Cutting element

Abstract

A tool component, which is typically a cutting element or a gauge stone in a rotary drill bit, comprises a layer of ultra-hard abrasive material bonded to a substrate, the layer of ultra-hard abrasive material comprising a pair of opposed end surfaces, an upper surface defined between the end surfaces, and at least one curved and tapered cutting edge defined at the intersection of the respective end surfaces and the upper surface. The respective cutting edges of the tool component and the respective end surfaces leading to the cutting edges are generally wedge-shaped, the upper surface of the layer following generally the same or a similar profile, at least in the region of the cutting edges.

1 . A tool component comprising a layer of ultra-hard abrasive material bonded to a substrate, the layer of ultra-hard abrasive material comprising a pair of opposed end surfaces, an upper surface defined between the end surfaces, and at least one curved and tapered cutting edge defined at the intersection of the respective end surfaces and the upper surface.  
     
     
         2 . A tool component according to  claim 1 , wherein the end surfaces are tapered complementary to the cutting edges.  
     
     
         3 . A tool component according to  claim 2 , wherein the respective cutting edges and end surfaces are generally wedge-shaped.  
     
     
         4 . A tool component according to any one of  claims 1  to  3 , wherein the upper surface follows generally the same or a similar profile to that of the respective cutting edges, at least in the region of the cutting edges.  
     
     
         5 . A tool component according to  claim 1 , wherein the tool component has an essentially cylindrical shape presenting opposite ends and a curved side surface, the layer of ultra-hard abrasive material being located in the curved side surface and presenting a curved upper surface.  
     
     
         6 . A tool component according to  claim 1 , comprising an essentially rectangular or cylindrical substrate to which the layer of ultra-hard abrasive material is bonded, the layer of ultra-hard abrasive material presenting a curved upper surface.  
     
     
         7 . A tool component according to any one of the preceding claims, wherein the interface between the layer of ultra-hard abrasive material and the substrate is planar, curved or otherwise profiled.  
     
     
         8 . A tool component according to any one of the preceding claims, wherein the layer of ultra-hard abrasive material is PCD, PCBN or CVD diamond.  
     
     
         9 . A tool component according to any one of the preceding claims, wherein the substrate is a cemented carbide substrate.  
     
     
         10 . A tool component according to  claim 9 , wherein the substrate is a cemented tungsten carbide substrate.  
     
     
         11 . A method of cutting or abrading a workpiece or substrate, the method including the steps of: 
 1) providing a tool component according to any one of the preceding claims;    2) providing a workpiece or substrate;    3) contacting the workpiece or substrate with a curved and tapered cutting edge of the tool component; and    4) advancing the cutting edge into the workpiece or substrate.    
     
     
         12 . A method according to  claim 11 , wherein the tool component is a cutting element or a gauge stone in a drill bit for subterranean rock drilling.  
     
     
         13 . A method of manufacturing a tool component according to any one of  claims 1  to  10 , the method including the steps of: 
 1) providing a body comprising a layer of ultra-hard abrasive material bonded to a substrate;    2) cutting a blank from the body transverse to the longitudinal axis of the body and through the interface between the layer of ultra-hard abrasive material and the substrate; and    3) shaping the blank into the desired shape for the tool component.