Polycrystalline Diamond Tool Apex Curvature Impact Resistance
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Solution Overview
Problem
Existing cutting tools used in machinery such as crushers and drill bits lack sufficient impact resistance and wear durability, particularly in high-pressure and high-temperature applications, leading to reduced tool life and efficiency.
Innovation Solution
A high-impact resistant tool is developed by bonding a sintered polycrystalline diamond body with a curved surface to a cemented metal carbide substrate, featuring a pointed geometry with a narrow apex and increased body thickness, providing enhanced bonding strength and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cutting tool design is used, then the tool structure is simple, but the impact resistance is insufficient
Solution Approach 1:
The cutting tool is divided into distinct functional segments: a carbide substrate providing structural support, a superhard material layer providing cutting edge durability, and a curved surface geometry providing impact resistance. Each segment performs its specific function optimally, resolving the contradiction between strength and complexity.
Solution Approach 2:
The tool combines multiple materials with complementary properties: carbide substrate for toughness, superhard material for wear resistance, and curved surface geometry for impact absorption. This composite structure achieves high impact resistance while maintaining manageable complexity through functional integration.
2Strength
If the apex width is increased, then the tool structure is more robust, but the ability to withstand impact forces is reduced
Solution Approach 1:
The tool features a curved surface with a radius of curvature between 0.050 and 0.110 inches at the apex region. This curvature allows the tool to withstand over 200 Joules of impact by distributing impact forces across a broader area while maintaining a narrow apex width for effective cutting, resolving the contradiction between shape and strength.
3Reliability
If a thin superhard material layer is used, then the manufacturing cost is reduced, but the wear durability is insufficient
Solution Approach 1:
The superhard material layer is applied with varying thickness across the tool surface: thicker at the apex and cutting edges where wear resistance is most critical, and thinner on less critical surfaces. This localized quality distribution achieves high wear durability while optimizing material usage and cost-effectiveness.
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 tool exhibits improved durability and impact resistance, capable of withstanding over 200 Joules of impact, extending tool life and maintaining performance in demanding industrial applications like drill bits, crushers, and milling machines.
Implementation Method 1
an abrasion resistant layer of super hard material affixed thereto using a high pressure high temperature press apparatus
Data Source
AI summary
In one aspect of the present invention, a high impact resistant tool comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface, the body comprising a substantially pointed geometry with an apex, the apex comprising a curved surface that joins a leading side and a trailing side of the body at a first and second transitions respectively, an apex width between the first and second transitions is less than a third of a width of the substrate, and the body also comprises a body thickness from the apex to the interface greater than a third of the width of the substrate.