Layered Mining Bit Cutting Tips for Uniform Abrasion

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Solution Overview

Problem

Conventional mining bits face challenges in maintaining uniform abrasive particle concentration and optimal abrasion, leading to premature tip breakage and high economic losses due to non-uniform distribution and inadequate shaping of cutting tips during deep drilling operations.

Innovation Solution

The mining bit features cutting tips with a plurality of layers arranged horizontally, where the interlayer distance is minimized to ensure uniform abrasive particle distribution and optimal exposure, with a shape of an arch having rounded inner and outer surfaces, achieved through a manufacturing process involving a drilling jig and metal binder infiltration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If abrasive particles are arranged with small interlayer distance to enhance concentration, then abrasion performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveabrasion performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The abrasive particles are arranged in a predetermined pattern on each layer before lamination, ensuring uniform distribution and optimal concentration. This preliminary arrangement simplifies the final manufacturing process while achieving reliable abrasion performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting tip is divided into multiple layers with abrasive particles arranged on each layer. This segmentation allows for systematic arrangement of particles with controlled interlayer distances, improving abrasion performance while maintaining manufacturability through modular construction

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If cutting tips are made through conventional pressurization, forming, and sintering, then manufacturing is simplified, but the arch shape with rounded surfaces cannot be achieved

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidarch shape with rounded surfaces

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The cutting tip is designed with an arch shape featuring rounded inner and outer surfaces. This curvature is achieved through a specialized manufacturing process that forms layers with controlled radii of curvature, enabling the desired shape while maintaining manufacturing feasibility

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The manufacturing process transitions from conventional 2D lamination to 3D arch-shaped structure formation by controlling the curvature of each layer. This dimensional approach allows achieving rounded surfaces and arch geometry that cannot be obtained through flat lamination and subsequent sintering

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If metal powder and diamond particles are mixed for infiltration, then material utilization is improved, but uniform distribution of diamond particles cannot be achieved

Engineering Contradiction:

Improvematerial utilizationVSAvoiduniform distribution of diamond particles

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

Diamond particles are arranged in specific predetermined patterns on each layer rather than being randomly mixed with metal powder. This local arrangement ensures uniform distribution and consistent abrasive performance while maintaining high material utilization through the infiltration process

Inventive Principle:

Principle #3Local quality

4Productivity

If cutting tips are used with broken abrasive particles, then drilling work continues, but tip strength decreases leading to premature failure

Engineering Contradiction:

Improvedrilling continuityVSAvoidtip strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The layered structure with metal binder and systematically arranged abrasive particles provides structural support and cushioning to the cutting tip. This design allows abrasive particles to wear down and be replaced during drilling while maintaining tip strength and preventing premature failure, ensuring drilling continuity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

This design enhances the continuity and efficiency of drilling by maintaining a high concentration of abrasive particles, reducing tip damage and ensuring uniform cutting, even in high-hardness materials, while simplifying the manufacturing process and maintaining accurate tip sizes without shrinkage.

Implementation Method 1

by heating the metal binder over a melting point, and by filling the metal binder in the interior of the formed body through a capillary force

Methodology Applied

Scientific EffectCapillary force: Capillary Action

Data Source

PatentUS11136831B2Mining bit and method of manufacturing the bit

Publication Date: 2021.10.05 NIWA DAIYAMONDO INDS

AI summary

A mining bit includes: a shank; and cutting tips attached to the shank, each cutting tip having a plurality of layers and a plurality of abrasive particles, wherein the layers have a shape of an arch with flat surfaces in such a manner as to be laminated onto each other in a horizontal direction with respect to a cut surface of each cutting tip, and a distance (D2) between the abrasive particles on the adjacent layers is less than a distance (D1) between the abrasive particles on each layer.