Segmented Polycrystalline Diamond Insert for Core Bits
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Solution Overview
Problem
Existing hard material inserts for working tools, such as drills and core bits, face inefficiencies in material removal and are prone to stress superelevations and fissure formation under point loads, limiting their load capacity and service life.
Innovation Solution
A hard material insert with a planar polycrystalline diamond layer featuring two convex cutting sections and a smooth concave transitional region, where the apex of the transitional region is on the central line, allowing for simultaneous breaking zones and reduced stress peaks, enhancing cutting efficiency and preventing jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rounded transitional regions are used to reduce stress superelevations and fissure formation, then load capacity and service life are improved, but material removal efficiency deteriorates
Solution Approach 1:
The main cutting element is segmented into two distinct cutting sections (first and second cutting sections) separated by a transitional region. Each cutting section functions as an independent cutting edge, allowing simultaneous engagement with the constructional component. This segmentation enables dual cutting zones that work together to improve material removal efficiency while the transitional region maintains structural integrity and reduces stress concentrations.
2Ease of manufacture
If a single cutting element is used, then manufacturing and mounting are simple, but cutting efficiency is limited
Solution Approach 1:
The main cutting element incorporates two distinct cutting sections within a single insert body, effectively providing dual cutting functionality without requiring multiple separate inserts. This segmentation allows simultaneous engagement of two cutting edges with the workpiece, doubling the material removal capacity while maintaining the simplicity of a single insert design for manufacturing and mounting purposes.
Solution Approach 2:
Two cutting sections are merged into a single main cutting element structure, combining the functionality of multiple cutting edges into one integrated component. The first and second cutting sections, along with the transitional region, form a unified insert that provides enhanced cutting efficiency while maintaining manufacturing and mounting simplicity characteristic of single-element designs.
Data Source
AI summary
A segmental hard material insert for a working tool has a planar polycrystalline diamond layer (13) having, in its layer plane, a main cutting element (16, 36) and a contact edge (15) located opposite the main cutting element, with the main cutting element (16, 36) having two, facing outwardly, convex cutting sections (17, 27; 37, 47) and a smooth, facing outwardly, concave transitional region (19; 39, 49) connecting the two convex cutting sections (17, 27; 37, 47), and with the apex (20; 40) of the transitional region (19; 39, 47) being located on a central line of the main cutting element (16; 36).