Pointed Superhard Tool Non-Planar Interface Impact Resistance
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Solution Overview
Problem
High impact resistant tools used in machinery such as drill bits and crushers face issues with stress and delamination of superhard material layers from carbide substrates due to intense forces and temperature variations, leading to reduced wear life and efficiency.
Innovation Solution
A high impact resistant tool design featuring a superhard material bonded to a cemented metal carbide substrate at a non-planar interface with a tapered surface and pointed geometry, which distributes impact forces and reduces stress concentrations, enhancing the tool's ability to withstand greater impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a planar interface is used between superhard material layer and carbide substrate, then the manufacturing process is simple, but stress concentrations occur leading to delamination and reduced impact resistance
Solution Approach 1:
The interface between the superhard material layer and carbide substrate is designed with a curved or non-planar geometry instead of a flat surface. This curvature distributes stress more evenly across the interface, preventing stress concentrations that would lead to delamination. The rounded transition zone allows impact forces to be dispersed throughout the structure, significantly improving impact resistance while maintaining manufacturing feasibility.
2Strength
If the superhard material layer is made thicker to withstand impact forces, then impact resistance improves, but the tool weight and material cost increase
Solution Approach 1:
The tool employs varying thickness of superhard material at different locations. The superhard material layer is thickest at the impact zone or cutting edge where maximum strength is needed, and gradually thinns toward the base. This localized thickness distribution provides optimal impact resistance at critical areas while minimizing overall tool weight and material cost. The non-planar interface further enhances this by concentrating material where stress is highest.
3Reliability
If a non-planar interface with tapered surface is used, then stress distribution improves and delamination is reduced, but manufacturing complexity increases
Solution Approach 1:
The tapered surface and curved interface are designed with radii and angles that can be achieved through standard machining or forming operations. The curvature is gradual rather than abrupt, allowing it to be produced using conventional tooling with minimal complexity. This approach maintains bonding stability by distributing stress evenly while keeping manufacturing processes within industrial capabilities.
4Weight of moving object
If the superhard material layer is made thinner to reduce weight, then tool weight decreases, but impact resistance and wear life are reduced
Solution Approach 1:
The superhard material is concentrated at the cutting edge and impact zone where it is most needed for wear resistance and impact absorption. The thickness varies locally, being maximum at the functional tip and reducing toward the base. This localized placement maintains cutting element life and impact resistance in critical areas while minimizing overall weight. The non-planar interface ensures that even the thinner regions provide adequate support.
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 significantly improved impact resistance, withstanding forces up to 80 joules and prolonging the life of the cutting elements by effectively distributing stress and preventing chipping or breaking, as demonstrated by drop test results and Finite Element Analysis.
Implementation Method 1
The substrates and adjacent diamond crystal hyers are then compressed under HPHT conditions which promotes a sintering of the diamond grains to form the polycrystalline diamond structure. As a result, the diamond grains become mutually bonded to form a diamond layer over the substrate interface. The diamond layer is also bonded to the substrate interface.
Data Source
Figure 1
Figure 2~3
Figure 3a
AI summary
In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having.050 to.125 inch radius. The superhard material also has a.100 to.500 inch thickness from the apex to the non-planar interface.