Impact Tool Superhard Tip Bonded to Carbide Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tools used in formation degradation processes such as asphalt milling, mining, or excavating experience wear due to the abrasive nature of the materials, leading to reduced tool lifespan and inefficiencies.
Innovation Solution
An impact tool with a super hard material impact tip bonded to a cemented metal carbide substrate at a non-planar interface, secured to a bolster which is press-fit onto a driving mechanism, providing enhanced durability and resistance to erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional tools are used in formation degradation processes, then the tools can perform basic functions, but the tools experience rapid wear and have reduced lifespan due to abrasive materials
Solution Approach 1:
The impact tool employs a composite structure combining a superhard material impact tip (such as diamond or cubic boron nitride) with a cemented metal carbide substrate. This composite material approach provides both extreme hardness for abrasion resistance and toughness for impact resistance, allowing the tool to withstand the abrasive forces of formation degradation while maintaining structural integrity and extending tool lifespan.
Solution Approach 2:
The patent applies different material properties to different parts of the tool: the impact tip uses superhard material optimized for abrasion resistance where it contacts the formation, while the substrate and bolster use cemented metal carbide optimized for toughness and impact resistance. This local differentiation of material properties allows each component to excel at its specific function while collectively resolving the wear problem.
2Reliability
If super hard materials are used for impact tips, then wear resistance is improved, but the complexity of bonding and manufacturing increases
Solution Approach 1:
The superhard material impact tip is pre-formed as a separate component with its specific geometry and properties established before bonding to the substrate. This preliminary preparation allows for optimized manufacturing of each component independently using appropriate processes for superhard materials, rather than attempting to form the complete tool in a single complex operation.
Solution Approach 2:
The tool is divided into distinct segments: the superhard material impact tip, the cemented metal carbide substrate, and the bolster. This segmentation allows each component to be manufactured using processes suited to its material properties, then assembled through bonding. The non-planar interface between tip and substrate provides mechanical interlocking that enhances bonding reliability while accommodating thermal expansion differences.
3Strength
If a non-planar interface is used for bonding the impact tip to the substrate, then bonding strength and resistance to delamination are improved, but manufacturing precision requirements increase
Solution Approach 1:
The non-planar interface between the impact tip and substrate employs curved or tapered surfaces rather than flat planes. This curvature provides mechanical interlocking that resists delamination forces during impact operations. The curved geometry also helps distribute stresses more evenly across the bonding interface, reducing stress concentration points that could lead to failure.
Solution Approach 2:
The bonding interface uses an asymmetric non-planar geometry with specific taper angles and surface profiles that are optimized for both bonding strength and stress distribution. This asymmetric design provides directional resistance to delamination forces while accommodating the different material properties of the superhard tip and carbide substrate.
Data Source
AI summary
An impact tool for use with a driving mechanism, the impact tool including an impact tip formed from a super hard material and having an apex and an attachment end, with the attachment end being bonded to a cemented metal carbide substrate at a non-planar interface. The cemented metal carbide substrate is bonded in turn to the front end of a cemented metal carbide bolster. The carbide bolster is securable against an outer surface of a driving mechanism through a press fit.