Polycrystalline diamond tools and method of making thereof
The present invention is a tool insert. The tool insert includes a abrasive layer and a substrate. The abrasive layer has a periphery forming a cutting surface and is located on the substrate. The abrasive layer includes at least one of polycrystalline diamond or cubic boron nitride. The abrasive layer tool insert has a sum value of an impact resistance number and an abrasion resistance number that is ≧19,000. The impact resistance number is equal to a total number of hits before failure of the tool insert. The abrasion resistance number is equal to equation (1) (1) abrasion resistance=final volume of granite removed by the tool insert (inch 3 )/final tool wear land area (inch 2 ).
1 . A tool insert comprising:
a abrasive layer having a periphery forming a cutting surface wherein said continuous abrasive layer comprises at least one of polycrystalline diamond or cubic boron nitride; and
a substrate, said abrasive layer being located on said substrate, wherein said abrasive layer tool insert has a sum value of an impact resistance number and an abrasion resistance number ≧19,000, wherein the impact resistance number is equal to a total number of hits before failure of the tool insert and the abrasion resistance number is equal to equation (1)
abrasion
resistance
=
final
volume
of
granite
removed
by
the
tool
insert
(
inch
3
)
final
tool
wear
land
area
(
inch
2
)
.
(
1
)
2 . The tool insert of claim 1 , wherein said abrasive layer is sintered with a high pressure high temperature process.
3 . The tool insert of claim 1 , wherein said abrasive layer is formed from a bimodal powder mixture having at least one of the polycrystalline diamond or cubic boron nitride.
4 . The tool insert of claim 3 , wherein the bimodal powder mixture comprises fine particles of a substantially uniform size and coarse particles of a substantially uniform size, said coarse particles having a different substantially uniform size than the substantially uniform size of the fine particles.
5 . The tool insert of claim 4 , wherein an average size ratio of fine particles over coarse particles is between about 0.02 and about 0.75.
6 . The tool insert of claim 4 , wherein an average size ratio of fine particles over coarse particles is between about 0.05 and about 0.5.
7 . The tool insert of claim 4 , wherein an average size ratio of fine particles over coarse particles is between about 0.1 and about 0.5.
8 . The tool insert of claim 4 , wherein a standard deviation of particle size distribution of fine particles and coarse particles is smaller than about 0.6 d, where d is an average particle size.
9 . The tool insert of claim 4 , wherein abrasive crystals of said abrasive layer have an average aspect ratio of particles of greater than about 0.3.
10 . The tool insert of claim 4 , wherein abrasive crystals of said abrasive layer have an average aspect ratio of particles of greater than about 0.4.
11 . The tool insert of claim 4 , wherein abrasive crystals of said abrasive layer have an average aspect ratio of particles of greater than about 0.5.
12 . The tool insert of claim 4 , wherein a volume fraction of fine particles is between about 5% to 90%, and a volume fraction of coarse particles is between about 10% to about 95%.
13 . The tool insert of claim 4 , wherein a volume fraction of fine particles is between about 10% to 80%, and a volume fraction of coarse particles is between about 20% and about 90%.
14 . The tool insert of claim 4 , wherein a volume fraction of fine particles is between about 15% to 70%, and a volume fraction of coarse particles is between about 30% and about 85%.
15 . The tool insert of claim 3 , wherein said abrasive layer has at least about 93 vol. % of diamond.
16 . A method for manufacturing a tool insert component comprising:
forming an abrasive layer with a bimodal powder comprising at least one of polycrystalline diamond and cubic boron nitride, said bimodal powder comprising fine particles of a substantially uniform size and coarse particles of a substantially uniform size, said coarse particles having a different substantially uniform size than the fine particles of substantially uniform size, wherein abrasive crystals of said abrasive layer have an average aspect ratio of particles greater than about 0.3; and
sintering said abrasive layer with a high pressure high temperature process.
17 . The method according to claim 16 , further comprising the step of bonding a substrate to said abrasive layer.
18 . The method according to claim 16 , wherein said abrasive layer having abrasion resistance and impact resistance properties, has a sum value of an impact resistance number and an abrasion resistance number ≧19,000, wherein the impact resistance number is equal to a total number of hits before failure of the tool insert and the abrasion resistance number is equal to equation (1)
abrasion
resistance
=
final
volume
of
granite
removed
by
the
tool
insert
(
inch
3
)
final
tool
wear
land
area
(
inch
2
)
.
(
1
)
19 . The method of claim 16 , wherein a volume fraction of fine particles is between about 5% to 90%, and a volume fraction of coarse particles is between about 10% and about 95%.
20 . The method of claim 16 , wherein an average size ratio of fine particles over coarse particles is about 0.02 to about 0.75.
21 . A tool insert having increased abrasion resistance and impact resistance properties, comprising an abrasive layer and a substrate, wherein said abrasive layer is formed from a bimodal powder mixture comprising fine particles of a substantially uniform size and coarse particles of a substantially uniform size, wherein abrasive crystals of the abrasive layer have an average aspect ratio of particles greater than about 0.3.