Angled Chisel Insert Geometry for Cutting Element Durability
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Solution Overview
Problem
Cutting elements used in earth-boring, road milling, and mining applications are susceptible to chipping, cracking, or partial fracturing when subjected to high forces due to their design, which limits their durability and effectiveness.
Innovation Solution
A cutting element design featuring a substrate with a super-hard material bonded to it, where the super-hard material has a geometry with ridges protruding from its surface, and a central point offset from the surface, providing increased resistance to high forces by optimizing the distance and thickness of the super-hard material, and the positioning of ridges relative to the substrate's axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting elements use super-hard materials sintered to a substrate, then cutting effectiveness is improved, but susceptibility to chipping and cracking increases under high forces
Solution Approach 1:
The patent applies parameter changes by modifying the geometric parameters of the cutting element, specifically the angle of the cutting face relative to the central axis. By optimizing this angle, the design balances cutting effectiveness with resistance to chipping and cracking under high forces
Solution Approach 2:
The cutting element uses a composite structure consisting of super-hard material sintered to a substrate material. This composite approach combines the cutting effectiveness of super-hard materials with the structural support of the substrate to reduce susceptibility to chipping and cracking
2Ease of manufacture
If cutting elements are designed with standard geometry, then manufacturing is simplified, but durability under high forces is reduced
Solution Approach 1:
The patent modifies geometric parameters including the cutting face angle and the distribution of super-hard material thickness to enhance durability while maintaining manufacturability through controlled variations from standard geometry
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances the cutting element's resistance to high forces, prolonging its useful life and improving its durability and effectiveness in degrading tough materials by strategically positioning ridges and optimizing the geometry of the super-hard material.
Implementation Method 1
The cutting elements used in such applications often include super-hard materials, such as polycrystalline diamond, sintered to a substrate material in a high-pressure, high-temperature environment
Data Source
AI summary
A cutting element includes a substrate that is axially symmetric about a central axis. The substrate has a radius perpendicular to the central axis and that extends from the central axis to an outer surface of the substrate. A super-hard material is coupled to the substrate, and the central axis passes through the super-hard material. The super-hard material has an external surface defining at least one ridge protruding from a remainder of the external surface. A central point on the central axis is offset from the external surface of the super-hard material by a distance equal to the radius of the substrate. A distance measured from the external surface of the super-hard material to the central point is greatest at a position between 25° and 45° from the central axis of the substrate.