   y> 0 . 8  and z=0. 
     
     
       5. The cutting tool insert according to  claim 1 , wherein the layer of TiC x Ny has x≧0.5. 
     
     
       6. The cutting tool insert according to  claim 1 , wherein an average grain size of the WC is about  1 . 5 - 2 . 5  μm. 
     
     
       7. The cutting tool insert according to  claim 6 , wherein the average grain size of the WC is about  1 . 8  μm. 
     
     
       8. The cutting tool insert according to  claim 1 , wherein the thickness of the TiC x   N   y    layer is  2 - 2 . 7  μm.   
     
     
       9. The cutting tool insert according to  claim 1 , wherein the average diameter of the columnar grain structure of the TiC x   N   y    layer is  0 . 1 - 2  μm.   
     
     
       10. The cutting tool insert according to  claim 3 , wherein the layer of κ-Al 2   O   3    is at least partly removed along the cutting edge.   
     
     
       11. A cutting tool insert for milling of grey cast iron with or without cast skin under wet conditions at low and moderate cutting speeds and milling of nodular cast iron and compacted graphite iron under wet conditions at moderate cutting speeds, comprising:
 a cemented carbide body comprising WC,  7 . 3 - 7 . 9  wt. % Co,  1 . 4 - 1 . 7  wt. % cubic carbides of Ta and Nb, and a highly W-alloyed binder phase with a CW-ratio of  0 . 86 - 0 . 94 ;    a coating comprising a first, innermost layer of TiC x   N   y   O   z    with x+y+z= 1 , y> 0 . 8  and z= 0  having an equiaxed grain structure with a size < 0 . 5  μm and a total thickness of  0 . 1 - 1 . 5  μm;      a layer of TiC x   N   y    with x+y= 1 , x> 0 . 5  and y> 0 . 3  with a thickness of  1 - 4  μm having a columnar grain structure with an average diameter of < 5  μm;      a layer of a smooth, fine-grained,  0 . 5 - 2  μm κ-Al 2   O   3    with a thickness of  1 - 2 . 5  μm; and      an outer layer of TiN with a thickness of  0 . 5 - 1 . 0  μm.   
     
     
       12. The cutting tool insert according to  claim 11 , wherein the outer layer of TiN is removed along a cutting edge. 
     
     
       13. The cutting tool insert according to  claim 12 , wherein the layer of κ-Al 2   O   3    is at least partly removed along the cutting edge.   
     
     
       14. The cutting tool insert according to  claim 11 , wherein an average grain size of the WC is about  1 . 5 - 2 . 5  μm. 
     
     
       15. The cutting tool insert according to  claim 14 , wherein the average grain size of the WC is about  1 . 8  μm. 
     
     
       16. The cutting tool insert according to  claim 11 , wherein the thickness of the TiC x   N   y    layer is  2 - 2 . 7  μm.   
     
     
       17. The cutting tool insert according to  claim 11 , wherein the average diameter of the columnar grain structure of the TiC x   N   y    layer is  0 . 1 - 2  μm.