EP1527251A1 - Outils de coupe a double profil d'inclinaison - Google Patents
Outils de coupe a double profil d'inclinaisonInfo
- Publication number
- EP1527251A1 EP1527251A1 EP03764305A EP03764305A EP1527251A1 EP 1527251 A1 EP1527251 A1 EP 1527251A1 EP 03764305 A EP03764305 A EP 03764305A EP 03764305 A EP03764305 A EP 03764305A EP 1527251 A1 EP1527251 A1 EP 1527251A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- ranging
- substrate
- face
- periphery
- tool insert
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000005520 cutting process Methods 0.000 title claims abstract description 43
- 239000000758 substrate Substances 0.000 claims abstract description 50
- 229910003460 diamond Inorganic materials 0.000 claims description 53
- 239000010432 diamond Substances 0.000 claims description 53
- 238000000034 method Methods 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
- 229910052582 BN Inorganic materials 0.000 claims description 7
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 7
- 150000001247 metal acetylides Chemical class 0.000 claims description 3
- 229910052984 zinc sulfide Inorganic materials 0.000 claims description 3
- 230000003292 diminished effect Effects 0.000 abstract description 2
- 230000035882 stress Effects 0.000 description 51
- 239000002245 particle Substances 0.000 description 13
- 239000000463 material Substances 0.000 description 9
- 239000002131 composite material Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 4
- 238000005553 drilling Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 230000032798 delamination Effects 0.000 description 3
- 239000010955 niobium Substances 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- 239000010937 tungsten Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000010438 granite Substances 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 238000004901 spalling Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 2
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- -1 VIB metals Chemical class 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 235000012773 waffles Nutrition 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- E21B10/573—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
- E21B10/5735—Interface between the substrate and the cutting element
Definitions
- the present invention relates to the field of abrasive tool inserts.
- An abrasive particle compact is a polycrystalline mass of abrasive particles, such as diamond and/or cubic boron nitride (CBN), bonded together to form an integral, tough, high-strength mass.
- abrasive particles such as diamond and/or cubic boron nitride (CBN)
- CBN cubic boron nitride
- Such components can be bonded together in a particle-to-particle self-bonded relationship, by means of a bonding medium disposed between the particles, or by combinations thereof.
- the abrasive particle content of the abrasive compact is high and there is an extensive amount of direct particle-to-particle bonding.
- Abrasive compacts are made under elevated or high pressure and temperature (HP/HT) conditions at which the particles, diamond or CBN, are crystallographically stable.
- HP/HT high pressure and temperature
- a supported abrasive particle compact herein termed a composite compact, is an abrasive particle compact, which is bonded to a substrate material, such as cemented tungsten carbide.
- Abrasive compacts tend to be brittle and, in use, they frequently are supported by being bonded to a cemented carbide substrate. Such supported abrasive compacts are known in the art as composite abrasive compacts. Compacts of this type are described, for example, in U.S. Pats. Nos. 3,743,489, 3,745,623, and 3, 767,371. The bond to the support can be formed either during or subsequent to the formation of the abrasive particle compact. Composite abrasive compacts may be used as such in the working surface of an abrasive tool. Composite compacts have found special utility as cutting elements in drill bits.
- Drill bits for use in rock drilling, machining of wear resistant materials, and other operations which require high abrasion resistance or wear resistance generally consist of a plurality of polycrystalline abrasive cutting elements fixed in a holder.
- U.S. Pat. No. 4,109,737 describes drill bits with a tungsten carbide stud (substrate) having a polycrystalline diamond compact on the outer surface of the cutting element. A plurality of these cutting elements then are mounted generally by interference fit into recesses into the crown of a drill bit, such as a rotary drill bit.
- These drill bits generally have means for providing water-cooling or other cooling fluids to the interface between the drill crown and the substance being drilled during drilling operations.
- the cutting element comprises an elongated pin of a metal carbide (stud) which may be either sintered or cemented carbide (such as tungsten carbide) with an abrasive particle compact (e.g., polycrystalline diamond) at one end of the pin for form a composite compact.
- a metal carbide stud
- a metal carbide such as tungsten carbide
- an abrasive particle compact e.g., polycrystalline diamond
- Fabrication of the composite compact typically is achieved by placing a cemented carbide substrate into the container of a press.
- a mixture of diamond grains or diamond grains and catalyst binder is placed atop the substrate and compressed under HP/HT conditions.
- a composite compact formed in the above-described manner may be subject to a number of shortcomings.
- the coefficients of thermal expansion and elastic constants of cemented carbide and diamond are close, but not exactly the same.
- thermally induced stresses occur at the interface between the diamond layer and the cemented carbide substrate, the magnitude of these stresses being dependent, for example
- Another potential shortcoming relates to the creation of internal stresses within the diamond layer, which can result in a fracturing of that layer. Such stresses also result from the presence of the cemented carbide substrate and are distributed according to the size, geometry, and physical properties of the cemented carbide substrate and the polycrystalline diamond layer.
- the tools are subject to delamination failures caused by thermally induced axial residual stresses on the outer diameter of the superabrasive layer. The stresses reduce the effectiveness of the tools and limit the applications in which they can be used.
- 4,972,637 proposes a PDC having an interface containing discrete, spaced-apart recesses extending into the cemented carbide layer, the recesses containing abrasive material (e.g., diamond) and being arranged in a series of rows, each recess being staggered relative to its nearest neighbor in an adjacent row.
- U.S. Patent No. 5,007,207 proposes an alternative PDC structure having a number of recesses in the carbide layer, each filled with diamond, which recesses are formed into a spiral or concentric circular pattern.
- U.S. Patent No. 5,605,199 proposes a profile comprising an peripheral region with inclined inner surface surrounding an inner region.
- 6,315,652 proposes an abrasive tool insert having an interface formed in a sawtooth pattern of concentric rings extending from said center to the periphery.
- U.S. Patent No. 5,484,330 suggests a saw tooth shaped cross-sectional profile and U.S. Patent No. 5,494,777 proposes an outward sloping profile in the interface design.
- U.S. Patent No. 5,743,346 proposes an interface having an inner surface and an outer chamfer that forms a 5° to 85° angle to the vertical, wherein the inner surface is other than the chamfer.
- U.S. Patent No. 5,486,137 also proposes a tool insert having an outer downwardly sloped interface surface.
- the present invention relates to an abrasive tool insert which comprises a substrate having a support face that includes: an inner support table; an outer shoulder having a width, S w ; a downwardly sloping interface from the support table to the shoulder which interface has a slope angle, S a ; and a continuous abrasive layer integrally formed on the substrate support face, which abrasive layer includes: (a) a center having a height, D c ; (b) a diameter, D ; (c) a periphery having a height, D p , in contact with the shoulder and which periphery forms a cutting edge; wherein, (i) S w :D d ranges from between 0 and about 0.5; and (ii) for each S a and S w :Da, D C :D P is selected so as to diminish residual stress in the abrasive layer.
- the invention relates to an abrasive tool insert formed from a substrate having an inner face that has a center, and annular face which annular face has a periphery.
- the inner face slopes outwardly and downwardly from the center at an angle ranging from between about 5° and 30° from the horizontal.
- the annular face surrounds by the inner face and terminates at the periphery.
- the annular face slopes downwardly and outwardly from the inner face at an angle of between about 20° and 75° from the horizontal.
- a continuous abrasive layer, having a center and a periphery forming a cutting edge, is integrally formed on the substrate and defines an interface therebetween.
- the present invention further relates to a method of manufacturing abrasive tool inserts that possess diminished residual stress.
- the invention relates to a method for forming an abrasive tool insert, which commences with providing a substrate having an inner face that has a center, and annular face which annular face has a periphery.
- the inner face slopes outwardly and downwardly from the center at an angle ranging from between about 5° and 30° from the horizontal.
- the annular face surrounds by the inner face and terminates at the periphery.
- the annular face slopes downwardly and outwardly from the inner face at an angle of between about 20° and 75° from the horizontal.
- a continuous abrasive layer, having a center and a periphery forming a cutting edge, is integrally formed on the substrate and defines an interface therebetween.
- Fig. 1 graphically plots axial stress as a function of both slope angle and height ratio for a PCD tool insert
- Fig. 2 graphically plots radial stress as a function of both slope angle and height ratio for a PCD tool insert
- Fig. 3 graphically plots stress as a function of should width fraction for a PCD tool insert
- Fig. 4 is a cross-sectional elevational view of a tool insert showing its various components: substrate having an inner support table, an outer shoulder, and a downwardly sloping interface therebetween; and a continuous abrasive layer having a center, a diameter, and a periphery;
- Fig. 5 is a top plan view of the support of the tool insert of Fig. 4;
- Fig. 6 is a perspective view of the support of Fig. 5;
- Fig. 7 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the support slope is slightly curved;
- Fig. 8 is a top plan view of the support of Fig. 7;
- Fig. 9 is a perspective view of the support of Fig. 8.
- Fig. 10 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table is concentrically grooved;
- Fig. 1 1 is a top plan view of the support of Fig. 10;
- Fig. 12 is a perspective view of the support of Fig. 1 1 ;
- Fig. 13 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table has outwardly radiating channels;
- Fig. 14 is a top plan view of the support of Fig. 13;
- Fig. 15 is a perspective view of the support of Fig. 14;
- Fig. 16 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table has a series of generally parallel channels;
- Fig. 17 is a top plan view of the support of Fig. 16;
- Fig. 18 is a perspective view of the support of Fig. 17
- Fig. 19 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table has a waffle pattern of channels;
- Fig. 20 is a top plan view of the support of Fig. 19;
- Fig. 21 is a perspective view of the support of Fig. 20;
- Fig. 22 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table is concave and has outwardly radiating channels;
- Fig. 23 is a top plan view of the support of Fig. 22;
- Fig. 24 is a perspective view of the support of Fig. 21 ;
- Fig. 25 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the inner support table has outwardly radiating rectangular ridges;
- Fig. 26 is a top plan view of the support of Fig. 25;
- Fig. 27 is a perspective view of the support of Fig. 26;
- Fig. 28 is a cross-sectional elevational view of a tool insert like Fig. 4, except that the shoulder has a series of radiating raised rectangular ridges;
- Fig. 29 is a top plan view of the support of Fig. 28.
- Fig. 30 is a perspective view of the support of Fig. 29.
- Fig. 31 is a perspective view of one embodiment of the two-sloped interface configuration of the present invention.
- Fig. 32 is a cross-sectional elevational view of the substrate of Fig. 31 ;
- Fig. 33 graphically displays the stress (MPa) versus inner face angle for a cutter element having the profile as depicted in Fig. 32.
- the present invention is based on several relationships regarding residual stresses in cutting tool inserts that have eluded the art.
- Applicants have found a unique geometry for cutters, wherein a sloped profile is incorporated in the interior of the cutter.
- the sloped profile is combined with a steeper slope on the outer edge of the cutter, further reduces the surface residual stresses.
- the slope angle of the diamond / substrate interface which features not known in the prior art, is found to affect the overall residual stresses in the cutting tool insert.
- the height ratio between the center diamond table thickness and the periphery thickness is found to change the overall stress as it interacts with the slope angle.
- the diamond table thickness is found to have an effect the overall residual stresses.
- the cutting tool insert, or cutter may be manufactured, in one embodiment by fabricating a cemented carbide substrate in a generally cylindrical shape.
- the cemented metal carbide substrate is conventional in composition and, thus, may be include any of the Group IVB, VB, or VIB metals, which are pressed and sintered in the presence of a binder of cobalt, nickel or iron, or alloys thereof. Examples include carbides of tungsten (W), niobium (Nb), zirconium (Zr), vanadium (V), tantalum (Ta), titanium (Ti), tungsten Ti) and hafnium (Hf).
- the metal carbide is tungsten carbide.
- the end face(s) on the carbide substrate are formed by any suitable cutting, grinding, stamping, or etching process.
- a sufficient mass of superabrasive material is then placed on the substrate forming the upper abrasive layer.
- the upper layer is polycrystalline diamond (PCD).
- the upper abrasive layer comprises at least one of synthetic and natural diamond, cubic boron nitride (CBN), wurtzite boron nitride, combinations thereof, and like materials.
- the polycrystalline material layer (or the diamond table layer) and the substrate are subjected to pressures and temperatures sufficient to effect intercrystalline bonding in the polycrystalline material, and create a solid polycrystalline material layer.
- chemical vapor deposition may also be used to deposit the polycrystalline material on the substrate. This is accomplished by coating the particles of the individual diamond crystals with various metals such as tungsten, tantalum, niobium, or molybdenum, and the like by chemical vapor techniques using fluidized bed procedure. Chemical vapor deposition techniques are also known in the art which utilize plasma assisted or heated filament methods.
- FEA finite element stress analyses
- the inventive cutter has an increased useful life with the reduced thermally induced residual radial and axial stresses in the abrasive layer.
- the inventive cutter demonstrates increased impact performance and extended working life.
- Figs.l and 2 display the maximum surface axial stress and radial stress dependent on the slope angle and the height ratio from one FEA study.
- the hoop stress is not shown here because it is much smaller than axial and radial stresses.
- the optimum range for minimum axial and radial stresses is very close.
- a larger slope angle generally leads to smaller stress.
- the optimum slope angle is between about 40° and about 50°, as higher angles tend to cause manufacturing difficulty. For a given slope angle, there exists a range of height ratios corresponding to minimum residual tensile stress.
- a factor that affects residual stresses in cutting tools is the shoulder width (S w ) fraction of the radius of diamond table diameter (D d ). As illustrated in Fig. 3, the residual stress increases with shoulder width fraction. However, the shoulder can provide the better shaping capability and flexibility for post-sintering finishing. In one embodiment, the shoulder width fraction ranges from between about 0.02 and 0.05.
- the interface can vary in a number of ways to ensure better bonding strength and manufacturing feasibility. This has been demonstrated in the art listed above.
- the center interface can be slightly concave or convex, and some non-planar patterns can be combined with the outwardly sloped design. As long as the outwardly slope interface for the cutting tool is optimized based on the precepts of the present invention, the residual stresses can be minimized.
- the cutting tool inserts are based on cylindrical supports having a diameter that ranges from between about 6 and 30 mm. This also is the nominal diameter, D d , of the abrasive compact upper surface. In another embodiment, the height of the abrasive particle at its periphery, D p , ranges from about 3 to about 6 mm in thickness. Using a practical S w :D d ratio of about 0.1 to about 0.5, translates into the shoulder, S w , having a width of from between about 0.003 and about 0.083 mm.
- the slope angle, S a ranges from about 40° to 50°.
- D C :D P ranges from between about 0.1 and 0.8.
- the D C :D P ratio ranges from about 0.2 and 0.7.
- the D C :D P ratio ranges from between about 0.3 and 0.6.
- the D C :D P ratio ranges from about 0.4 and 0.5.
- a diamond table, 8 has a diameter, D d ; a diamond table periphery thickness, D p ; a diamond table center thickness, D c ; a slope angle, S a ; and a shoulder width, S w .
- the illustrated cutting tool insert has a substrate, 10, that has a support face, which includes an inner support table, 12, an outer shoulder, 14, and a downwardly sloping (from support table 12) interface, 16, that forms a slope angle, S a , between support table 12 and shoulder 14.
- support table 12 and shoulder 14 are planar, while interface 16 is linear between support table 12 and shoulder 14. It will be appreciated that the interface between diamond table 8 and support 10 are mirror images. In manufacturing, the interface of diamond table 8 will confirm to the interface of support 10.
- the cutting tool insert has a slightly curved sloping interface, 18. As shown in the figure, the interface is slightly curved both at its junction with the inner support table, 20, and with the shoulder, 22.
- the inner support table 24 of the cutter is concentrically grooved from the center of support table 24, to the sloping interface, 26.
- the concentric grooves are intended to provide better support for and a better bond to the diamond table, 28.
- the cross-section of these grooves can be of a configuration other than that illustrated.
- the inner support table 30 has a series of channels that radiate from its center to the sloping interface 32.
- the number of such channels can be lesser or greater than the number shown. Additionally, the depth and height of each channel can vary from channel to channel. In another embodiment that is not shown, the cross-section of these channels need not be rectangular, but can consist of other geometries as well.
- the channels in the support substrate 34 serve to provide a better bond for the diamond table 36 that it supports and to which it is bonded.
- the sloping interface and shoulder can be in any configuration illustrated herein.
- the cutting tool insert as in previous embodiments is like the insert of Fig. 4, except that the inner support table 38 of the substrate 40, and the diamond table 42, contain a series of substantially parallel channels across its face.
- the number of such channels can be lesser or greater than the number shown.
- the depth and height of each channel can also vary from channel to channel.
- the cross-section of these channels need not be rectangular, but can consist of other geometries as well.
- the sloping interface and shoulder can be in any configuration illustrated herein.
- the inner support table 44 of the substrate 46 and the diamond table 48 contain a matrix of substantially parallel intersecting channels (a waffle-like pattern) across its face.
- the number of such channels can be lesser or greater than the number shown, as can the depth and height of each channel, which can vary from channel to channel. It should be noted that the cross-section of these channels need not be rectangular, but can consist of other geometries as well.
- the sloping interface and shoulder can be in any configuration illustrated herein.
- the inner support table 50 of the substrate 52 is domed and contains a series of radiating channels from its center to the sloping interface 56 with the diamond table 54.
- the number of such channels can be lesser or greater than the number shown, as can the depth and height of each channel, which can vary from channel to channel.
- the cross- section of these channels is not rounded, but can consist of other geometries.
- the shape of the dome also can vary.
- the sloping interface and shoulder can be in any configuration illustrated herein.
- the inner support table 58 of the substrate 60 contains a series of raised rectangular ridges that radiate from its center to the sloping interface 64 with the diamond table 62.
- the number of such ridges can be lesser or greater than the number shown, as can the width and height of each ridge, which can vary from ridge to ridge.
- the cross-section of these ridges need not be rectangular, but can consist of other geometries as well.
- the sloping interface and shoulder can be in any configuration illustrated herein.
- the sloping interface 72 between the inner support table 68 and the diamond table 70 is linear (as in Fig. 4), except that it has a series of radiating raised ridges that extend from support table 66 to the shoulder, 74.
- the number of such ridges can be lesser or greater than the number shown, as can the width and height of each ridges, which can vary from ridge to ridge. In fact, the cross-section of these ridges need not be rectangular, but can consist of other geometries as well. As shown in Figs.
- the carbide support contains 2 distinctive faces of support for the abrasive material, each face being disposed at an angle (relative to the horizontal) so as to optimized (minimize) radial stress and axial stress.
- a cutter, 310 is formed from a lower support, 312, and an upper abrasive layer, 14 (see Fig. 32).
- Support 312 has a central inner face 316 (support table), that extends outwardly and downwardly from an apex or center, 318.
- Surrounding face 318 is an outer annular face, 320, that extends outwardly and downwardly from the outer periphery of face 316.
- annular face 320 terminates in a ledge 322 of the outer periphery of annular face 320.
- superimposed on inner face 316 can be saw tooth annuli and troughs, such as are disclosed in U. S. Patent No. 6,315,652.
- outer annular face 320 slopes downwardly from the horizontal at an angle of between about 20° and 75°.
- outer annular face slopes downwardly at an angle of about 45°.
- inner face 16 slopes downwardly from the horizontal at an angle of between about 5° and 30°.
- inner face 316 slopes downwardly at an angle of 7.5°.
- the outer surface configuration of the diamond (upper abrasive) layer 314 is not critical.
- the surface configuration of the diamond layer may be in the form of hemispherical, planar, conical, reduced or increased radius, chisel, or non-axisymmetric in shape.
- all forms of tungsten carbide inserts used in the drilling industry may be enhanced by the addition of a diamond layer, and in one embodiment is further improved by the current invention by addition of a pattern of ridges.
- the inventive cutter demonstrates an increased useful life with the reduced residual stresses (axial, radial, and hoop tensile) in the abrasive layer at locations where spalling and delamination typically occur.
- reduced residual stresses is obtained for virtually any size tool insert.
- the residual tensile stress in cutting tool inserts is significantly reduced with the axial tensile stress decreased by about 90%, the radial tensile stress decreased by about 60%, and the hoop stress becoming completely compressive.
- the surface axial residual stress is reduced by 83% compared to a flat, planar interface and by 23% compared to a substrate with a single sloped rim. The reduction of the surface axial residual stress increases the impact performance and extends the working lifetime of the cutting tool.
- Example 1 The following prior art cutters are used, a cutting tool having a flat interface, a cutting tool having a single slope interface with 19 mm diameter, 16 mm overall height, and 3 mm diamond table thickness.
- a cutting tool with an outer annular face with an angle of 45° with respect to the horizontal, while the inner face angle varied between about 0° and 30° from the horizontal is used.
- the cutting tool inserts are manufactured by conventional high pressure/high temperature (HP/HT) techniques well known in the art. Such techniques are disclosed, inter alia, in the art cited above.
- HP/HT high pressure/high temperature
- the inventive cutter is compared to a single slope tool insert of the prior art.
- the performance of the cutter on a chamfer piece is measured, with each piece having a carbide chamfer of greater than about 0.2 mm, less than l .0 mm radial or 45° on the locating base.
- the cutter (0.010" chamfered edge) sample is mounted in a steel holder, with Rake angle to work piece 7 deg radial/ 12 degrees axial. The cutter is rotated and cuts in an interrupted fashion at a depth of 0.150" and transverse distance of 0.010" through a granite work piece at a cutting speed of
- the inventive cutter shows unexpected improvement in impact resistance, with a count of 12600 as opposed to 1 1500 for the prior art cutter.
- Example 2 In this example, the prior art cutter has a flat interface, 19 mm diameter, 16 mm overall height, 3 mm diamond table thickness.
- Table 3 display correlations of shoulder angle (Sa) and diamond table height ratio Dc:Dp as predicted by FEA models. The ratios displayed are approximate.
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- Mining & Mineral Resources (AREA)
- Geology (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US39518202P | 2002-07-10 | 2002-07-10 | |
US39518102P | 2002-07-10 | 2002-07-10 | |
US395182P | 2002-07-10 | ||
US395181P | 2002-07-10 | ||
PCT/US2003/018692 WO2004007901A1 (fr) | 2002-07-10 | 2003-06-12 | Outils de coupe a double profil d'inclinaison |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1527251A1 true EP1527251A1 (fr) | 2005-05-04 |
EP1527251B1 EP1527251B1 (fr) | 2008-01-23 |
Family
ID=30118481
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP03764305A Expired - Lifetime EP1527251B1 (fr) | 2002-07-10 | 2003-06-12 | Outils de coupe a double profil d'inclinaison |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1527251B1 (fr) |
CN (1) | CN100374685C (fr) |
AU (1) | AU2003248688A1 (fr) |
WO (1) | WO2004007901A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2017114678A1 (fr) * | 2015-12-31 | 2017-07-06 | Element Six (Uk) Limited | Structures super dures et leurs procédés de fabrication |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1606488A1 (fr) * | 2003-02-26 | 2005-12-21 | Element Six (PTY) Ltd | Element coupant secondaire pour trepan de forage |
US8858662B2 (en) * | 2011-03-04 | 2014-10-14 | Baker Hughes Incorporated | Methods of forming polycrystalline tables and polycrystalline elements |
US10107042B2 (en) | 2012-09-07 | 2018-10-23 | Smith International, Inc. | Ultra-hard constructions with erosion resistance |
US9138872B2 (en) | 2013-03-13 | 2015-09-22 | Diamond Innovations, Inc. | Polycrystalline diamond drill blanks with improved carbide interface geometries |
US9080385B2 (en) | 2013-05-22 | 2015-07-14 | Us Synthetic Corporation | Bearing assemblies including thick superhard tables and/or selected exposures, bearing apparatuses, and methods of use |
GB201309798D0 (en) * | 2013-05-31 | 2013-07-17 | Element Six Abrasives Sa | Superhard constructions & methods of making same |
US10465447B2 (en) | 2015-03-12 | 2019-11-05 | Baker Hughes, A Ge Company, Llc | Cutting elements configured to mitigate diamond table failure, earth-boring tools including such cutting elements, and related methods |
CN105127430B (zh) * | 2015-08-24 | 2017-11-24 | 珠海市钜鑫科技开发有限公司 | 一种具有立方氮化硼、纤锌矿型氮化硼和金刚石的超硬材料及其制备方法 |
US10400517B2 (en) | 2017-05-02 | 2019-09-03 | Baker Hughes, A Ge Company, Llc | Cutting elements configured to reduce impact damage and related tools and methods |
US10570668B2 (en) | 2018-07-27 | 2020-02-25 | Baker Hughes, A Ge Company, Llc | Cutting elements configured to reduce impact damage and mitigate polycrystalline, superabrasive material failure earth-boring tools including such cutting elements, and related methods |
US10577870B2 (en) | 2018-07-27 | 2020-03-03 | Baker Hughes, A Ge Company, Llc | Cutting elements configured to reduce impact damage related tools and methods—alternate configurations |
US20210372203A1 (en) * | 2018-11-12 | 2021-12-02 | Schlumberger Technology Corporation | Non planar cutting element with non planar interface design and tools incorporating such elements |
US11920409B2 (en) | 2022-07-05 | 2024-03-05 | Baker Hughes Oilfield Operations Llc | Cutting elements, earth-boring tools including the cutting elements, and methods of forming the earth-boring tools |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5494477A (en) * | 1993-08-11 | 1996-02-27 | General Electric Company | Abrasive tool insert |
GB9412779D0 (en) * | 1994-06-24 | 1994-08-17 | Camco Drilling Group Ltd | Improvements in or relating to elements faced with superhard materials |
CN2293415Y (zh) * | 1996-11-08 | 1998-10-07 | 郑州新亚复合超硬材料有限公司 | 金刚石复合片 |
US5971087A (en) * | 1998-05-20 | 1999-10-26 | Baker Hughes Incorporated | Reduced residual tensile stress superabrasive cutters for earth boring and drill bits so equipped |
US6189634B1 (en) * | 1998-09-18 | 2001-02-20 | U.S. Synthetic Corporation | Polycrystalline diamond compact cutter having a stress mitigating hoop at the periphery |
CN2392909Y (zh) * | 1999-07-14 | 2000-08-23 | 郑州新亚复合超硬材料有限公司 | 金刚石/硬质合金复合片 |
-
2003
- 2003-06-12 AU AU2003248688A patent/AU2003248688A1/en not_active Abandoned
- 2003-06-12 CN CNB038163136A patent/CN100374685C/zh not_active Expired - Fee Related
- 2003-06-12 EP EP03764305A patent/EP1527251B1/fr not_active Expired - Lifetime
- 2003-06-12 WO PCT/US2003/018692 patent/WO2004007901A1/fr active IP Right Grant
Non-Patent Citations (1)
Title |
---|
See references of WO2004007901A1 * |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2017114678A1 (fr) * | 2015-12-31 | 2017-07-06 | Element Six (Uk) Limited | Structures super dures et leurs procédés de fabrication |
US11111728B2 (en) | 2015-12-31 | 2021-09-07 | Element Six (Uk) Limited | Super hard constructions and methods of making same |
Also Published As
Publication number | Publication date |
---|---|
WO2004007901A1 (fr) | 2004-01-22 |
EP1527251B1 (fr) | 2008-01-23 |
AU2003248688A1 (en) | 2004-02-02 |
CN100374685C (zh) | 2008-03-12 |
CN1668827A (zh) | 2005-09-14 |
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