Coated cemented carbide tool for steel roughing applications and methods for machining

Claim 1

A method of rough cut machining steel comprising turning a steel work piece on a lathe at an effective speed of up to about 275 surface feet per minute; moving a coated cemented carbide cutting tool across the surface of said steel workpiece at a feed rate from about 0.01 to about 0.04 inches per revolution, said coated cemented carbide cutting tool consisting essentially of a densified body having tungsten carbide grains, metal carbide grains selected from the group consisting of TiC, TaC, NbC, HfC, and combinations thereof, and a bonding phase consisting essentially of cobalt; said tungsten carbide grains being equal to or greater than 70 weight percent of said densified body, said tungsten carbide grains having an average grain size from about 0.9 to about 1.3 microns, and less than 10 percent of said tungsten carbide grains having a size less than 0.5 microns; said cobalt being from about 5 to about 10 weight percent of said densified body and the remainder being said metal carbide grains; said densified body being coated with an adherent refractory coating layer; and cutting said steel workpiece with said coated cemented carbide cutting tool to effect a depth of cut of about 0.125 to about 0.500 inches.

Claim 2

A method of rough cut machining steel comprising turning a steel work piece on a lathe at an effective speed of up to about 275 surface feet per minute; moving a coated cemented carbide cutting tool across the surface of said steel workpiece at a feed rate from about 0.01 to about 0.04 inches per revolution, said coated cemented carbide cutting tool consisting essentially of a densified body having tungsten carbide grains, metal carbide grains selected from the group consisting of TiC, TaC, NbC, HfC, and combinations thereof, and a bonding phase consisting essentially of cobalt; said tungsten carbide grains being equal to or greater than 70 weight percent of said densified body, said tungsten carbide grains having an average grain size from about 0.9 to about 1.3 microns, and less than 10 percent of said tungsten carbide grains having a size less than 0.5 microns; said cobalt being from about 5 to about 10 weight percent of said densified body and the remainder being said metal carbide grains; said densified body being coated with an adherent refractory coating layer; and cutting said steel workpiece with said coated cemented carbide cutting tool to effect a depth of cut of about 0.125 to about 0.500 inches.

Claim 3

A method of rough cut machining steel comprising turning a steel work piece on a lathe at an effective speed of up to about 130 surface feet per minute; moving a coated cemented carbide cutting tool across the surface of said steel workpiece at a feed rate from about 0.050 to about 0.080 inches per revolution; said coated cemented carbide cutting tool consisting essentially of a densified body having tungsten carbide grains, metal carbide grains selected from the group consisting of TiC, TaC, NbC, HfC, and combinations thereof, and a bonding phase consisting essentially of cobalt; said tungsten carbide grains being equal to or greater than 70 weight percent of said densified body, said cobalt being from about 5 to about 10 weight percent said densified body and the remainder being said metal carbide grains; said tungsten carbide grains having an average grain size from about 0.9 to about 1.3 microns and less than 10 percent of said tungsten carbide grains having a size less than 0.5 microns; said densified body being coated with an adherent refractory coating layer; and cutting said steel workpiece with said coated cemented carbide cutting tool to effect a depth of cut of about 0.150 to about 0.700 inches.

Claim 4

A method of rough cut machining steel comprising turning a steel work piece on a lathe at an effective speed of up to about 130 surface feet per minute; moving a coated cemented carbide cutting tool across the surface of said steel workpiece at a feed rate from about 0.050 to about 0.080 inches per revolution; said coated cemented carbide cutting tool consisting essentially of a densified body having tungsten carbide grains, metal carbide grains selected from the group consisting of TiC, TaC, NbC, HfC, and combinations thereof, and a bonding phase consisting essentially of cobalt; said tungsten carbide grains being equal to or greater than 70 weight percent of said densified body, said cobalt being from about 5 to about 10 weight percent said densified body and the remainder being said metal carbide grains; said tungsten carbide grains having an average grain size from about 0.9 to about 1.3 microns and less than 10 percent of said tungsten carbide grains having a size less than 0.5 microns; said densified body being coated with an adherent refractory coating layer; and cutting said steel workpiece with said coated cemented carbide cutting tool to effect a depth of cut of about 0.150 to about 0.700 inches.