Superhard cutter element

Patent metadata

Field	Value
Publication number	US-9233422-B2
Application number	US-201013319015-A
Country	US
Kind code	B2
Filing date	May 14, 2010
Priority date	May 15, 2009
Publication date	Jan 12, 2016
Grant date	Jan 12, 2016

Abstract

A superhard cutter element for machining a workpiece comprising wood, metal, ceramic material or composite material, the superhard cutter comprising a superhard structure ( 140 ) having a rake side ( 110 ) and a flank side ( 120 ), the rake side ( 110 ) and the flank side ( 120 ) enclosing a wedge angle ω; and a protective layer ( 170 ) bonded to the superhard structure ( 140 ) at a rake interface ( 180 ) on the rake side ( 110 ), the protective layer ( 170 ) being softer than the material of the superhard structure ( 140 ).

First claim

The invention claimed is:

1. A superhard cutter element for machining a workpiece comprising wood, metal, ceramic material or composite material, the superhard cutter element comprising a superhard structure having a rake side and a flank side, the rake side and the flank side enclosing a wedge angle; and a protective layer bonded to the superhard structure at a rake interface on the rake side, the protective layer being softer than the material of the superhard structure; the wedge angle being at least 20 degrees and at most 75 degrees, a region of the protective layer proximate the cutting edge having a thickness in microns of at least (13.3-0.11ω) and at most the lower of (380-5.0ω) and (126.6-0.11ω), where the wedge angle ω is in the range from 35 degrees to 65 degrees.

2. A superhard cutter element as claimed in claim 1 , a region of the protective layer proximate the cutting edge having a thickness in microns of at least (46.7-0.56ω and at most the lower of (380-5.0ω) and (126.6-0.11ω), where the wedge angle ω is in the range from 35 degrees to 65 degrees.

3. A superhard cutter element as claimed in claim 1 , a region of the protective layer proximate the cutting edge having a thickness in microns of at least 20 microns and at most 200 microns, where the wedge angle ω is in the range from 35 degrees to 65 degrees.

4. A superhard cutter element as claimed in claim 1 , a region of the protective layer proximate the cutting edge having a thickness in microns of greater than (86.6-1.33ω) and less than (380-5.0ω), where the wedge angle ω is in the range from 35 degrees to 65 degrees.

5. A superhard cutter element as claimed in any one of the preceding claims, the protective layer comprising a superhard material.

6. A superhard cutter element as claimed in claim 1 , the protective layer comprising a first sub-layer adjacent the rake interface, comprising inter-bonded diamond grains, and a second sub-layer that is substantially free of superhard material.

7. A superhard cutter element as claimed in claim 6 , the protective layer comprising a first sub-layer adjacent the rake interface, comprising inter-bonded diamond grains, and a second sub-layer that is substantially free of superhard material, the protective layer having a region proximate the cutting edge having a thickness of less than 50 micron.

8. A superhard cutter element as claimed in claim 1 , the protective layer comprising a layer or sub-layer that is free of superhard material, the layer or sub-layer having thickness in the range from 1 micron to 80 microns.

9. A superhard cutter element as claimed in any one of the preceding claims, comprises polycrystalline diamond (PCD) material in which the diamond content is at least 80 volume % of the PCD material and the PCD material comprises inter-bonded diamond grains having a mean size of at least 0.5 microns at most 55 microns.

10. A superhard cutter element as claimed in claim 1 , the mean Vickers hardness of the protective layer is at least 10% less than that of the superhard structure.

11. A superhard cutter element as claimed in claim 1 , the protective layer comprising carbide of a metal selected from the group consisting of Mo, W, Nb, Ta, V, Ti, Cr, Zr, Hf and Si.

12. A superhard cutter element as claimed in claim 1 , the superhard structure comprising PCD material in the form of a layer having a substantially uniform thickness, the mean value of which is at least 10 microns and at most 400 microns.

13. A segment, insert, blade or tool for machining or cutting a workpiece, comprising a superhard cutter element as claimed in claim 1 .

14. A segment, insert, blade or tool as claimed in claim 13 , for machining or cutting a body comprising material for laminate flooring.

15. A segment, insert, blade or tool as claimed in claim 13 , for performing an interrupted or rough cutting operation on a workpiece comprising metal.

16. An insert for performing an interrupted or rough cutting operation on a workpiece comprising metal, the insert comprising a superhard cutter element as claimed in claim 3 .

17. A method of using a segment, insert or tool comprising a superhard cutter element as claimed in claim 1 , the method including engaging a workpiece comprising wood, composite or metal material, and removing material selectively from the workpiece.

Assignees

• Harden Peter Michael
• Cooper Anthony Joseph
• Element Six Ltd

Inventors

• Harden Peter Michael
• Cooper Anthony Joseph

Classifications

• Y10T407/24

  with chip breaker, guide or deflector · CPC title

• B23B27/141 Primary

  Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness (with specially shaped plate-like exchangeable cutting inserts, e.g. chip-breaking groove, B23B27/1603; with removable plate-like milling cutting inserts of special shape B23C5/202) · CPC title

• B22F7/06 Primary

  of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} · CPC title

• B23B2226/315

  polycrystalline [PCD] · CPC title

• C22C2204/00

  End product comprising different layers, coatings or parts of cermet · CPC title