Polycrystalline Diamond Compact Segmentation for Uniform Sintering
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Solution Overview
Problem
Polycrystalline diamond compacts used in cutting tools face issues with non-uniform sintering characteristics between the center and edges, leading to variations in impact resistance and abrasion resistance due to temperature differences during the sintering process.
Innovation Solution
A method involving the formation of multiple polycrystalline diamond sintered bodies on a cemented substrate, where a first sintered body is positioned at the center and a second sintered body is formed around it, allowing for separate sintering of the interior and exterior to achieve uniform characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large polycrystalline diamond sintered body is formed on the cemented substrate, then the overall size and coverage are sufficient, but the sintering characteristics become non-uniform between center and edges due to temperature differences
Solution Approach 1:
The patent divides the sintered body into multiple smaller sintered bodies (first, second, and third sintered bodies) positioned at different locations on the cemented substrate. This segmentation allows each small sintered body to achieve uniform sintering characteristics while collectively covering the required area, resolving the contradiction between coverage and uniformity.
2Productivity
If the sintering temperature is increased to improve sintering speed and productivity, then the sintering process is faster, but the temperature difference between center and outer edges increases causing non-uniform properties
Solution Approach 1:
By segmenting the sintered body into multiple smaller units, the patent enables faster sintering at higher temperatures while maintaining uniformity. Each small sintered body experiences more uniform heat distribution, allowing high-temperature sintering without the center-edge temperature differential problem that plagues large single-piece sintering.
Solution Approach 2:
The patent positions different sintered bodies at specific locations (center, inner circumferential, outer circumferential) on the substrate. This spatial arrangement ensures that each location receives appropriate thermal conditions during sintering, with smaller units at the edges experiencing less thermal gradient than they would in a large continuous structure, thereby achieving uniform properties throughout.
3Manufacturing precision
If the sintering temperature is too low to avoid overheating edges, then temperature uniformity is maintained, but the sintering properties such as impact resistance and abrasion resistance fall below desired levels
Solution Approach 1:
The segmentation into multiple small sintered bodies allows the use of higher sintering temperatures that would otherwise cause edge overheating in a large single structure. Each small unit maintains uniform temperature distribution, enabling optimal sintering properties (impact resistance, abrasion resistance) to be achieved without sacrificing uniformity.
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 approach ensures uniform sintered characteristics across the polycrystalline diamond compact, maximizing impact resistance and abrasion resistance by minimizing internal and external sintering differences.
Implementation Method 1
a second step for producing a first polycrystalline diamond sintered body having a diameter smaller than the diameter of a cemented substrate by sintering the first diamond powder
Data Source
AI summary
The present invention relates to a polycrystalline diamond compact having multiple polycrystalline diamond sintered bodies and a method for producing the polycrystalline diamond compact. The method for producing the polycrystalline diamond includes: preparing first diamond powder; producing a first polycrystalline diamond sintered body having a diameter smaller than the diameter of a cemented substrate by sintering the first diamond powder under 5 to 6 GPa pressure and 1300 to 1500° C. temperature; positioning the first polycrystalline diamond sintered body in the center of the cemented substrate, and granulating second diamond powder around the first polycrystalline diamond sintered body; and sintering the second diamond powder under 5 to 6 GPa pressure and 1300 to 1500° C. temperature to form a second polycrystalline diamond sintered body. The polycrystalline diamond sintered body has uniform sintered characteristics at the center and outer edges thereof.