Superhard tool tip, method for making same and tool comprising same

Patent metadata

Field	Value
Publication number	US-9844814-B2
Application number	US-201113576049-A
Country	US
Kind code	B2
Filing date	Feb 11, 2011
Priority date	Feb 12, 2010
Publication date	Dec 19, 2017
Grant date	Dec 19, 2017

Abstract

A tip ( 20 ) for a rotary machine tool comprising a superhard structure ( 12 ) joined to a cemented carbide substrate 14 by means of at least one intermediate layer ( 161, 62, 163 ) disposed between the superhard structure ( 12 ) and the cemented carbide substrate ( 14 ), the intermediate layer or layers ( 161, 162, 163 ) comprising grains of superhard material and grains of a metal carbide material dispersed in a metal binder material.

First claim

The invention claimed is:

1. A tip for a twist drill or an end mill, the tip comprising a superhard structure joined to a cemented carbide substrate by at least two intermediate layers disposed between the superhard structure and the cemented carbide substrate, the intermediate layers comprising grains of superhard material and grains of a metal carbide material dispersed in a metal binder material, each intermediate layer comprising different compositions of diamond grains, metal carbide grains, and metal binder, the superhard structure comprising any of a polycrystalline diamond (PCD) material and a polycrystalline boron nitride (PCBN) material, the superhard structure having a thickness of greater than 1 mm, the tip comprising at least two flutes, a peripheral side of the superhard structure defining a cylindrical land connecting the flutes.

2. A tip as claimed in claim 1 , in which the superhard structure comprises PCD material.

3. A tip as claimed in claim 1 , in which the superhard structure comprises PCD material and the intermediate layers comprise at least 30 volume percent diamond grains and at most 80 volume percent diamond grains.

4. A tip as claimed in claim 1 , in which the superhard structure comprises PCBN material and the intermediate layers comprise at least 10 volume percent cBN grains and at most 50 volume percent cBN grains.

5. A tip as claimed in claim 1 , in which the superhard structure comprises PCD material and at least one intermediate layer has a thickness of at least 0.1 mm.

6. A tip as claimed in claim 1 , in which the superhard structure comprises PCBN material comprising at least 80 volume percent cBN grains dispersed in a binder matrix comprising Co, W and Al, and in which the cBN grains have mean size of at most 5 microns.

7. A tip as claimed in claim 1 , in which the superhard structure comprises PCD material comprising at most 10 volume percent metal catalyst material for diamond.

8. A rotary machine tool comprising a tip as claimed in claim 1 .

9. A method of making a tip as claimed in claim 1 , the method including providing a blank body comprising a superhard structure joined to a cemented carbide substrate by at least two intermediate layers disposed between the superhard structure and the cemented carbide substrate, each intermediate layer comprising grains of superhard material and grains of a metal carbide material, the intermediate layers comprising different compositions of diamond grains, metal carbide grains and metal binder; and removing material from the blank body to form cutting edges, wherein the superhard structure comprises a material selected from any of polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN), the method further comprising removing material from the blank body to form at least two flutes such that a peripheral side of the superhard structure defines a cylindrical land connecting the flutes.

10. A tip for a twist drill or an end mill, the tip comprising a superhard structure joined to a cemented carbide substrate by at least two intermediate layers disposed between the superhard structure and the cemented carbide substrate, the intermediate layers comprising grains of superhard material and grains of a metal carbide material dispersed in a metal binder material comprising cobalt (Co), each intermediate layer comprising different compositions of diamond grains, metal carbide grains, and metal binder; the tip comprising at least two flutes, a peripheral side of the superhard structure defining a cylindrical land connecting the flutes, the superhard structure comprises a material selected from any of polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) and has a thickness greater than 1 mm.

11. A tip as claimed in claim 10 , in which the superhard structure defines a chisel edge between cutting edges.

12. A tip as claimed in claim 10 , in which the superhard structure comprises PCD material comprising at least 85 volume percent diamond.

13. A tip as claimed in claim 10 , in which the superhard structure comprises PCBN material comprising at least 80 volume percent cBN grains dispersed in a binder matrix comprising Co, W and Al, and in which the cBN grains have mean size of at most 5 microns.

14. A tip as claimed in claim 10 , in which the substrate has a proximate end and a distal end and the superhard structure covers substantially the entire proximate end, the distal end being attachable to a component for a rotary tool.

15. A method of machining a body comprising carbon fibre-reinforced polymer (CFRP) material using a twist drill or an end mill comprising a tip, the tip comprising a superhard structure joined to a cemented carbide substrate by at least two intermediate layers disposed between the superhard structure and the cemented carbide substrate, each intermediate layer comprising grains of superhard material and grains of a metal carbide material dispersed in a metal binder material, the intermediate layers comprising different compositions of diamond grains, metal carbide grains, and metal binder, wherein the superhard structure comprises a material selected from any of polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) and has a thickness greater than 1 mm, the method further comprising removing material from the blank body to form at least two flutes such that a peripheral side of the superhard structure defines a cylindrical land connecting the flutes.

16. A method as claimed in claim 15 , in which the body comprises titanium (Ti) and carbon fibre-reinforced polymer (CFRP) material.

Assignees

• Jonker Cornelis Roelof
• Fries Robert
• Kasonde Maweja
• Barry John James
• Element Six Abrasives Sa
• Element Six Ltd

Inventors

• Jonker Cornelis Roelof
• Fries Robert
• Kasonde Maweja
• Barry John James

Classifications

• Y10T428/12146

  Nonmetal particles in a component · CPC title

• Y10T428/12028

  Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.] · CPC title

• Y10T408/78

  Tool of specific diverse material · CPC title

• Y10T407/1904

  Composite body of diverse material · CPC title

• Y10T29/49801

  Shaping fiber or fibered material · CPC title