Polycrystalline diamond and CBN cutting tools

Claim 2

A cutting tool consisting essentially of a polycrystalline diamond or cubic boron nitride layer directly adhered to an integral substrate structure, said substrate structure consisting essentially of a substrate having only one substantially straight edge from which a wall extends integrally, said substrate having a flat support surface which forms a support area with said wall, said support area being substantially in the form of a half circle, said substrate being substantially in the form of a half circle, said support area being substantially filled with said diamond or cubic boron nitride layer, said diamond or cubic boron nitride layer being substantially in the form of a half circle having a round cutting edge and one substantially straight adhered edge, a face of said diamond or cubic boron nitride layer being adhered to said flat support surface and the adhered edge of said diamond or cubic boron nitride layer being adhered to a side of said wall, the thickness of said polycrystalline layer and the height of said wall being substantially equivalent, said substrate structure consisting essentially of polycrystalline metal carbide containing a metallic cementing agent.

Claim 3

The cutting tool according to claim 1 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 4

A cutting tool consisting essentially of a polycrystalline diamond or cubic boron nitride layer directly adhered to an integral substrate structure, said substrate structure consisting essentially of a substrate having two substantially straight adjoining edges from which two adjoining walls extend integrally, said substrate having a flat support surface which forms a support area with said two adjoining walls, said support area being in the form of a sector of a circle, said substrate being in the form of a sector of a circle, said support area being substantially filled with said diamond or cubic boron nitride layer, said diamond or cubic boron nitride layer being substantially in the form of a sector of a circle having a round cutting edge and two straight adjoining adhered edges, a face of said diamond or cubic boron nitride layer being adhered to said flat support surface and each said straight adhered edge being adhered to one of said straight adjoining walls, the thickness of said diamond or cubic boron nitride layer and the height of said two walls being substantially equivalent, said substrate structure consisting essentially of polycrystalline metal carbide containing a metallic cementing agent.

Claim 5

A cutting tool consisting essentially of a polycrystalline diamond or cubic boron nitride layer directly adhered to an integral substrate structure, said substrate structure consisting essentially of a substrate having two substantially straight adjoining edges from which two adjoining walls extend integrally, said substrate having a flat support surface which forms a support area with said two adjoining walls, said support area being in the form of a sector of a circle, said substrate being in the form of a sector of a circle, said support area being substantially filled with said diamond or cubic boron nitride layer, said diamond or cubic boron nitride layer being substantially in the form of a sector of a circle having a round cutting edge and two straight adjoining adhered edges, a face of said diamond or cubic boron nitride layer being adhered to said flat support surface and each said straight adhered edge being adhered to one of said straight adjoining walls, the thickness of said diamond or cubic boron nitride layer and the height of said two walls being substantially equivalent, said substrate structure consisting essentially of polycrystalline metal carbide containing a metallic cementing agent.

Claim 6

The cutting tool according to claim 3 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.