US20020033383A1 - Machining of polycrystalline diamond - Google Patents
Machining of polycrystalline diamond Download PDFInfo
- Publication number
- US20020033383A1 US20020033383A1 US09/682,425 US68242501A US2002033383A1 US 20020033383 A1 US20020033383 A1 US 20020033383A1 US 68242501 A US68242501 A US 68242501A US 2002033383 A1 US2002033383 A1 US 2002033383A1
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- US
- United States
- Prior art keywords
- polycrystalline diamond
- component
- working surface
- interstices
- electrically conductive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000010432 diamond Substances 0.000 title claims abstract description 47
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 45
- 238000003754 machining Methods 0.000 title claims description 15
- 239000000463 material Substances 0.000 claims abstract description 26
- 239000004020 conductor Substances 0.000 claims abstract description 14
- 239000011159 matrix material Substances 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 35
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- 229910002804 graphite Inorganic materials 0.000 claims description 6
- 239000010439 graphite Substances 0.000 claims description 6
- 238000005470 impregnation Methods 0.000 claims description 6
- 239000000758 substrate Substances 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 239000000725 suspension Substances 0.000 claims description 3
- 238000009877 rendering Methods 0.000 claims 1
- 238000007747 plating Methods 0.000 description 5
- 239000010941 cobalt Substances 0.000 description 4
- 229910017052 cobalt Inorganic materials 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000001764 infiltration Methods 0.000 description 3
- 230000008595 infiltration Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000002386 leaching Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000009760 electrical discharge machining Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 238000005491 wire drawing Methods 0.000 description 1
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
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- C04B37/02—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
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- F16C2206/02—Carbon based material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
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- F16C33/02—Parts of sliding-contact bearings
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- Y10T407/00—Cutters, for shaping
- Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition
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- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Earth Drilling (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
- Cutting Tools, Boring Holders, And Turrets (AREA)
- Drilling Tools (AREA)
- Catalysts (AREA)
Abstract
Description
- This application claims priority from U.S. Provisional Patent Application No. 60/234,075 filed Sep. 20, 2000, and from U.S. Provisional Patent Application No. 60/281,054 filed Apr. 2, 2001.
- 1. Field of the Invention.
- This invention relates to machining techniques for use with polycrystalline diamond.
- 2. Description of the Related Art.
- It is known, for example in the manufacture of cutters for earth boring drill bits, to form a relatively large diameter polycrystalline diamond component bonded to a substrate, and then to machine the component to cut the component into a plurality of pieces. This technique for use in the manufacture of cutters is described in, for example, U.S. Pat. No. 6,011,232 and EP 0857537.
- The machining technique used in the manufacture of such a cutter is most often an electron discharge machine (EDM) technique, and relies upon the component being machined being of electrically conductive form. Generally, polycrystalline diamond components comprise a plurality of diamond crystals defining therebetween a matrix of interstices. The interstices usually contain a catalyzing material, typically cobalt, used in the formation of the polycrystalline diamond and in bonding the diamond to the substrate. The presence of cobalt in the interstices renders the component electrically conductive and hence suitable for use with electron discharge machining techniques.
- It has been found that the abrasion resistance of a polycrystalline diamond cutter can be increased by removing the catalyzing material from a volume of the polycrystalline diamond close to a working surface thereof. Although treatment of the polycrystalline diamond to render the interstices close to the working surface substantially free of catalyzing material improves the wear resistance, it also results in the part of the polycrystalline diamond close to the working surface being of poor electrical conductivity and hence electron discharge machining techniques cannot be used effectively in machining polycrystalline diamonds so treated.
- It is an object of the invention to provide a technique whereby machining of such polycrystalline diamonds can be achieved in a simple and convenient manner.
- According to the present invention there is provided a machining method comprising treating a polycrystalline diamond component of the type including a volume close to a working surface that is substantially free of catalyzing material to render the polycrystalline diamond electrically conductive, and using an electron discharge machining technique to machine the polycrystalline diamond material.
- The polycrystalline diamond may be plated with an electrically conductive material to render it conductive. Alternatively, an infiltration technique may be used to infiltrate a conductive material into the interstices from which catalyzing material has been removed to render the polycrystalline diamond electrically conductive.
- Where a plating technique is used, the polycrystalline diamond may be plated with a layer of nickel or another metallic material.
- Where an infiltration technique is used, the technique may involve vacuum impregnation of a conductive paint, a graphite suspension or another electrically conductive material into the interstices. Alternatively a pressure impregnation technique may be used with, for example, graphite or other electrically conductive media such as a mounting compound.
- The invention will further be described, by way of example, with reference to the accompanying drawings.
- FIG. 1 is a plan view of a polycrystalline diamond component.
- FIG. 2 is a side view of the component of FIG. 1.
- FIG. 3 is a diagrammatic view illustrating the structure of part of the component of FIG. 1.
- FIG. 4 is a view similar to FIG. 3 of an alternative arrangement.
- FIGS. 1 and 2 illustrate a
component 10 intended for use in the formation of three cutters for use in earth boring drill bits. Although the invention will be described in relation to the formation of cutters for earth boring drill bits, the invention can be used in connection with other components, for example wire-drawing dies, bearing components or other components subject to wear, in use. Thecomponent 10 comprises a polycrystalline diamond table 12 bonded to asubstrate 14 of tungsten carbide. The component is manufactured using a well known technique involving exposing a substrate, diamond powder and a catalyst to high temperature, high pressure conditions. - The polycrystalline diamond table12 of a
component 10 manufactured in this manner takes the form of diamond crystals that define therebetween a matrix of interstices containing the catalyzing material. It has been found that, by appropriate treatment of thecomponent 10 to remove the catalyzing material from the interstices located within a volume close to a surface which, in the final product, will be a working surface thereof, the abrasion resistance can be improved. The removal of the catalyzing material can be achieved in a number of ways. For example, the catalyzing material can be leached from the component. Such leaching of the catalyzing material leaves thecomponent 10 with a layer or volume of porous form, as shown in FIG. 3. The leaching of the catalyzing material further results in thecomponent 10 including a layer or volume of poor electrical conductivity with the result that electron discharge machining techniques cannot be used in machining the component. - In order to allow an electrical discharge machining technique to be used, in accordance with the invention the component is treated to render it electrically conductive.
- FIG. 3 illustrates part of the polycrystalline diamond table12, showing that the table 12 is made up of
diamond crystals 16 defining therebetween a matrix ofinterstices 18. Remote from a workingsurface 20, the interstices contain catalyzing material in the form ofcobalt 22, theinterstices 18 closer to the workingsurface 20 being substantially free of cobalt as it has been leached from the diamond to a depth D. - In order to render the component electrically conductive, an electrically conductive material plating is applied to the component. In the arrangement illustrated the plating comprises a
layer 24 of nickel applied using a conventional plating/deposition technique. - The provision of the
layer 24 allows an electron discharge machining technique, for example, a wire erosion EDM technique, to be used to cut from thecomponent 10 three circular cutters. - FIG. 4 illustrates part of a
component 10 treated in another way to render it electrically conductive. In the arrangement of FIG. 4, rather than apply a plating layer to the component, an infiltration technique is used to incorporate an electrically conductive material into thecomponent 10. In FIG. 4, the electrically conductive material is agraphite suspension 26 that has been infiltrated into the interstices using a vacuum impregnation technique. Alternatively, a conductive paint material could be used. As further alternatives, a pressure impregnation technique may be used with a conductive media such as a mounting compound or with graphite. - Although specific embodiments of the invention have been described hereinbefore, it will be appreciated that modifications or alterations may be made to the embodiments without departing from the scope of the invention as defined by the appended claims.
- Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
Claims (11)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US09/682,425 US6410085B1 (en) | 2000-09-20 | 2001-08-31 | Method of machining of polycrystalline diamond |
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US23407500P | 2000-09-20 | 2000-09-20 | |
US28105401P | 2001-04-02 | 2001-04-02 | |
US09/682,425 US6410085B1 (en) | 2000-09-20 | 2001-08-31 | Method of machining of polycrystalline diamond |
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US20020033383A1 true US20020033383A1 (en) | 2002-03-21 |
US6410085B1 US6410085B1 (en) | 2002-06-25 |
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US09/682,466 Expired - Lifetime US6435058B1 (en) | 2000-09-20 | 2001-09-06 | Rotary drill bit design method |
US09/947,678 Expired - Lifetime US6601662B2 (en) | 2000-09-20 | 2001-09-06 | Polycrystalline diamond cutters with working surfaces having varied wear resistance while maintaining impact strength |
US09/682,471 Expired - Lifetime US6481511B2 (en) | 2000-09-20 | 2001-09-06 | Rotary drill bit |
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US09/682,466 Expired - Lifetime US6435058B1 (en) | 2000-09-20 | 2001-09-06 | Rotary drill bit design method |
US09/947,678 Expired - Lifetime US6601662B2 (en) | 2000-09-20 | 2001-09-06 | Polycrystalline diamond cutters with working surfaces having varied wear resistance while maintaining impact strength |
US09/682,471 Expired - Lifetime US6481511B2 (en) | 2000-09-20 | 2001-09-06 | Rotary drill bit |
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US (4) | US6410085B1 (en) |
CA (1) | CA2865443A1 (en) |
CY (1) | CY1109825T1 (en) |
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ZA (2) | ZA200107625B (en) |
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-
2001
- 2001-06-25 DE DE60140617T patent/DE60140617D1/en not_active Expired - Lifetime
- 2001-08-31 US US09/682,425 patent/US6410085B1/en not_active Expired - Lifetime
- 2001-09-05 CA CA 2865443 patent/CA2865443A1/en not_active Abandoned
- 2001-09-06 US US09/682,466 patent/US6435058B1/en not_active Expired - Lifetime
- 2001-09-06 US US09/947,678 patent/US6601662B2/en not_active Expired - Lifetime
- 2001-09-06 US US09/682,471 patent/US6481511B2/en not_active Expired - Lifetime
- 2001-09-11 DE DE60142425T patent/DE60142425D1/en not_active Expired - Lifetime
- 2001-09-17 ZA ZA2001/07625A patent/ZA200107625B/en unknown
- 2001-09-17 ZA ZA2001/07622A patent/ZA200107622B/en unknown
-
2010
- 2010-02-24 CY CY20101100174T patent/CY1109825T1/en unknown
Also Published As
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CA2865443A1 (en) | 2002-03-28 |
US6435058B1 (en) | 2002-08-20 |
CY1109825T1 (en) | 2014-09-10 |
US6601662B2 (en) | 2003-08-05 |
US6481511B2 (en) | 2002-11-19 |
US6410085B1 (en) | 2002-06-25 |
US20020074168A1 (en) | 2002-06-20 |
ZA200107625B (en) | 2002-06-26 |
DE60140617D1 (en) | 2010-01-07 |
DE60142425D1 (en) | 2010-08-05 |
US20020033282A1 (en) | 2002-03-21 |
US20020033077A1 (en) | 2002-03-21 |
ZA200107622B (en) | 2002-06-26 |
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