Earthwork cutting tools, earthwork cutting devices, and related methods

Abstract

An earth cutting tool may include one or more earth cutting devices. Each earthwork cutting device may include a plurality of inserts positioned within a body of the cutting device. The insert may be tapered to correspond to tapering of a pocket defined in the body to facilitate insertion and attachment of the insert to the body to avoid the body may crack during brazing and / or heat treatment after the insert is positioned in the pocket.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an earth cutting tool, an earth cutting device that can be used in such a tool, and methods for making and using the earth cutting tool and the earth cutting device. BACKGROUND

[0002] Examples of cutting tool assemblies for earth working can be found in U.S. Patent Application Publication Nos. 2013 / 0105231, 20150035343, or 20170342831. Cutting tools can be configured to cut through earth (e.g., dirt, soil, rock, etc.) or to cut in earth (e.g., the earth’s crust or rock formation or soil). For example, earth cutting tools can include drilling tools that can be used for fracking, oil exploration or mining, oil or gas drilling. SUMMARY

[0003] Due to the harsh operating environment, cutting tools can be subjected to strong forces. These forces can damage or degrade the cutting tool, which can then need to be replaced. This type of degradation can be exacerbated when the cutting insert is made of a different material than the underlying body to which the cutting insert is attached.

[0004] Cutting inserts made of ceramic materials, carbides, tungsten carbide, or polycrystalline diamond (PCD) can be inserted into a steel body to form a cutting tool (e.g., positioned and permanently attached, bonded, and / or held in the steel body, etc.). We have discovered that differences in the coefficient of thermal expansion between these different materials can cause cracking that can occur when the formed cutting tool is brazed and then heat treated. For example, we have discovered that such cracking can occur when the formed cutting tool is brazed and then quenched or otherwise cooled during the manufacturing process. We have discovered that such cracking can occur through the brazing process (e.g., brazing, torch brazing, furnace brazing, etc.) and a subsequent heat treatment process (e.g., quenching or other type of heat treatment that can cause cooling of the joined materials, etc.). For example, we have discovered that rapid cooling of the steel body and insert can cause the steel body to crack during quenching. We have discovered that this cracking can occur because the steel body cannot withstand the stresses that occur as the steel and insert materials shrink at different rates as they cool during brazing and / or subsequent heat treatment.

[0005] We have developed a cutting tool and a method of making a cutting tool that can avoid such manufacturing defects and that can help provide a more robust tool with a better joint or connection between the insert and the steel body to which the insert is attached. Embodiments can provide a more reliably formed cutting tool that has improved ability to withstand the operating environment so that the formed tool can provide improved durability and a longer cutting tool life.

[0006] In some embodiments, the cutting tool can include a base formed of steel having a plurality of pockets defined in the body. Each pocket can have an outer mouth at an outer surface of the body and taper to a pocket bottom, which can be an innermost portion of the pocket within the steel body. The tapered pocket can extend linearly from the outer mouth to the pocket bottom, such that a sidewall of the pocket extending from the pocket bottom to the outer mouth extends continuously and linearly from the pocket bottom to the outer mouth along a predefined angle. A tapered cutting insert can be inserted into each pocket such that there is a respective insert of a plurality of inserts in each pocket. The tapered insert can have a bottom that is narrower than its top, and can have a sidewall that extends continuously from the bottom to the top of the tapered insert along a predefined angle to correspond to the taper of the pocket into which the tapered insert is positioned. An upper portion of the insert can protrude from the steel body and can be positioned to directly contact the earth for cutting the earth.

[0007] The inserts can be positioned in the pockets via a brazing operation. In some embodiments, the steel body and / or the inserts can each be heated to a preselected brazing temperature, and the inserts can then be inserted into the pockets. After insertion, the formed cutting tool at the preselected brazing temperature can be placed into a bath of a liquid (e.g., oil, water, quenching liquid, etc.) to rapidly cool to a preselected quenching temperature. Thereafter, the formed cutting tool can undergo other post-quenching processing (e.g., undergo heat treatment, undergo machining of the steel body, etc.) as needed to complete the formed cutting tool. In some embodiments, for example, the formed cutting tool can be inserted or attached into a mounting body to facilitate mounting of the cutting tool to a rotatable body that can be rotated to effect earth cutting to form a hole or other type of aperture in the earth to facilitate fracking or other types of earth boring.

[0008] In some embodiments, the size design of the inserts and pockets can be configured to facilitate use of an intermediate brazing material to help facilitate insertion and connection of the inserts to the pockets. In other embodiments, such intermediate material can not be needed.

[0009] The size design of the inserts and pockets can also be provided such that the bottom of each insert is spaced apart from the pocket bottom to facilitate gas escape that can occur during the brazing process.

[0010] In a first aspect, a cutting tool is provided. Embodiments of the cutting tool can include a shaft having a first end and a second end. The shaft can be rotatable in a first rotational direction (e.g., a clockwise direction or a counterclockwise direction). A plurality of cutting devices can be attached to the first end of the shaft. Each of the cutting devices can include a body having a top side and a bottom side. The top side can be opposite the bottom side. The bottom side can be positioned proximate the first end of the shaft, and the top side can be further from the first end of the shaft than the bottom side. The body can also have a plurality of sidewalls extending between the bottom side and the top side. The plurality of sidewalls can include a first end wall and a second end wall opposite the first end wall. The first end wall can extend from a first end of the bottom side to a first end of the top side, and the second end wall can extend from a second end of the bottom side to a second end of the top side. The plurality of sidewalls of the body can also include an outwardly facing peripheral sidewall and an inwardly facing peripheral sidewall. The outwardly facing peripheral sidewall can extend between the top side and the bottom side, and also between the first end wall and the second end wall. The inwardly facing peripheral sidewall can be opposite the outwardly facing peripheral sidewall. The inwardly facing peripheral sidewall can extend between the top side and the bottom side, and also between the first end wall and the second end wall.

[0011] The body of each cutting device can include a plurality of pockets defined therein. The plurality of pockets can include at least one first pocket, at least one second pocket, and at least one third pocket. Each pocket can be defined as having a mouth in an outer surface of the body, a bottom defined inside the body, and at least one pocket sidewall extending linearly and continuously from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket. The top side of the body can have the at least one first pocket defined therein, the outwardly facing peripheral sidewall can have the at least one second pocket defined therein; and the inwardly facing peripheral sidewall can have the at least one third pocket defined therein.

[0012] A plurality of inserts can be included in the body. For example, the inserts can include at least one first insert having an inner portion affixed within the at least one first pocket and an outer portion extending from the at least one first pocket, at least one second insert having an inner portion affixed within the at least one second pocket and an outer portion extending from the at least one second pocket, and at least one third insert having an inner portion affixed within the at least one third pocket and an outer portion extending from the at least one third pocket.

[0013] In some embodiments, the insert can be composed of a material that is harder than the material of the body. For example, the body can be composed of steel, and the insert can be composed of a ceramic material, a carbide material, a PCD material, or a tungsten carbide material.

[0014] In a second aspect, an outer portion of the first insert can be wider than an inner portion of the first insert, an outer portion of the second insert can be wider than an inner portion of the second insert, and an outer portion of the third insert can be wider than an inner portion of the third insert.

[0015] In a third aspect, each insert has at least one side wall extending from an inner end of the insert to a mouth of the pocket in which the insert is positioned, along at least one pocket side wall of the pocket in which the insert is positioned, so as to attach within the pocket in which the insert is positioned. For example, the first insert positioned in the first pocket can have a side wall extending from an inner end of the first insert to the mouth of the first pocket, along a pocket side wall of the first pocket, the second insert positioned in the second pocket can have a side wall extending from an inner end of the second insert to the mouth of the second pocket, along a pocket side wall of the second pocket, and the third insert positioned in the third pocket can have a side wall extending from an inner end of the third insert to the mouth of the third pocket, along a pocket side wall of the third pocket.

[0016] In some embodiments, each of the inserts has at least one side wall extending from an inner end of the insert to a mouth of the pocket in which the insert is positioned, at a preselected angle. In some embodiments, the preselected angle can be between 10° and 60°. For example, a side wall of the first insert can extend from an inner end of the first insert to a mouth of the first pocket, at an angle between 10° and 60°, a side wall of the second insert can extend from an inner end of the second insert to a mouth of the second pocket, at an angle between 10° and 60°, and a side wall of the third insert can extend from an inner end of the third insert to a mouth of the third pocket, at an angle between 10° and 60°.

[0017] In a fourth aspect, for each insert, a joint can be defined between at least one side wall of the insert extending from an inner end of the insert to a mouth of the pocket in which the insert is located and at least one pocket side wall of the pocket in which the insert is located. In some embodiments, the joint can include a braze material. For example, a first insert positioned in a first pocket can have a side wall extending along a pocket side wall of the first pocket from an inner end of the first insert to a mouth of the first pocket, and a first joint can be present between the side wall of the first insert and the pocket side wall of the first pocket, a second insert positioned in a second pocket can have a side wall extending along a pocket side wall of the second pocket from an inner end of the second insert to a mouth of the second pocket, and a second joint can be present between the side wall of the second insert and the pocket side wall of the second pocket, and a third insert positioned in a third pocket can have a side wall extending along a pocket side wall of the third pocket from an inner end of the third insert to a mouth of the third pocket, and a third joint can be present between the side wall of the third insert and the pocket side wall of the third pocket.

[0018] In a fifth aspect, for each pocket, a gap can be present between an inner end of an insert positioned in the pocket and a bottom of the pocket. For example, a first insert positioned in a first pocket can have its inner end spaced apart from a bottom of the first pocket by a first gap, a second insert positioned in a second pocket can have its inner end spaced apart from a bottom of the second pocket by a second gap, and a third insert positioned in a third pocket can have its inner end spaced apart from a bottom of the third pocket by a third gap.

[0019] In a sixth aspect, a first end wall of the body does not have an insert, and a second end wall of the body does not have an insert.

[0020] In a seventh aspect, the shaft can have a chamber in communication with a mouth defined in a first end of the shaft.

[0021] In an eighth aspect, the body can be sized and shaped and the inserts can be sized and shaped to suit a preselected set of design criteria. For example, the body can be polygonal in shape or have another type of shape and the inserts can include outer portions having preselected shapes to facilitate achieving a cutting profile that meets a preselected set of design criteria.

[0022] In a ninth aspect, the earth-working cutting tool of the first aspect can include one or more features of the second aspect, the third aspect, the fourth aspect, the fifth aspect, the sixth aspect, the seventh aspect, and / or the eighth aspect. Embodiments can also include other elements or features. For example, examples of such other elements or features can be appreciated, e.g., from the example embodiments discussed herein.

[0023] In a tenth aspect, a cutting device for connecting to a distal end of a rotatable shaft of an earth working tool is provided. The cutting device can include a body composed of a metal. The body can have a top side and a bottom side. The top side can be opposite the bottom side. The bottom side can be positioned proximate the distal end of the rotatable shaft. The body can also have a plurality of side walls extending between the bottom side and the top side. The side walls can include a first end wall and a second end wall opposite the first end wall. The first end wall can extend from a first end of the bottom side to a first end of the top side, and the second end wall extends from a second end of the bottom side to a second end of the top side.

[0024] The plurality of side walls of the body can also include an outer peripheral facing side wall and an inner peripheral facing side wall. The outer peripheral facing side wall can extend between the top side and the bottom side, and also between the first end wall and the second end wall. The inner peripheral facing side wall can be opposite the outer peripheral facing side wall. The inner peripheral facing side wall can extend between the top side and the bottom side, and also between the first end wall and the second end wall.

[0025] The body can also have a plurality of pockets defined therein. The plurality of pockets can include at least one first pocket, at least one second pocket, and at least one third pocket. Each pocket can be defined as having a mouth in an outer surface of the body, a bottom defined inside the body, and at least one pocket side wall extending linearly and continuously from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket. The top side can have the at least one first pocket defined therein, the outer peripheral facing side wall can have the at least one second pocket defined therein, and the inner peripheral facing side wall can have the at least one third pocket defined therein.

[0026] A plurality of inserts composed of a material having a different coefficient of thermal expansion than the coefficient of thermal expansion of the metal of the body can also be included. The plurality of inserts can include at least one first insert having an inner portion affixed within the at least one first pocket and an outer portion extending from the at least one first pocket, at least one second insert having an inner portion affixed within the at least one second pocket and an outer portion extending from the at least one second pocket, and at least one third insert having an inner portion affixed within the at least one third pocket and an outer portion extending from the at least one third pocket.

[0027] In some embodiments, the inserts can be composed of a material that is harder than the material of the body. For example, the body can be composed of steel, and the inserts can be composed of a ceramic material, a carbide material, a PCD material, or a tungsten carbide material.

[0028] In an eleventh aspect, each insert can have at least one side wall extending from an inner end of the insert to a mouth of the pocket in which the insert is positioned, along at least one pocket side wall of the pocket in which the insert is positioned, so as to be attached within the pocket in which the insert is positioned. In some embodiments, the preselected angle is between 10° and 60°.

[0029] For example, a side wall of the first insert can extend from an inner end of the first insert to a mouth of the first pocket at an angle between 10° and 60°, a side wall of the second insert can extend from an inner end of the second insert to a mouth of the second pocket at an angle between 10° and 60°, and a side wall of the third insert can extend from an inner end of the third insert to a mouth of the third pocket at an angle between 10° and 60°.

[0030] In some embodiments, for each insert, a joint can be defined between at least one side wall of the insert extending from an inner end of the insert to a mouth of the pocket in which the insert is positioned, and at least one pocket side wall of the pocket in which the insert is positioned. In some embodiments, the joint can comprise a brazing material. For example, a first insert positioned in a first pocket can have a side wall extending from an inner end of the first insert to a mouth of the first pocket, along a pocket side wall of the first pocket, and a first joint can be present between the side wall of the first insert and the pocket side wall of the first pocket, a second insert positioned in a second pocket can have a side wall extending from an inner end of the second insert to a mouth of the second pocket, along a pocket side wall of the second pocket, and a second joint can be present between the side wall of the second insert and the pocket side wall of the second pocket, and a third insert positioned in a third pocket can have a side wall extending from an inner end of the third insert to a mouth of the third pocket, along a pocket side wall of the third pocket, and a third joint can be present between the side wall of the third insert and the pocket side wall of the third pocket.

[0031] In a twelfth aspect, a gap can be present between a bottom of a pocket and an inner end of an insert positioned in the pocket. For example, a first insert positioned in a first pocket can have its inner end spaced apart from a bottom of the first pocket by a first gap, a second insert positioned in a second pocket can have its inner end spaced apart from a bottom of the second pocket by a second gap, and a third insert positioned in a third pocket can have its inner end spaced apart from a bottom of the third pocket by a third gap.

[0032] In a thirteenth aspect, the cutting apparatus of the tenth aspect can include one or more features of the eleventh aspect and / or the twelfth aspect. Embodiments can also include other features or elements. Examples of such additional features or elements can be appreciated from the discussion herein of exemplary embodiments of cutting apparatuses.

[0033] In a fourteenth aspect, a method of forming a cutting device is provided. Embodiments of the method can include providing a body composed of a metal. The body can have a top side opposite a bottom side, an outwardly facing peripheral sidewall extending from the bottom side to the top side, and an inwardly facing peripheral sidewall opposite the outwardly facing peripheral sidewall. The inwardly facing peripheral sidewall can extend from the bottom side to the top side. The body can also have a plurality of pockets including at least one first pocket defined in the top side of the body, at least one second pocket defined in the outwardly facing peripheral sidewall, and at least one third pocket defined in the inwardly facing peripheral sidewall. Each pocket can have a bottom, a mouth defined in an outer surface of the body, and at least one sidewall extending linearly from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket.

[0034] The method can also include positioning an insert into a pocket of the body such that an inner end of each insert is spaced apart from the bottom of the pocket in which the insert is positioned, and at least one sidewall of the insert extends from the inner end of the insert to the mouth of the pocket along at least one sidewall of the pocket, and an outer portion of the insert extends away from the body. Each insert can be composed of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

[0035] The method can also include heating the body having the inserts positioned in the pockets to a preselected brazing temperature, and applying a heat treatment to the body having the inserts positioned in the pockets to form a cutting device.

[0036] In some embodiments, the inserts can include at least one first insert having an inner portion affixed within the at least one first pocket and an outer portion extending from the at least one first pocket, at least one second insert having an inner portion affixed within the at least one second pocket and an outer portion extending from the at least one second pocket, and at least one third insert having an inner portion affixed within the at least one third pocket and an outer portion extending from the at least one third pocket. The sidewall of the first insert can extend from the inner end of the first insert to the mouth of the first pocket at an angle between 10° and 60°, the sidewall of the second insert can extend from the inner end of the second insert to the mouth of the second pocket at an angle between 10° and 60°, and the sidewall of the third insert can extend from the inner end of the third insert to the mouth of the third pocket at an angle between 10° and 60°.

[0037] In a fifteenth aspect, the method can include applying a braze material to the insert and / or the pocket prior to positioning the insert in the pocket. In some embodiments, the braze material can be used to form a joint between the insert and the pocket. For example, in some embodiments, for each insert, a joint can be defined between at least one side wall of the insert extending from an inner end of the insert to a mouth of the pocket in which the insert is positioned and at least one pocket side wall of the pocket in which the insert is positioned. For example, a first insert positioned in a first pocket can have a side wall extending along a pocket side wall of the first pocket from an inner end of the first insert to a mouth of the first pocket, and a first joint can exist between the side wall of the first insert and the pocket side wall of the first pocket, a second insert positioned in a second pocket can have a side wall extending along a pocket side wall of the second pocket from an inner end of the second insert to a mouth of the second pocket, and a second joint can exist between the side wall of the second insert and the pocket side wall of the second pocket, and a third insert positioned in a third pocket can have a side wall extending along a pocket side wall of the third pocket from an inner end of the third insert to a mouth of the third pocket, and a third joint can exist between the side wall of the third insert and the pocket side wall of the third pocket.

[0038] In a sixteenth aspect, applying a heat treatment to a body having an insert positioned within a pocket to form a cutting device includes placing the body having the insert positioned within the pocket in a quenching liquid held in a bath to quench the body and the insert for a preselected quenching period of time. For some embodiments, the quenching liquid can include oil or other suitable liquid that can be held at a preselected quenching liquid temperature. The pockets of the body can be sized and configured to prevent cracking when the body having the insert positioned within the pocket is in the quenching liquid for the preselected quenching period of time.

[0039] In some embodiments, the body having the insert positioned within the pocket is moved into a quenching liquid to solidify a braze of the body and the insert to retain the insert within the pocket. For example, such braze solidification can cause a joint to be formed between the insert and the pocket.

[0040] In a seventeenth aspect, the positioning of the insert in the pocket can be performed such that, for each insert positioned in a respective one of the pockets, a joint is formed at an interface between at least one side wall of the insert and at least one side wall of the pocket.

[0041] In an eighteenth aspect, applying a heat treatment to the body having the insert positioned within the pocket to form the cutting device can include cooling the body having the insert positioned within the pocket. The pocket can be defined in the body to prevent cracking when the body having the insert positioned within the pocket is cooled via the application of the heat treatment.

[0042] In a nineteenth aspect, embodiments of the process can be implemented to form embodiments of the cutting device. Embodiments of the process can also include other steps or features. For example, the method of the fourteenth aspect can include one or more features or elements of the fifteenth aspect, the sixteenth aspect, the seventeenth aspect, and / or the eighteenth aspect. Embodiments can also include other processing steps or features.

[0043] These and other embodiments will be described in greater detail herein, and shown in the accompanying drawings, which show exemplary embodiments. As such, other details, objects, and advantages of the application will become apparent to those skilled in the art upon consideration of the following description and the attached drawings. BRIEF DESCRIPTION OF DRAWINGS

[0044] Exemplary embodiments of earth cutting tools, earth cutting devices of earth cutting tools, and methods of manufacturing and using the same are shown in the drawings. It should be appreciated that the same reference numbers in different drawings can identify the same component.

[0045] Figure 1 is a block diagram showing a first exemplary embodiment of an earth cutting tool.

[0046] Figure 2 is a schematic view of the first exemplary embodiment of the earth cutting tool from a distal end configured to cut into the earth via movement (e.g., rotation) of the cutting tool.

[0047] Figure 3 is a perspective view of an exemplary embodiment of an earth cutting device 9 of the first exemplary embodiment of the earth cutting tool.

[0048] Figure 4 is a perspective view of an exemplary embodiment of an earth cutting device 9 of the first exemplary embodiment of the earth cutting tool. Figure 3 is another perspective view of the exemplary embodiment of the earth cutting device 9 shown in

[0049] Figure 5 is a cross-sectional view of the exemplary embodiment of the earth cutting device 9 shown in Figure 3 and Figure 4 is a cross-sectional view of the exemplary embodiment of the earth cutting device 9 shown in

[0050] Figure 6 is a flowchart showing an exemplary process for manufacturing an exemplary embodiment of an earth cutting device. DETAILED DESCRIPTION

[0051] Reference is made toFigures 1 to 5 The earth-cutting tool 1 can be configured to move for cutting into the earth. Some embodiments can be configured such that the shaft 3 (e.g., hollow shaft 3 or tubular shaft 3) can be rotated in the first rotational direction Rl for cutting into the earth for drilling into the earth to facilitate fracking or oil exploration or other types of drilling applications. The cutting tool 1 can be coupled to a drive mechanism (not shown) to drive rotation of the shaft 3 of the cutting tool 1 to cut into the earth and form a bore (e.g., hole, well, etc.) in the earth.

[0052] The cutting tool 1 can have a shaft 3 with a first end 5 and a second end 7. The first end 5 can be considered a distal end that is configured to cut into the earth. The second end 7 can be considered a proximal end that can be configured for coupling to a drive mechanism or other element. The shaft can include a central chamber 3c therein. In some embodiments, the chamber can extend from a mouth 5m defined at the first end 5 such that the chamber 3c extends from the mouth 5m through the length of the shaft 3 to the second end 7 of the shaft 3. The hollow chamber can facilitate movement of cut earth from the first end 5 to the second end 7 as the shaft is rotated when the first end 5 is in contact with the earth for drilling or otherwise cutting into the earth.

[0053] The first end 5 of the shaft 3 can have a plurality of cutting devices 9 attached to the first end. Each cutting device can be configured to include one or more inserts 11 that can protrude from a body 10 of the cutting device 9 to contact the earth such that rotation of the device can cause cutting of the earth to drill a hole or otherwise cut into the earth.

[0054] Rotation of the shaft 3 in the first rotational direction Rl can cause each cutting device 9 to rotate to cut into the earth along three different sides of the first end 5 of the shaft. For example, an outward-facing side of each cutting device 9 can directly contact the earth along an outer circumference of the first end 5 of the shaft 3 for cutting into the earth in a first cutting direction C1 as shown. An inward-facing side of each cutting device 9 can directly contact the earth along an inner circumference of the first end 5 of the shaft 3 that faces the chamber 3c of the shaft for cutting into the earth in a second cutting direction C2 as shown. An outer face of each cutting device 9 can be a downward-facing side of the cutting device that directly contacts the earth for cutting into the earth in a third cutting direction C3 (e.g., downward direction). For example, the third cutting direction can be a downward direction when the shaft 3 is rotated to drill into the earth, and the first cutting direction C1 and the second cutting direction C2 can be opposite inner and outer circumferential sides of the shaft 3 that are above the lower third cutting direction C3 at the distal end of the first end 5 of the shaft 3. Figure 2 Figure 2 Rotation of the shaft 3 in the first rotational direction Rl can cause each cutting device 9 to rotate to cut into the earth along three different sides of the first end 5 of the shaft. For example, an outward-facing side of each cutting device 9 can directly contact the earth along an outer circumference of the first end 5 of the shaft 3 for cutting into the earth in a first cutting direction C1 as shown. An inward-facing side of each cutting device 9 can directly contact the earth along an inner circumference of the first end 5 of the shaft 3 that faces the chamber 3c of the shaft for cutting into the earth in a second cutting direction C2 as shown. An outer face of each cutting device 9 can be a downward-facing side of the cutting device that directly contacts the earth for cutting into the earth in a third cutting direction C3 (e.g., downward direction). For example, the third cutting direction can be a downward direction when the shaft 3 is rotated to drill into the earth, and the first cutting direction C1 and the second cutting direction C2 can be opposite inner and outer circumferential sides of the shaft 3 that are above the lower third cutting direction C3 at the distal end of the first end 5 of the shaft 3.

[0055] ​The first end of the shaft 3 can include a plurality of different mounts for connection of different cutting devices to the first end 5. In some embodiments, the mounting of the different cutting devices 9 can be provided via welding, fasteners, mounting devices, or a combination of such attachment mechanisms. The cutting devices 9 can be mounted to the first end such that the insert 11 of the cutting device protrudes in one or more different directions— (a) inward into the chamber 3c, (b) outward away from the shaft 3, and / or (c) outward away from the first end 5. In some preferred embodiments, the insert 11 protrudes in all three of these different directions.

[0056] Each cutting device 9 can include a body 10 that can be composed of steel. The body 10 can be formed to have any type of desired geometry. In some embodiments, the body 10 can include a top side 10c opposite a bottom side 10d. The top side 10c can be configured to face in the third cutting direction C3 when the cutting device 9 is mounted to the shaft 3. The bottom side 10d can be configured to face the first end 5 of the shaft 3 when the cutting device 9 is mounted to the shaft 3.

[0057] The body 10 can also include a plurality of side walls extending between the bottom side 10d and the top side 10c. These side walls can include a first end wall 10e and a second end wall 10f opposite the first end wall 10e. The first end wall 10e and the second end wall 10f can not include any inserts positioned therein. The first end wall 10e can extend from a first end of the bottom side 10d to a first end of the top side 10c. The second end wall 10f can extend from a second end of the bottom side 10d to a second end of the top side 10c. The first end wall 10e can face in a first rotational direction R1 of rotation of the shaft 3, and the second end wall 10f can face in the opposite direction. Alternatively, the second end wall 10f can face in the first rotational direction of rotation of the shaft 3, and the first end wall 10e can face in the opposite direction.

[0058] The side walls of the body 10 can also include a peripheral- outward-facing side wall 10a and a peripheral-inward-facing side wall 10b. The peripheral-inward-facing side wall 10b can face toward the mouth 5m of the first end 5 and / or the chamber 3c of the shaft 3 when the cutting device 9 is mounted to the first end 5 of the shaft 3. The peripheral-outward-facing side wall 10a can be on a side of the body 10 opposite the peripheral-inward-facing side wall 10b to face the land that can surround the outer periphery or circumference of the first end 5 of the shaft 3.

[0059] The peripheral-inward-facing side wall 10b can have a proximal end adjacent to or at an inner side of the bottom side 10d, and can extend to a distal end thereof adjacent to or at an inner side of the top side 10c of the body. The peripheral-outward-facing side wall 10a can have a proximal end adjacent to or at an outer side of the bottom side 10d, and can extend to a distal end thereof adjacent to or at an outer side of the top side 10c of the body.

[0060] In some embodiments, the cutting device 9 can be formed such that the top side 10c of the body 10 has a plurality of inserts 11, the outwardly facing side wall 10a of the body 10 has at least one insert 11 (e.g., a single insert 11, two inserts 11, or more than two inserts 11), and the inwardly facing side wall 10b of the body 10 has at least one insert 11 (e.g., only a single insert 11, two inserts 11, or more than two inserts 11). For example, there can be at least one first pocket 12 defined in the top side 10c of the body 10 to receive at least one first insert therein, at least one second pocket 12 defined in the outwardly facing side wall 10a of the body 10 to receive at least one second insert therein, and at least one third pocket defined in the inwardly facing side wall 10b of the body 10 to receive at least one third insert therein.

[0061] For example, the body 10 can have a plurality of pockets 12 including at least one first pocket defined in the top side 10c of the body, at least one second pocket 12 defined in the outwardly facing side wall 10a, and at least one third pocket defined in the inwardly facing side wall 10b. Each pocket 12 can have a bottom 12b defined in the outer surface 10o of the body 10, a mouth 12m, and at least one side wall 12c extending linearly from the bottom 12b of the pocket 12 to the mouth 12m of the pocket 12 at a preselected angle such that the mouth 12m of the pocket 12 is wider than the bottom 12b of the pocket 12.

[0062] The inserts can be positioned in the pockets 12 such that at least one first insert 11 is positioned in the at least one first pocket 12 of the top side 10c of the body, at least one second insert 11 is positioned in the at least one second pocket 12 of the outwardly facing side wall 10a, and at least one third insert 11 is positioned in the at least one third pocket 12 of the inwardly facing side wall 10b such that the inner end 11e of each insert 11 is spaced apart from the bottom 12b of the pocket 12 in which the insert 11 is positioned, and at least one side wall 11w of the insert 11 extends from the inner end 11e of the insert 11 to the mouth 12m of the pocket along at least one side wall 12c of the pocket 12. The outer portion 11p of the insert 11 can extend away from the body 10 to contact the ground to cut the ground. The insert 11 can be composed of a material having a coefficient of thermal expansion different than the coefficient of thermal expansion of the metal of the body 10 (e.g., the body 10 can be steel, and the insert can be composed of a ceramic material, a carbide material, a PCD material, or a tungsten carbide material, etc.).

[0063] For example, from Figure 3 , Figure 4 and Figure 5It can be best appreciated that the top side 10c of the body 10, the outwardly facing sidewall 10a, and / or the inwardly facing sidewall 10b can have one or more pockets 12 defined therein for receiving and retaining an insert 11. Each pocket 12 can receive a respective insert 11. Each pocket 12 can be defined in the body 10 such that the pocket 12 has a bottom 12b that is the innermost portion of the pocket within the core 10i of the body (e.g., the interior portion of the body), and a mouth 12m at the outer surface 10o of the body 10. Each pocket 12 can be defined by a continuous sidewall 12c that can extend from the pocket bottom 12b to an outer end 12a of the pocket 12 at the outer surface 10o of the body 10 to define the mouth 12m of the pocket 12. The size and shape of the sidewall 12c can be set to define a tapered shape of the pocket such that the wall 12c extends linearly and continuously from the pocket bottom 12b to the outer end 12a along a preselected angle.

[0064] In some embodiments, the size and shape of each pocket 12 can be set to have a plurality of sidewalls 12c positioned to define a pocket 12 having a tapered polygonal cross-sectional shape (e.g., hexagonal, octagonal, etc.). In such configurations, each sidewall 12c can extend linearly and continuously from the pocket bottom 12b to the outer end 12a along a preselected angle to define the tapered shape of the pocket 12. In such configurations, the mouth 12m of the pocket 12 can be a polygonal shape, rather than a circular or elliptical shape.

[0065] Each cutting device 9 can also include a plurality of inserts 11 that can be constructed of a material that is harder than the material of the body 10. For example, the material of the inserts 11 can be harder than the steel of the body 10. In some embodiments, the inserts 11 can be constructed of, for example, a ceramic material, carbide, polycrystalline diamond (PCD), or tungsten carbide. Each insert 11 can have a shape such that an inner portion 11b of the insert has a shape that corresponds to the shape of the pocket 12 into which the insert is to be inserted, so as to be attached within the pocket 12. Each insert 11 can include an outer portion 11p that extends out from the body 10 to engage the ground to cut the ground. The outer portion 11p can have a distal end 11d.

[0066] For example, each insert 11 can include an outer portion 11p that protrudes outwardly away from the body 10, and an inner portion 11b that is sized to be positioned in a respective pocket 12 defined in the body 10 such that a sidewall 11w that extends from an inner end 11e of the insert toward its distal end 11d extends along a linearly extending sidewall 12c of the pocket 12 that extends from the pocket bottom 12b to the outer end 12a of the pocket 12a, which can define the mouth 12m of the pocket 12.

[0067] The body of the insert 11 can be sized such that the inner end 11e of the insert 11 is positioned within the pocket 12 adjacent the pocket bottom 12b such that a gap 12d exists between the pocket bottom 12b and the inner end 11e of the insert 11. This gap 12d can be sized to facilitate gas release that can occur as a result of the insertion of the insert 11 that can occur when the insert 11 is positioned into its respective pocket 12.

[0068] In some embodiments, each insert 11 can be positioned in the respective pocket 12 for brazing therein for attachment to the body 10 within the pocket 12. Such brazing can include the use of a brazing material along the pocket sidewall 12c such that a joint can be formed at the interface 15 between the insert wall 11w within the pocket 12 and the portion of the body 10 that defines the pocket sidewall 12c.

[0069] In some embodiments, flux can be applied to each insert 11 prior to insertion of each insert into the respective pocket 12. The flux can help to increase the wettability of the brazing material such that the brazing material can be applied more uniformly over a larger surface area of the insert. The size of the gap 12d can be sized to facilitate gas escape that can occur during the brazing process.

[0070] In other embodiments, a brazing material can not be needed or used. Instead, to achieve attachment at the interface 15 where the pocket sidewall 12c contacts the insert sidewall 11w, each insert 11 can be cold shrink fit within the respective pocket 12 by the body 10 clamping the insert 11 within the pocket 12 after the insert is positioned in the pocket, and the body 10 and insert 11 are subsequently cooled to form the cutting device 9.

[0071] In some embodiments, each cutting device 9 can be configured to be attached to the first end 5 of the shaft 3 of the cutting tool 1. Each cutting device 9 can include a body 10 having a top side 10c and a bottom side 10d opposite the top side 10c. The bottom side 10d can be positioned adjacent the first end 5 of the shaft 3, and the top side 10c can be further from the first end 5 of the shaft 3 than the bottom side 10d.

[0072] The body 10 can also have a plurality of sidewalls extending between the bottom side 10d and the top side 10c. These sidewalls can include a first end wall 10e and a second end wall 10f opposite the first end wall 10e. The first end wall 10e can extend from a first end of the bottom side 10d to a first end of the top side 10c, and the second end wall 10f can extend from a second end of the bottom side 10d to a second end of the top side 10c.

[0073] The plurality of sidewalls of the body 10 can further include an outer circumferentially facing sidewall 10a and an inner circumferentially facing sidewall 10b. The outer circumferentially facing sidewall 10a can extend between a top side 10c and a bottom side 10d of the body 10 and can further extend between a first end wall 10e and a second end wall 10f. The inner circumferentially facing sidewall 10b can be opposite the outer circumferentially facing sidewall 10a. The inner circumferentially facing sidewall 10a can extend between the top side 10c and the bottom side 10d of the body 10 and can further extend between the first end wall 10e and the second end wall 10f.

[0074] The body can have a plurality of pockets 12 defined therein. The plurality of pockets 12 can include at least one first pocket 12, at least one second pocket 12, and at least one third pocket 12. Each pocket 12 can be defined as having a mouth 12m in an outer surface 10o of the body 10, a bottom 12b defined inside the body 10, and at least one pocket sidewall 12c extending linearly and continuously from the bottom 12b of the pocket 12 to the mouth 12m of the pocket 12 at a preselected angle such that the mouth 12m of the pocket is wider than the bottom 12b of the pocket.

[0075] The top side 10c of the body can have at least one first pocket 12 defined therein, the outer circumferentially facing sidewall 10a can have at least one second pocket 12 defined therein, and the inner circumferentially facing sidewall 10b can have at least one third pocket 12 defined therein.

[0076] The plurality of inserts 11 can include at least one first insert 11 having an inner portion 11b attached within at least one first pocket 12 and an outer portion 11p extending from the at least one first pocket 12, at least one second insert having an inner portion 11b attached within at least one second pocket 12 and an outer portion 11p extending from the at least one second pocket 12, and at least one third insert 11 having an inner portion 11b attached within at least one third pocket 12 and an outer portion 11p extending from the at least one third pocket 12.

[0077] The outer portion 11p of the first insert 11 can be wider than the inner portion 11b of the first insert 11, the outer portion 11p of the second insert 11 can be wider than the inner portion 11b of the second insert 11, and the outer portion 11p of the third insert 11 can be wider than the inner portion 11b of the third insert 11.

[0078] In different embodiments, the number of pockets 12 and inserts 11 can be any of a number of suitable different arrangements. In some configurations, there can be a plurality of first inserts 11 positioned in respective first pockets 12 defined in a plurality of first pockets defined in the top surface 10c. There can also be a plurality of second inserts 11 positioned in respective second pockets 12 defined in a plurality of second pockets defined in the outwardly facing side wall 10a. There can also be a plurality of third inserts 11 positioned in respective third pockets 12 defined in a plurality of third pockets defined in the inwardly facing side wall 10b. Each insert 11 can have at least one side wall 11w extending from an inner end 11e of the insert 11 to a mouth 12m of the pocket 12 in which the insert 11 is positioned along at least one side wall 12c of the pocket 12 in which the insert 11 is positioned so as to be attached within the pocket 12 in which the insert 11 is positioned.

[0079] In some embodiments, a joint can be defined between the at least one side wall 11w of the insert 11 extending from the inner end 11e of the insert 11 to the mouth 12m of the pocket 12 in which the insert 11 is positioned and the at least one side wall 12c of the pocket 12 in which the insert 11 is positioned. The joint can for example include a brazing material. In other embodiments, no such joint is formed at the interface 15 between the at least one side wall 11w of the insert 11 and the at least one side wall 12c of the pocket 12 in which the insert 11 is positioned, and the pocket side wall 12c can directly contact the at least one side wall 11w of the insert 11 for the insert 11 to be attached within the pocket 12.

[0080] Each of the inserts 11 can have at least one side wall 11w extending from an inner end 11e of the insert 11 to a mouth 12m of the pocket 12 in which the insert 11 is positioned at a preselected angle (e.g., an angle between 10° and 60° or between 15° and 45°, etc.).

[0081] In some embodiments, the body 10 can be configured to have pockets 12 for receiving inserts 11 to maximize the utilization of material between all of the different pockets 12. Embodiments can be configured such that the pocket locations are defined in the body 10 such that the material defined between immediately adjacent pockets 12 in the body is maximally utilized to account for the geometry of the body and the size design of the inserts 11 to be utilized. Other embodiments can utilize other types of geometries, pocket spacing, and insert configurations.

[0082] Referring to Figure 6 , an exemplary embodiment of a process for manufacturing the cutting device 9 is shown. Embodiments of the process can be used to form the exemplary embodiment of the cutting device 9.

[0083] In a first step S1, a body 10 can be formed and an insert 11 can be formed. The body 10 can be formed of steel, and the insert 11 can be formed of, for example, a ceramic material, carbide, PCD, or tungsten carbide material. The formation of the steel body 10 can include forging and / or machining. For example, the body 10 can be formed of steel, and the body 10 can then be machined to a desired shape, and also to include a desired number of pockets 12. The insert 11 can be formed of a material that is harder than the material of the body 10.

[0084] In some embodiments, the body 10 can be molded to include the tapered pockets 12 therein. In other embodiments, the pockets 12 can be defined in the body 10 via machining or drilling, which can occur after the body is constructed if the body is formed of steel or other suitable metal.

[0085] The formation of the insert 11 can also be provided via molding and / or machining. In some embodiments, the insert 11 can be formed via molding of the insert to have a desired shape. In some embodiments, the insert 11 can be machined to a desired shape after the body of the insert is molded.

[0086] In some embodiments, the formation of the insert 11 and the body 10 can occur simultaneously using different production lines. In other embodiments, the insert 11 can be formed at a different time than the body 10, and the components can then be positioned in proximity to each other to include the insert 11 into the steel body 10 at a later time according to a preselected manufacturing schedule or other desired schedule for manufacturing the cutting device 9.

[0087] In a second step S2, each insert 11 can be positioned in a respective one of the pockets 12 defined in the body 10. Each insert 11 can be positioned such that an inner portion 1 lb of each insert is within the respective pocket 12, and an outer portion 1 lp of the insert 11 extends from a mouth 12m of the pocket 12 in which the insert is positioned. In some embodiments, braze material can be applied to the side walls 1 lw of the insert 11 and / or the side walls 12c of the pocket 12 to facilitate attachment of the insert 11 to the body 10 within the pocket 12 via an interface between the side walls 12c of the pocket 12 and the side walls 1 lw of the insert 11. This can occur, for example, prior to positioning the insert 11 in the pocket 12. The insertion of the inserts 11 into the pockets 12 of the body 10 can all occur simultaneously or can occur in a sequence of insertion steps.

[0088] At a third step S3, the body 10 with the insert 11 positioned in the pocket 12 can be heated to a preselected brazing temperature. The preselected brazing temperature can be a temperature between 300°C and 500°C or other suitable temperature. For example, in some embodiments, the preselected brazing temperature can be a suitable temperature. In some embodiments that utilize a brazing material, the applied heating can facilitate heating of the brazing material to form the joint.

[0089] After each insert 11 is positioned in the respective pocket in which the pocket 12, the body 10 with the insert 11 can be maintained at a preselected insert brazing temperature or other temperature for a preselected holding period. Such a period can be between 2 minutes and 60 minutes, between 5 minutes and 30 minutes, or other suitable period. Alternatively, such a holding period can not be required.

[0090] At a fourth step S4, the body 10 with the insert 11 can undergo a heat treatment. The heat treatment can be applied to help form the joint or attachment of the insert 11 within the pocket 12. For example, after the brazing material is liquefied via heating, the body 10 with the insert 11 can undergo a heat treatment to cool the body 10, the brazing material, and the insert. In embodiments that can not utilize a brazing material, the heat treatment can cool the insert 11 and the body 10 to attach the insert 11 in the pocket 12 of the body 10.

[0091] For example, the body 10 with the insert 11 can be rapidly cooled via quenching, or can be cooled via other types of heat treatment processes. For example, after the insertion of the insert 11 and the heating of the body with the insert positioned therein, the entire cutting device 9 can be rapidly cooled via quenching in a bath of a holding quenching liquid (e.g., oil, a quenching fluid that can include oil and other additives, another type of quenching liquid). The quenching liquid can be at a preselected quenching liquid temperature (e.g., an ambient temperature or another temperature that is significantly lower than the temperature of the steel body 10) to provide rapid cooling of the body 10 and the insert 11. The body 10 with the insert 11 can be positioned into the bath of the holding quenching liquid so that the entire body 10 and insert 11 are fully submerged within the quenching liquid inside the bath for a preselected quenching period (e.g., five minutes, ten minutes, a time between greater than 0 seconds and 20 minutes, etc.).

[0092] In some embodiments, the heat treatment process can not utilize quenching. Alternatively, another type of heat treatment process can be utilized. As yet another alternative, quenching can be utilized in addition to other post-brazing heat treatment processes.

[0093] Cooling of the steel body 10 and insert 11 of the cutting device 9 can occur via full immersion into a quenching liquid or other heat treatment process, such that the steel body 10 and insert 11 shrink at different rates due to the significantly different coefficients of thermal expansion of the different materials of the insert 11 and body 10. Due to the thickness of the inner core 10i of the material present in the body 10 between the different pockets 12, which can be provided via the tapering of the pockets 12 and the size and shape of the corresponding shaped cutting insert 11, cracking due to this different rate of shrinkage of the insert 11 and body 10 can be avoided.

[0094] After the heat treatment, additional process steps can be performed. For example, in a fifth step S5 (shown in dashed lines), a post-heat treatment process of the formed cutting device 9 can be performed. This can include a post-quenching heat treatment, polishing, machining, and / or packaging of the cutting device 9 for shipment to a customer, who can install the cutting device 9 onto the first end 5 of the shaft 3 of the cutting tool 1.

[0095] As another example, in a sixth step S6, the cutting device 9 can be provided for attachment to the first end 5 of the shaft 3 of the cutting tool 1. For example, multiple cutting devices 9 can be formed and provided for attachment to different locations along the circumference of the first end 5 of the shaft 3 for attachment to the shaft to provide cutting of the ground in the first cutting direction CI, the second cutting direction C2, and the third cutting direction C3.

[0096] The formed cutting device 9 can be formed via Figure 6 Embodiments of the formed cutting device 9 formed by the example embodiments of the processes shown can include the above-described embodiments of the cutting device 9. Embodiments of the formed cutting device 9 can be configured for attachment to the rotatable shaft 3 of the cutting tool 1.

[0097] We have surprisingly found that embodiments of the cutting device 9 can allow for more reliable manufacturing of higher quality cutting devices 9. Embodiments can provide a stronger connection between the insert 11 and the body 10 to provide a cutting device 9 that can have improved life and durability. In addition, we have found that manufacturing of embodiments of the cutting device 9 can be performed more reliably and efficiently while reducing material loss and waste due to the avoidance of cracking during quenching.

[0098] It should be appreciated that the example embodiments discussed herein can be adapted to account for a particular set of design criteria. For example, the size of the steel body 10, the size and shape of the insert 11, the size and shape of the pocket 12, and the type of material used for the insert and body can be any of a number of different options. For example, the type of steel used for the body 10 and the type of insert material used for the insert (e.g., ceramic material, carbide, PCD, tungsten carbide, etc.) can be any of a number of suitable different grades or other options. As another example, the shape of the protruding upper portion of the insert 11 can be any type of suitable shape in order to achieve a desired cutting profile of the cutting device 9. Thus, while certain presently preferred embodiments of apparatuses (e.g., the cutting tool 1 and / or the cutting device 9) and embodiments of methods for making and using the apparatuses have been shown and described above, it should be clearly understood that the present application is not limited thereto, but can be otherwise variously embodied and practiced within the scope of the appended claims.

Claims

1. A cutting tool comprising: a shaft having a first end and a second end, the shaft rotatable in a first rotational direction; a plurality of cutting devices attached to the first end of the shaft, each of the cutting devices including: a body having a top side and a bottom side, the top side opposite the bottom side, the bottom side positioned proximate the first end of the shaft, and the top side further from the first end of the shaft than the bottom side; the body further having a plurality of side walls extending between the bottom side and the top side, the plurality of side walls including a first end wall and a second end wall opposite the first end wall, the first end wall extending from a first end of the bottom side to a first end of the top side, the second end wall extending from a second end of the bottom side to a second end of the top side; the plurality of side walls of the body further including an outer peripheral facing side wall and an inner peripheral facing side wall, the outer peripheral facing side wall extending between the top side and the bottom side and further extending between the first end wall and the second end wall, the inner peripheral facing side wall opposite the outer peripheral facing side wall, the inner peripheral facing side wall extending between the top side and the bottom side and further extending between the first end wall and the second end wall; the body having a plurality of pockets defined therein, the plurality of pockets including at least one first pocket, at least one second pocket, and at least one third pocket, each of the pockets defined as having a mouth in an outer surface of the body, a bottom defined inside the body, and at least one pocket side wall extending linearly and continuously from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket; the top side having the at least one first pocket defined therein, the outer peripheral facing side wall having the at least one second pocket defined therein; the inner peripheral facing side wall having the at least one third pocket defined therein; a plurality of inserts including: at least one first insert having an inner portion affixed within the at least one first pocket and an outer portion extending from the at least one first pocket; at least one second insert having an inner portion affixed within the at least one second pocket and an outer portion extending from the at least one second pocket; and at least one third insert having an inner portion affixed within the at least one third pocket and an outer portion extending from the at least one third pocket.

2. The cutting tool of claim 1, wherein the outer portion of the first insert is wider than the inner portion of the first insert, the outer portion of the second insert is wider than the inner portion of the second insert, and the outer portion of the third insert is wider than the inner portion of the third insert.

3. The cutting tool of claim 1, wherein each of the inserts has at least one side wall extending from an inner end of the insert to the mouth of the pocket in which the insert is located so as to be attached within the pocket in which the insert is positioned.

4. The cutting tool of claim 3, wherein for each of the inserts, a joint is defined between the at least one side wall of the insert extending from the inner end of the insert to the mouth of the pocket in which the insert is located and the at least one pocket side wall of the pocket in which the insert is located.

5. The cutting tool of claim 4, wherein the joint comprises a braze material, and wherein for each of the at least one pockets, there is a gap between the inner end of the insert positioned within the pocket and a bottom of the pocket.

6. The cutting tool of claim 3, wherein each of the inserts has at least one side wall extending from the inner end of the insert to the mouth of the pocket in which the insert is located at the preselected angle, the preselected angle being between 10° and 60°.

7. The cutting tool of claim 3, wherein the first end wall has no insert and the second end wall has no insert.

8. The cutting tool of claim 2, wherein the shaft has a chamber in communication with a mouth defined in the first end of the shaft.

9. A cutting device for connection to a distal end of a rotatable shaft of an earth cutting tool, the cutting device comprising: a body composed of metal, the body having a top side and a bottom side, the top side opposite the bottom side, the bottom side positionable adjacent the distal end of the rotatable shaft; the body further having a plurality of side walls extending between the bottom side and the top side, the plurality of side walls including a first end wall and a second end wall opposite the first end wall, the first end wall extending from a first end of the bottom side to a first end of the top side, the second end wall extending from a second end of the bottom side to a second end of the top side; the plurality of side walls of the body further including an outer peripheral facing side wall and an inner peripheral facing side wall, the outer peripheral facing side wall extending between the top side and the bottom side and further extending between the first end wall and the second end wall, the inner peripheral facing side wall opposite the outer peripheral facing side wall, the inner peripheral facing side wall extending between the top side and the bottom side and further extending between the first end wall and the second end wall; the body has a plurality of pockets defined therein, the plurality of pockets including at least one first pocket, at least one second pocket, and at least one third pocket, each of the pockets being defined as having a mouth in an outer surface of the body, a bottom defined inside the body, and at least one pocket sidewall extending linearly and continuously from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket; the top side has the at least one first pocket defined therein, the outwardly facing peripheral sidewall has the at least one second pocket defined therein; the inwardly facing peripheral sidewall has the at least one third pocket defined therein; a plurality of inserts composed of a material having a coefficient of thermal expansion different than the coefficient of thermal expansion of the metal of the body, the plurality of inserts including: at least one first insert having an inner portion affixed within the at least one first pocket and an outer portion extending from the at least one first pocket; at least one second insert having an inner portion affixed within the at least one second pocket and an outer portion extending from the at least one second pocket; and at least one third insert having an inner portion affixed within the at least one third pocket and an outer portion extending from the at least one third pocket.

10. The cutting device of claim 9, wherein each of the inserts has at least one sidewall extending from an inner end of the insert to the mouth of the pocket in which the insert is located along the at least one pocket sidewall of the pocket in which the insert is located so as to be affixed within the pocket in which the insert is positioned; and wherein the preselected angle is between 10° and 60°.

11. The cutting device of claim 9, wherein for each of the pockets, there is a gap between the bottom of the pocket and an inner end of the insert positioned within the pocket.

12. A method of forming a cutting device, the method comprising: providing a body composed of a metal, the body having a top side opposite a bottom side, an outwardly facing peripheral sidewall extending from the bottom side to the top side, and an inwardly facing peripheral sidewall opposite the outwardly facing peripheral sidewall, the inwardly facing peripheral sidewall extending from the bottom side to the top side, the body having a plurality of pockets, the plurality of pockets including at least one first pocket defined in the top side of the body, at least one second pocket defined in the outwardly facing peripheral sidewall, and at least one third pocket defined in the inwardly facing peripheral sidewall, each of the pockets having a bottom, a mouth defined in an outer surface of the body, and at least one sidewall extending linearly from the bottom of the pocket to the mouth of the pocket at a preselected angle such that the mouth of the pocket is wider than the bottom of the pocket; positioning an insert into the pocket of the body such that an inner end of each insert is spaced apart from the bottom of the pocket in which the insert is positioned and at least one sidewall of the insert extends from the inner end of the insert to the mouth of the pocket along the at least one sidewall of the pocket and an outer portion of the insert extends away from the body, the insert being comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body; heating the body with the insert positioned in the pocket to a preselected brazing temperature, and applying a heat treatment to the body with the insert positioned within the pocket to form the cutting device.

13. The method of claim 12, comprising: applying a brazing material to the insert and / or in the pocket prior to positioning the insert in the pocket.

14. The method of claim 12, wherein the insert is comprised of a ceramic material, a carbide, a polycrystalline diamond, or a tungsten carbide.

15. The method of claim 12, wherein the preselected angle is between 10° and 60°.

16. The method of claim 12, wherein applying the heat treatment to the body with the insert positioned within the pocket to form the cutting device includes placing the body with the insert positioned within the pocket in a quenching liquid held in a bath to quench the body and the insert for a preselected quenching period of time.

17. The method of claim 16, wherein the pocket is sized and configured to prevent cracking when the body with the insert positioned within the pocket is in the quenching liquid for the preselected quenching period of time.

18. The method of claim 16, wherein the body with the insert positioned within the pocket is moved into the quenching liquid to solidify brazing of the body and the insert to retain the insert within the pocket.

19. The method of claim 12, wherein the positioning of the insert in the pocket is performed such that for each of the inserts positioned into a respective one of the pockets, a joint is formed at an interface between the at least one sidewall of the insert and the at least one sidewall of the pocket.

20. The method of claim 12, wherein applying the heat treatment to the body with the insert positioned within the pocket to form the cutting device includes cooling the body with the insert positioned within the pocket; and wherein the pocket is defined in the body to prevent cracking when the body with the insert positioned within the pocket is cooled via the application of the heat treatment.

21. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

22. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

23. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

24. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

25. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

26. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

27. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

28. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

29. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

30. The method of claim 12, wherein the body is comprised of a metal and the insert is comprised of a material having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the metal of the body.

Images