Polycrystalline Diamond Cutting Element for Chip and Spall Resistance
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Solution Overview
Problem
Cutting elements used in drilling and machine tools, such as those made of super-hard polycrystalline diamond, are susceptible to chipping and spalling due to high forces and temperatures, leading to reduced performance and lifespan.
Innovation Solution
A cutting element with a substrate and a body of superhard polycrystalline material featuring spaced cutting edges and recesses, bonded together using ultra-high pressure and temperature sintering, which enhances wear resistance and chip control through unique geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cutting elements are made of super-hard polycrystalline diamond material, then wear resistance is improved, but susceptibility to chipping and spalling increases under high forces
Solution Approach 1:
The cutting element features a non-planar cutting surface with varying topography including recesses, protrusions, and curved regions. This creates local variations in geometry where different areas have different functional properties - some areas provide cutting edges while others provide support or chip evacuation pathways, optimizing both wear resistance and fracture resistance locally
Solution Approach 2:
The cutting surface incorporates curved and rounded features rather than sharp angles or flat surfaces. The non-planar topology includes convex and concave curved regions that distribute stresses more evenly across the cutting element, reducing stress concentration points that would initiate chipping and spalling while maintaining effective cutting edges
2Ease of manufacture
If cutting elements have planar cutting surfaces, then manufacturing is simplified, but chip control and fracture resistance are reduced
Solution Approach 1:
The cutting surface is segmented into multiple distinct regions including recesses, protrusions, and varying topographic zones. This segmentation creates functional zones that perform different tasks - some areas concentrate cutting forces while others provide chip evacuation pathways or stress distribution, improving both chip control and fracture resistance without significantly complicating manufacturing
Solution Approach 2:
The cutting surface transitions from a two-dimensional planar surface to a three-dimensional non-planar topology with varying depth, curvature, and topography. This adds a vertical dimension to the cutting surface design, creating recesses and protrusions that provide chip evacuation pathways and stress distribution without requiring additional components or complex assembly
3Productivity
If cutting edges are continuous, then cutting efficiency is maintained, but fracture propagation risk increases under contact pressure
Solution Approach 1:
The cutting edge is segmented into multiple discrete cutting points or zones separated by recesses or gaps in the cutting surface. This segmentation maintains cutting efficiency by providing multiple active cutting points while preventing fracture propagation by creating discontinuities that block crack paths through the cutting element under contact pressure
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 solution provides improved resistance to chipping and spalling, extending the cutting element's lifespan and maintaining high penetration rates by directing rock or earth away from the drill bit and controlling chip formation.
Implementation Method 1
bonded together using ultra-high pressure and temperature sintering
Data Source
AI summary
A cutting element (30) includes a substrate (40); and a body of superhard polycrystalline material (34) bonded to the substrate (40) along an interface, the body of superhard polycrystalline material having a peripheral side edge (42). The body of superhard polycrystalline material has a cutting surface (34); a plurality of spaced apart cutting edges (36) extending to the cutting surface (34) through respective chamfer portions (38), the cutting edges being spaced around the peripheral side edge; a plurality of recesses/regions (48) extending from the cutting surface (34) towards the substrate, adjacent cutting edges (36) being spaced apart by a respective one of said recesses/regions (48); and a protrusion or recessed region extending from the cutting surface about a central longitudinal axis of the cutting element. A method of making such a cutting element is also disclosed.