Polycrystalline diamond compact capable of rapidly calibrating height of diamond layer

Abstract

The utility model discloses a polycrystalline diamond compact capable of quickly calibrating the height of a diamond layer, which comprises a diamond grinding layer, a diamond height calibration layer, a diamond plane layer and a hard alloy layer, the diamond grinding layer is provided with a first chamfer, and the section shape of the first chamfer is a first inclined plane; the diamond height calibration layer is provided with a second chamfer, the section shape of the second chamfer is a second inclined plane, the first inclined plane and the second inclined plane are continuous, the inclination angle alpha of the first inclined plane is smaller than the inclination angle beta of the second inclined plane, and after the diamond grinding layer is ground, the height of the upper surface of the diamond height calibration layer is the maximum height position of the diamond layer. And the lower surface height is the minimum height of the diamond layer. Diamond layer height calibration does not need to depend on a detection instrument, an inspector can rapidly and accurately judge whether the diamond layer is ground in place or not and whether the diamond layer deflects or not by observing slope information with naked eyes, operation is easy, the inspection efficiency is greatly improved, and the product quality is guaranteed.

Description

Technical Field

[0001] This utility model belongs to the field of polycrystalline diamond composite (PDC) manufacturing, specifically relating to a polycrystalline diamond composite for rapidly calibrating the height of the diamond layer. Background Technology

[0002] Polycrystalline diamond composite (PDC) sheets are synthesized from diamond micron powder and cemented carbide matrix under high temperature and high pressure (HTHP) conditions. The blank is generally cylindrical with a diamond layer on top and a cemented carbide matrix on the bottom. The blank sheet is then processed through annealing, diamond layer grinding, external cylindrical grinding, surface grinding, chamfering, polishing, and cleaning. The product is mainly used in geological drilling, oil and gas extraction, etc.

[0003] The height of the diamond layer affects the product's wear resistance, impact toughness, and stress. Therefore, the height of the diamond layer after grinding should be within a certain range. Products that exceed the standard range will cause fluctuations in the quality of this batch of products, directly affecting the drilling results for customers.

[0004] Diamond layer grinding generally requires multiple grinding processes, starting with rough grinding and then fine grinding. Rough grinding is used to quickly reduce the height of the diamond layer, while fine grinding is used to control the surface quality of the diamond layer and keep its height within the standard range. To ensure the diamond layer is well ground, it needs to be inspected and adjusted simultaneously. After multiple rough and fine grinding processes, the required diamond layer standard is achieved. The efficiency of inspection directly affects the processing efficiency of this step.

[0005] Currently, the inspection of diamond layer height during the grinding process mainly relies on visual inspection, standard sample comparison, and sampling inspection using imaging measuring instruments. Visual inspection and standard sample comparison are efficient but have poor accuracy. Imaging measuring instruments offer high single-piece, single-position measurement accuracy, but batch measurements can lead to errors due to inaccurate identification of diamond layer boundaries, making it impossible to achieve stable and accurate batch measurements. Furthermore, the height of the diamond layer varies at different locations after grinding, requiring the testing instrument to be moved to different positions for measurement, which undoubtedly increases the difficulty of equipment inspection. With market development, customers have increasingly higher requirements for the stability of drilling results and are paying more attention to the size and consistency of the diamond layer. Sampling inspection is gradually failing to meet customer needs. How to reliably and effectively determine whether the height of the diamond layer in batches meets the standards and guide the grinding process is a question that the entire industry has been pondering. Summary of the Invention

[0006] To address the aforementioned problems in the existing technology, this utility model provides a polycrystalline diamond composite sheet for rapidly calibrating the height of the diamond layer.

[0007] The purpose of this utility model is achieved in the following manner: a polycrystalline diamond composite sheet for rapidly calibrating the height of a diamond layer, comprising, from top to bottom, a diamond grinding layer, a diamond height calibration layer, a diamond planar layer, and a cemented carbide layer. The diamond grinding layer is provided with a first chamfer, the cross-sectional shape of which is a first inclined plane; the diamond height calibration layer is provided with a second chamfer, the cross-sectional shape of which is a second inclined plane. The first and second inclined planes are continuous, and the inclination angle α of the first inclined plane is less than the inclination angle β of the second inclined plane. After the diamond grinding layer is ground, the height of the upper surface of the diamond height calibration layer is the maximum height position of the diamond layer, and the height of the lower surface is the minimum height position of the diamond layer.

[0008] The inclination angle α of the first inclined plane is 30°-60°.

[0009] The height of the diamond grinding layer is 0.50-1.0mm.

[0010] There are rounded transitions between the diamond grinding layer and the diamond height calibration layer, and between the diamond height calibration layer and the diamond planar layer.

[0011] A cemented carbide chamfer layer is provided below the cemented carbide layer. The cemented carbide chamfer layer is provided with a third chamfer. The cross section of the third chamfer forms a third inclined surface. The width of the third chamfer is 0.50-2.0mm and the chamfer angle is 30-45°.

[0012] The height of the cemented carbide chamfer layer is 0.50-1.0mm.

[0013] There is a rounded transition between the cemented carbide layer and the cemented carbide chamfer layer.

[0014] The second inclined surface is uniformly provided with protrusions or grooves, which extend from the upper surface of the diamond height calibration layer to the lower surface of the diamond height calibration layer. The shapes of the protrusions or grooves are circular, elliptical, triangular, rhomboid, heart-shaped, or star-shaped.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] By designing a diamond height calibration layer, the diamond layer height calibration no longer relies on testing instruments. Inspectors can quickly and accurately determine whether the diamond layer height has been ground to the correct level and whether there are any issues with the diamond layer's skewing simply by visually observing the bevel information. This simple operation greatly improves inspection efficiency and ensures product quality. Furthermore, the diamond height calibration layer design reduces the amount of grinding required for the diamond layer of polycrystalline diamond composite sheets, improving processing efficiency by over 20% and reducing processing costs. The diamond height calibration layer design also prevents defects such as chipping and edge breakage caused by collisions between sheets during product processing, thus improving the yield rate. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

[0018] Figure 2 This is another structural schematic diagram of the present invention. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are only for illustrating the present invention and are not intended to limit the scope of the present invention. After reading the contents of the present invention, those skilled in the art can make various modifications or alterations to the present invention, and these equivalent forms also fall within the scope defined by the present invention.

[0020] like Figure 1 As shown, a polycrystalline diamond composite sheet for rapidly calibrating the height of a diamond layer includes, from top to bottom, a diamond grinding layer 1, a diamond height calibration layer 2, a diamond planar layer 3, and a cemented carbide layer 4. The diamond grinding layer 1 has a first chamfer, the cross-sectional shape of which is a first inclined surface 5. The diamond height calibration layer 2 has a second chamfer, the cross-sectional shape of which is a second inclined surface 6. The first inclined surface 5 and the second inclined surface 6 are continuous, and the inclination angle α of the first inclined surface 5 is less than the inclination angle β of the second inclined surface 6. After the diamond grinding layer 1 is ground, the height of the upper surface of the diamond height calibration layer 2 is the maximum height position of the diamond layer, and the height of the lower surface is the minimum height position of the diamond layer.

[0021] Furthermore, the inclination angle α of the first inclined surface 5 is 30°-60°. The diamond grinding layer is an impurity layer that needs to be removed by grinding. The smaller the inclination angle α of the first inclined surface 5, that is, the smaller the first chamfer, the smaller the volume of the impurity layer that needs to be removed, and the lower the grinding cost.

[0022] Furthermore, the preferred height of the diamond grinding layer 1 is 0.50-1.0 mm. The thinner the diamond grinding layer, the smaller the volume of the impurity layer that needs to be removed, and the lower the grinding cost. After the diamond grinding layer is ground, the diamond height calibration layer 2 is exposed. Since the cross-sectional shape of the second chamfer is the second inclined surface 6, it can be determined whether the height of the diamond layer meets the design standard by observing whether the second inclined surface 6 is fully exposed.

[0023] The inclination angle of the second bevel is the second chamfer. The size and angle of the chamfer are not less than the finished size of the polycrystalline diamond composite sheet. The chamfer width is generally 0.25-0.55mm.

[0024] Furthermore, there are rounded transitions between the diamond grinding layer 1 and the diamond height calibration layer 2, and between the diamond height calibration layer 2 and the diamond planar layer 3. These rounded transitions improve the structural strength, making it more robust, preventing stress concentration, and enhancing stability. They also prevent defects such as chipping and edge breakage caused by chipping during the various processing steps, thus improving the yield rate.

[0025] Furthermore, such as Figure 2 As shown, a cemented carbide chamfer layer 7 is provided at the bottom of the cemented carbide layer 4. The preferred height of the cemented carbide chamfer layer 7 is 0.50-1.0mm. The cemented carbide chamfer layer 7 is provided with a third chamfer. The cross-section of the third chamfer forms a third inclined surface 8. The size and angle of the third chamfer are not less than the finished size of the polycrystalline diamond composite sheet. The width of the third chamfer is generally 0.50-2.0mm and the chamfer angle is 30-45°.

[0026] Furthermore, protrusions or grooves are evenly distributed on the second inclined surface 6, extending from the upper surface of the diamond height calibration layer 2 to its lower surface. The shapes of the protrusions or grooves are circular, elliptical, triangular, rhomboid, heart-shaped, star-shaped, or other irregular shapes. Under normal circumstances, after the diamond grinding layer 1 is ground, the second inclined surface and the protrusions or grooves on it are exposed. The integrity of the protrusions or grooves on the second inclined surface is observed to determine whether the diamond layer height has been ground to the required level.

[0027] A method for quickly calibrating the height of the diamond layer: After the diamond grinding layer 1 is ground, the second inclined surface 6 is exposed. The height of the upper surface of the diamond height calibration layer 2 is the maximum height of the diamond layer, and the height of the lower surface is the minimum height of the diamond layer. If the second inclined surface 6 disappears, the diamond layer is too low. If the second inclined surface 6 is not exposed, but the first inclined surface 5 is still above, the diamond layer is too high. If the second inclined surface 6 is partially exposed and partially not exposed, the diamond layer is skewed.

[0028] By designing diamond height calibration layer 2, the diamond layer height calibration no longer relies on testing instruments. Inspectors can quickly and accurately determine whether the diamond layer height has been ground properly and whether there is any skewness in the diamond layer by visually observing information such as the number of bevels. The operation is simple, greatly improving inspection efficiency and ensuring product quality.

[0029] Furthermore, by directly synthesizing chamfered polycrystalline diamond composite blanks, the consumption of grinding wheels in external cylindrical grinding and chamfering processes can be significantly reduced, improving processing efficiency and reducing grinding wheel wear. The chamfered polycrystalline diamond composite blanks avoid defects such as chipping and edge breakage caused by collisions between blanks or during the initial grinding wheel feed, thus improving the yield rate. The chamfered polycrystalline diamond composite blanks also reduce the amount of diamond micron powder and cemented carbide used, lowering raw material costs. Observing the chamfer size and consistency of the polycrystalline diamond composite blanks can provide feedback on the product's stability during the high-temperature, high-pressure synthesis process, facilitating monitoring and improvement of product quality. Based on the results, the synthesized product exhibits stable performance, increases processing efficiency by over 50%, reduces grinding wheel wear by over 30%, and achieves better product quality.

[0030] The above description is only a preferred embodiment of the present utility model. It should be noted that those skilled in the art can make several changes and improvements without departing from the overall concept of the present utility model, and these should also be considered within the protection scope of the present utility model.

Claims

1. A polycrystalline diamond composite sheet for rapidly calibrating the height of the diamond layer, characterized in that: From top to bottom, it includes a diamond grinding layer (1), a diamond height calibration layer (2), a diamond planar layer (3), and a cemented carbide layer (4). The diamond grinding layer (1) is provided with a first chamfer, and the cross-sectional shape of the first chamfer is a first inclined surface (5). The diamond height calibration layer (2) is provided with a second chamfer, and the cross-sectional shape of the second chamfer is a second inclined surface (6). The first inclined surface (5) and the second inclined surface (6) are continuous, and the inclination angle α of the first inclined surface (5) is less than the inclination angle β of the second inclined surface (6). After the diamond grinding layer (1) is ground, the height of the upper surface of the diamond height calibration layer (2) is the maximum height position of the diamond layer, and the height of the lower surface is the minimum height position of the diamond layer.

2. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 1, characterized in that: The inclination angle α of the first inclined plane (5) is 30°-60°.

3. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 1, characterized in that: The height of the diamond grinding layer (1) is 0.50-1.0mm.

4. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 1, characterized in that: The diamond grinding layer (1) and the diamond height calibration layer (2), and the diamond height calibration layer (2) and the diamond planar layer (3) are all connected by a rounded transition.

5. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 1, characterized in that: A cemented carbide chamfer layer (7) is provided at the bottom of the cemented carbide layer (4). The cemented carbide chamfer layer (7) is provided with a third chamfer. The cross section of the third chamfer forms a third inclined surface (8). The width of the third chamfer is 0.50-2.0mm and the chamfer angle is 30-45°.

6. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 5, characterized in that: The height of the carbide chamfer layer (7) is 0.50-1.0 mm.

7. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to claim 4, characterized in that: There is a rounded transition between the cemented carbide layer (4) and the cemented carbide chamfer layer (7).

8. The polycrystalline diamond composite sheet for rapid calibration of diamond layer height according to any one of claims 1-7, characterized in that: The second inclined surface (6) is uniformly provided with protrusions or grooves. The protrusions or grooves extend from the upper surface of the diamond height calibration layer (2) to the lower surface of the diamond height calibration layer (2). The shape of the protrusions or grooves is circular, elliptical, triangular, rhomboid, heart-shaped or star-shaped.

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