Variable-Depth PCD Tool Inserts for Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and complexity of producing shaped tool inserts from polycrystalline diamond (PCD) limit their widespread use due to the material's propensity for fracture and chipping, and the need for thicker PCD tables to achieve required depths, resulting in wastage and increased production costs.
Innovation Solution
A method involving adding diamond feedstock and a pre-shaped cemented carbide body to a refractory cup, compacting, sintering at high pressure and temperature, slicing, and shaping the PCD precursor body to create tool blanks with varying PCD table thickness, allowing only the necessary PCD to be used near the cutting edge, thereby reducing material waste and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shaped tool inserts are made from PCD using conventional methods, then the tool durability is improved, but the production cost increases and manufacturing complexity increases
Solution Approach 1:
The invention applies local quality by creating a tool insert where the PCD table thickness varies at different locations. The PCD is concentrated at the cutting edge where it is most needed for durability, while reducing or eliminating PCD in non-cutting areas. This selective distribution of the expensive superhard material maintains tool durability at the critical cutting zone while significantly reducing overall material cost and manufacturing complexity.
Solution Approach 2:
The invention segments the tool insert into distinct zones with different PCD concentrations. The cutting edge region contains the PCD table for durability, while the support structure uses less or no PCD. This segmentation allows the tool to maintain reliability where needed while reducing production costs in non-critical areas.
2Reliability
If shaped tool inserts are made from PCD using conventional methods, then the tool durability is improved, but the manufacturing complexity increases
Solution Approach 1:
By varying the PCD table thickness locally according to the specific geometry requirements of the tool insert, the invention reduces manufacturing complexity. Instead of creating a uniformly thick PCD table that requires extensive machining and shaping, the PCD is deposited or formed only where needed, simplifying the overall manufacturing process while maintaining tool durability at the cutting edge.
Solution Approach 2:
The invention applies preliminary action by forming the PCD table with the correct variable thickness profile during the sintering process itself, rather than creating a uniform PCD table and then machining it to the final shape. This preliminary formation of the correct geometry reduces subsequent machining operations and manufacturing complexity.
3Reliability
If thicker PCD tables are used to achieve required depths, then the tool durability is improved, but the material waste increases and production cost increases
Solution Approach 1:
The invention directly addresses material waste by implementing local quality - the PCD table thickness is varied to provide sufficient material only where cutting edge durability is required. Non-cutting areas have reduced or zero PCD thickness, eliminating the material waste that would occur with uniform thick PCD tables. This selective distribution maintains tool durability while minimizing PCD consumption.
Solution Approach 2:
The invention applies partial action by providing PCD thickness that is sufficient for durability only at the cutting edge, rather than using excessive thickness throughout the entire tool insert. This partial application of the expensive material eliminates unnecessary PCD usage in non-critical areas, reducing material waste while maintaining the required durability at the cutting zone.
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 method enables the production of economical shaped tool components with PCD only where needed, enhancing tool durability and reducing production costs by minimizing unnecessary PCD usage and addressing the issue of fracture and chipping.
Implementation Method 1
sintering the green body at a temperature between 1400° C. to 2100° C. and at a pressure of at least 7 GPa, for at least 30 seconds to form a sintered PCD precursor body that comprises a PCD table sinter-joined to the cemented carbide substrate at an interface
Data Source
AI summary
This disclosure relates to a method of making a shaped tool component from a precursor sintered body comprising polycrystalline diamond (PCD). The sintered body has a PCD table joined to a substrate, and the PCD table varies in depth. The resulting shaped tool component thus also has a PCD layer with varying depth. A method of making a shaped tool component comprising polycrystalline diamond (PCD), comprising the steps: h. Adding a diamond feed stock to a refractory cup; i. Adding a p re-shaped cemented carbide body to the refractory cup adjacent the diamond feed stock; j. Compacting the diamond feed stock and cemented carbide body to form a green body; k. Sintering the green body at a temperature between 1400° C. to 2100° C. and at a pressure of at least 7 GPa, for at least 30 seconds to form a sintered PCD precursor body that comprises a PCD table sinter-joined to the cemented carbide substrate at an interface;