High impact resistant tool with an apex width between a first and second transitions
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.
1. A high impact resistant tool, comprising:
a sintered diamond body bonded to a cemented metal carbide substrate at an interface;
the body comprises a substantially pointed geometry with an apex;
the apex comprising a curved surface that tangentially joins a leading side and a trailing side of the body at a first and second transitions respectively; and
an apex width between the first and second transitions is less than a third of a width of the substrate.
2. The tool of claim 1 , wherein the body thickness is measured along a central axis of the tool.
3. The tool of claim 2 , wherein a tool central axis intersects the apex and the interface.
4. The tool of claim 1 , wherein the apex width is a quarter or less than a width of the substrate.
5. The tool of claim 1 , wherein the diamond body comprises a volume between 75 and 150 percent of a substrate volume.
6. The tool of claim 1 , wherein the curved surface comprises a radius of curvature between 0.050 and 0.110 inches.
7. The tool of claim 1 , wherein the curved surface comprises a plurality of curvatures.
8. The tool of claim 1 , wherein the curved surface comprises a non-circular curvature.
9. The tool of claim 1 , wherein the body comprises a substantially conical shape.
10. The tool of claim 1 , wherein the body comprises a substantially pyramidal shape.
11. The tool of claim 1 , wherein the body comprises a substantially chisel shape.
12. The tool of claim 1 , wherein the body comprises a side which forms a 35 to 55 degree angle with a central axis of the tool.
13. The tool of claim 1 , wherein the body comprises a substantially convex side.
14. The tool of claim 1 , wherein the body comprises a substantially concave side.
15. The tool of claim 1 , wherein at the interface the substrate comprises a tapered surface starting from a cylindrical rim of the substrate and ending at an elevated flatted central region formed in the substrate.
16. The tool of claim 1 , wherein the tool comprises the characteristic of withstanding impact greater than 200 joules.
17. The tool of claim 1 , wherein the substrate is attached to a drill bit, a percussion drill bit, a roller cone bit, a fixed bladed bit, a milling machine, an indenter, a mining pick, an asphalt pick, a cone crusher, a vertical impact mill, a hammer mill, a jaw crusher, an asphalt bit, a chisel, a trenching machine, or combinations thereof.
18. The drill bit of claim 1 , wherein the leading side and trailing side extend smoothly to an outer diameter of the substrate.
19. The drill bit of claim 1 , wherein the body also comprises a body thickness from the apex to the interface greater than a third of the width of the substrate.
20. A high impact resistant tool, comprising:
a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface;
the body comprises 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; and
an apex width between the first and second transitions is less than a third of a width of the substrate;
wherein the leading side and trailing side extend smoothly to an outer diameter of the substrate.
21. The drill bit of claim 20 , wherein the at least one high impact tool is attached to the drill bit by interference fit.
22. The drill bit of claim 20 , wherein the curved surface tangentially joins the leading side and the trailing side.
23. A High Impact resistant tool, comprising:
a sintered polycrystalline diamond body boned to a cemented metal carbide substrate at an interface;
the body comprises 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;
wherein a volume contained by the curved surface comprises less than five percent of catalyzing material by volume, wherein at least 95 percent of the void between polycrystalline diamond grains comprise a catalyzing material.
24. The tool of claim 23 , wherein at least 99 percent of the void between polycrystalline diamond grains comprise a catalyzing material.
25. A downhole cutting tool, comprising:
a body having a plurality of fixed blades extending therefrom; and
at least one high impact tool attached to one of the plurality of fixed blades, wherein the at least one high impact tool comprises:
a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface and extending away from the interface to terminate in an apex;
the apex comprising:
a first curved portion and a second curved portion that joins a leading side and a trailing side of the body at a first and second transitions, respectively, and
a linear portion spanning between the first curved portion and second curved portion, wherein the linear portion is longer than it is wide.
26. The drill bit of claim 25 , wherein the apex is asymmetric.
27. The drill bit of claim 25 , wherein the linear portion is angled with respect to a line normal to a central axis of the high impact tool.
28. The drill bit of claim 25 , wherein the linear portion is offset from a center of the cemented metal carbide substrate.
29. The drill bit of claim 25 , wherein the leading side and trailing side form different angles with respect to an axis normal a surface of the cemented metal carbide substrate and which passes through the apex.
30. The drill bit of claim 25 , wherein the at least one high impact tool is attached to the drill bit by interference fit.
31. A downhole cutting tool, comprising:
a body having a plurality of fixed blades extending therefrom; and
at least one high impact tool attached to one of the plurality of fixed blades, wherein the at least one high impact tool comprises:
a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface and extending away from the interface to terminate in an apex;
the apex comprising:
a first curved portion and a second curved portion that joins a leading side and a trailing side of the body at a first and second transitions, respectively, and
wherein the leading side and trailing side form different angles with respect to an axis normal a surface of the cemented metal carbide substrate and which passes through the apex.
32. The drill bit of claim 31 , wherein the at least one high impact tool is attached to the drill bit by interference fit.
33. A downhole cutting tool, comprising:
a body having a plurality of fixed blades extending therefrom; and
at least one high impact tool attached to one of the plurality of fixed blades, wherein the at least one high impact tool comprises:
a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface and having a sidewall that extends away from the interface to terminate in an apex, wherein the apex tangentially joins the sidewall;
the apex comprising an axis which passes therethrough and which is normal a surface of the cemented metal carbide substrate that is laterally offset from an axis through a center of the cemented metal carbide substrate, the apex having a radius of curvature measured in a vertical orientation from the axis of the apex, the radius of curvature being from about 0.050 to 0.110 inches.
34. The drill bit of claim 33 , wherein the at least one high impact tool is attached to the drill bit by interference fit.
35. A downhole cutting tool, comprising:
a body having a plurality of fixed blades extending therefrom; and
at least one high impact tool attached to one of the plurality of fixed blades, wherein the at least one high impact tool comprises:
a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate at an interface and extending away from the interface to terminate in two apexes, each apex having a radius of curvature and an axis which passes therethrough which is normal a surface of the cemented metal carbide substrate, each apex having a radius of curvature measured in a vertical orientation from their respective axis, each radius of curvature being from about 0.050 to 0.110 inches, and the first apex being proximate a leading side of the body and the second apex being proximate a trailing side of the body.
36. The drill bit of claim 35 , wherein the radius of curvature of each of the two apexes is the same.
37. The drill bit of claim 35 , wherein the two apexes have unequal radii of curvature.
38. The drill bit of claim 35 , wherein the two apexes are at the same axial height.
39. The drill bit of claim 35 , wherein the two apexes are at differing axial heights.
40. The drill bit of claim 35 , wherein the at least one high impact tool is attached to the drill bit by interference fit.