Impact Tool Superhard Tip Bonded to Carbide Substrate
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Solution Overview
Problem
Existing tools used in formation degradation processes, such as asphalt milling and mining, experience wear and require frequent replacement due to the abrasive nature of the materials being worked on, leading to inefficiencies and increased maintenance costs.
Innovation Solution
An impact tool with a super hard material 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 wear through a combination of materials and geometric design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional tools are used in formation degradation processes, then initial tooling costs are lower, but tool life is short and wear resistance is poor
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 extended tool life and superior wear resistance, as the superhard tip material resists abrasion from formation materials while the carbide substrate provides structural support and shock absorption capabilities.
Solution Approach 2:
The patent applies different material properties to different parts of the tool: the impact tip uses superhard material for maximum wear resistance at the contact point, while the substrate uses cemented metal carbide for toughness and shock resistance. This local differentiation of material quality optimizes both durability and performance in the high-wear impact zone.
2Reliability
If super hard material tips are used, then wear resistance improves, but manufacturing complexity increases
Solution Approach 1:
The impact tool is divided into distinct segments: a superhard material impact tip and a cemented metal carbide substrate. This segmentation allows each component to be manufactured separately using optimized processes for that material, then bonded together. The non-planar interface design further segments the bonding area to enhance mechanical interlocking, simplifying the overall manufacturing approach while maintaining high wear resistance.
Solution Approach 2:
The patent employs a non-planar interface between the impact tip and substrate, featuring curved or tapered surfaces rather than flat interfaces. This curvature design improves the bonding strength and stress distribution, allowing for more robust attachment of the superhard tip to the substrate, thereby reducing manufacturing complexity associated with achieving precise flat surface bonds.
3Reliability
If frequent tool replacements are made, then wear damage is reset, but productivity decreases and maintenance costs increase
Solution Approach 1:
The composite construction of superhard tip material on a carbide substrate creates a tool with exceptional durability that can withstand prolonged exposure to abrasive formation materials. This extended tool life reduces the frequency of replacements needed, thereby maintaining higher productivity levels and reducing downtime associated with tool changes and maintenance activities.
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 extends the life of tools by minimizing wear and reducing the need for frequent replacements, maintaining efficiency and performance in demanding applications like milling and mining.
Implementation Method 1
The super hard impact tip may comprise diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, cubic boron nitride, refractory metal bonded diamond
Implementation Method 2
An impact tool may comprise an impact tip formed from a super hard material and bonded to a cemented metal carbide substrate at a non-planar interface
Implementation Method 3
The carbide bolster is secured against an outer surface of a driving mechanism, such as a drum, through a press fit
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.