Polycrystalline diamond and CBN cutting tools

Claim 2

A process for producing a composite of an annular polycrystalline diamond layer integrally adhered in an annular recess in an upper peripheral portion of a cemented carbide substrate structure wherein said diamond layer is directly bonded to said substrate structure at least partly by forming an interface therewith which consists essentially of forming a substrate structure consisting essentially of a substantially cylindrical substrate with an annular recess with only one side wall in an upper peripheral portion thereof, said cemented carbide consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent, filling said recess with crystals of diamond, heating the resulting assembly under an applied pressure to a temperature above the melting point of said metallic cementing agent but below a temperature which has any significant deleterious effect on said assembly for a period of time sufficient to bond said crystals together and form said composite and recovering said composite, the thickness of said polycrystalline diamond layer being substantially equivalent to the depth of said recess.

Claim 3

The process of claim 1 wherein said polycrystalline diamond layer has a width of at least about 0.025 inch.

Claim 4

The process of claim 1 wherein said recess has only one side wall.

Claim 5

The process of claim 1 wherein said cementing agent is selected from the group consisting of cobalt, nickel and iron.

Claim 6

The process of claim 1 wherein said cemented carbide is selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide and a mixture thereof.

Claim 7

The process of claim 1 wherein except for said recess said substrate structure has a thickness ranging from about 0.04 inch to about 0.25 inch.

Claim 8

The process of claim 1 wherein said temperature ranges from about 1300° C. to about 1600° C.

Claim 9

The process of claim 1 wherein said polycrystalline diamond layer ranges in thickness from about 0.005 inch to about 0.125 inch.

Claim 10

The process of claim 1 wherein said composite is sliced to form a plurality of cutting tools, each cutting tool being in the form of a sector of a circle and each having a substantially round cutting edge.

Claim 11

The process of claim 1 wherein said recess has an inner and an outer side wall.

Claim 12

The process according to claim 1 wherein said polycrystalline layer is free of metallic phase.

Claim 13

The process according to claim 1 wherein said polycrystalline layer is bonded to said substrate structure by forming an interface therewith.

Claim 14

The process according to claim 1 wherein said polycrystalline layer is free of metallic phase and is bonded to said substrate structure by forming an interface therewith.

Claim 15

A process for producing a composite of an annular polycrystalline cubic boron nitride layer integrally adhered in an annular recess in an upper peripheral portion of a cemented carbide substrate structure wherein said cubic boron nitride layer is directly bonded to said substrate structure at least partly by forming an interface therewith which consists essentially of forming a substrate structure consisting essentially of a substantially cylindrical substrate with an annular recess with only one side wall in an upper peripheral portion thereof, said cemented carbide consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent, filling said recess with crystals of cubic boron nitride, heating the resulting assembly under an applied pressure to a temperature above the melting point of said metallic cementing agent but below a temperature which has any significant deleterious effect on said assembly for a period of time sufficient to bond said crystals together and form said composite and recovering said composite, the thickness of said polycrystalline cubic boron nitride layer being substantially equivalent to the depth of said recess.

Claim 16

A process for producing a composite of an annular polycrystalline cubic boron nitride layer integrally adhered in an annular recess in an upper peripheral portion of a cemented carbide substrate structure wherein said cubic boron nitride layer is directly bonded to said substrate structure at least partly by forming an interface therewith which consists essentially of forming a substrate structure consisting essentially of a substantially cylindrical substrate with an annular recess with only one side wall in an upper peripheral portion thereof, said cemented carbide consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent, filling said recess with crystals of cubic boron nitride, heating the resulting assembly under an applied pressure to a temperature above the melting point of said metallic cementing agent but below a temperature which has any significant deleterious effect on said assembly for a period of time sufficient to bond said crystals together and form said composite and recovering said composite, the thickness of said polycrystalline cubic boron nitride layer being substantially equivalent to the depth of said recess.

Claim 17

The process of claim 14 wherein said polycrystalline cubic boron nitride layer has a width of at least about 0.025 inch.

Claim 18

The process of claim 14 wherein said recess has only one side wall.

Claim 19

The process of claim 14 wherein said cementing agent is selected from the group consisting of cobalt, nickel and iron.

Claim 20

The process of claim 14 wherein said cemented carbide is selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide and a mixture thereof.

Claim 21

The process of claim 14 wherein except for said recess said substrate structure has a thickness ranging from about 0.04 inch to about 0.25 inch.

Claim 22

The process of claim 14 wherein aluminum and an alloying metal selected from the group consisting of nickel, cobalt, manganese, iron, vanadium and chromium are deposited on said crystals of cubic boron nitride, said aluminum ranging from about 1% by weight to about 40% by weight of the weight of said crystals of cubic boron nitride and said alloying metal ranging from about 2% by weight to about 100% by weigth of the weight of said crystals of cubic boron nitride.

Claim 23

The process of claim 14 wherein said temperature ranges from about 1300° C. to about 1600° C.

Claim 24

The process of claim 14 wherein said polycrystalline cubic boron nitride layer ranges in thickness from about 0.005 inch to about 0.125 inch.

Claim 25

The process of claim 14 wherein said composite is sliced to form a plurality of cutting tools, each cutting tool being in the form of a sector of a circle and each having a substantially round cutting edge.

Claim 26

The process of claim 14 wherein said recess has an inner and an outer side wall.

Claim 27

The process according to claim 14 wherein said polycrystalline layer is free of metallic phase.

Claim 28

The process according to claim 14 wherein said polycrystalline layer is bonded to said substrate structure by forming an interface therewith.

Claim 29

The process according to claim 14 wherein said polycrystalline layer is free of metallic phase and is bonded to said substrate structure by forming an interface therewith.

Claim 30

A composite useful for slicing into a plurality of cutting tools wherein each cutting tool has a substantially circular cutting edge which consists essentially of an annular polycrystalline diamond or cubic boron nitride layer integrally adhered to an annular recess in an upper peripheral portion of a substrate structure at least partly forming an interface therewith, said substrate structure consisting essentially of a substantially cylindrical substrate having an annular recess with only one annular side wall in an upper peripheral portion thereof, a face of said polycrystalline layer being integrally adhered to the bottom surface of said recess, the inner annular side wall of said layer being integrally adhered to the inner annular side wall of said recess, the thickness of said polycrystalline layer being substantially equivalent to the depth of said recess, the mass of said substrate structure being significantly larger than the mass of said layer, said substrate structure consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent.

Claim 31

A composite useful for slicing into a plurality of cutting tools wherein each cutting tool has a substantially circular cutting edge which consists essentially of an annular polycrystalline diamond or cubic boron nitride layer integrally adhered to an annular recess in an upper peripheral portion of a substrate structure at least partly forming an interface therewith, said substrate structure consisting essentially of a substantially cylindrical substrate having an annular recess with only one annular side wall in an upper peripheral portion thereof, a face of said polycrystalline layer being integrally adhered to the bottom surface of said recess, the inner annular side wall of said layer being integrally adhered to the inner annular side wall of said recess, the thickness of said polycrystalline layer being substantially equivalent to the depth of said recess, the mass of said substrate structure being significantly larger than the mass of said layer, said substrate structure consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent.

Claim 32

The composite according to claim 28 wherein said metal carbide is predominantly comprised of a material selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide and a mixture thereof.

Claim 33

The composite according to claim 28 wherein the outer side wall of said layer is integrally adhered to an outer wall of said substrate structure.

Claim 34

The composite according to claim 28 wherein said polycrystalline layer is free of metallic phase.

Claim 35

The composite according to claim 28 wherein said polycrystalline layer is bonded to said substrate structure by forming an interface therewith.

Claim 36

The composite according to claim 28 wherein said polycrystalline layer is free of metallic phase and is bonded to said substrate structure by forming an interface therewith.

Claim 37

A cutting tool consisting essentially of a structure in the form of a sector of a circle having a substantially round cutting edge, said cutting tool consisting essentially of a polycrystalline diamond or cubic boron nitride layer integrally adhered to an annular recess with only one annular side wall in an upper peripheral portion of an integral substrate structure at least partly forming an interface therewith, said polycrystalline layer having a face adhered to the bottom surface of said recess and an inner annular side adhered to the wall of said recess of said substrate structure, said polycrystalline layer having an exposed portion in the form of said substantially round cutting edge, the thickness of said polycrystalline layer and the height of said wall being substantially equivalent, the mass of said substrate structure being significantly larger than the mass of said layer, said substrate structure consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent.

Claim 38

A cutting tool consisting essentially of a structure in the form of a sector of a circle having a substantially round cutting edge, said cutting tool consisting essentially of a polycrystalline diamond or cubic boron nitride layer integrally adhered to an annular recess with only one annular side wall in an upper peripheral portion of an integral substrate structure at least partly forming an interface therewith, said polycrystalline layer having a face adhered to the bottom surface of said recess and an inner annular side adhered to the wall of said recess of said substrate structure, said polycrystalline layer having an exposed portion in the form of said substantially round cutting edge, the thickness of said polycrystalline layer and the height of said wall being substantially equivalent, the mass of said substrate structure being significantly larger than the mass of said layer, said substrate structure consisting essentially of from about 75% by weight to about 97% by weight of polycrystalline metal carbide and from about 3% by weight to about 25% by weight of a metallic cementing agent.

Claim 39

The cutting tool according to claim 34 wherein said metal carbide consists essentially of a material selected from the group consisting of tungsten carbide, titanium carbide, tantalum carbide, and a mixture thereof.

Claim 40

The cutting tool according to claim 34 wherein said cementing agent is selected from the group consisting of cobalt, nickel and iron.

Claim 41

The cutting tool according to claim 34 where in said polycrystalline layer is free of metallic phase.

Claim 42

The cutting tool according to claim 34 wherein said polycrystalline layer is bonded to said substrate structure by forming an interface therewith.

Claim 43

The cutting tool according to claim 34 wherein said polycrystalline layer is free of metallic phase and is bonded to said substrate structure by forming an interface therewith.