Cutting elements having a pre-formed fracture plane for use in cutting tools

Abstract

Cutting elements for cutting tools comprise a pre-formed fracture plane disposed in at least one surface of the cutting elements. The pre-formed fracture plane can comprise a groove cut into one of the surfaces of the cutting element, or the pre-formed fracture plane can be formed by using a laser or other heat concentrating source to weaken a portion of one of the surfaces of the cutting element so that the cutting element will break along the pre-formed fracture plane.

1 . A cutting element comprising:
 a body comprising a cutting surface having a cutting profile and a non-cutting surface, wherein the non-cutting surface comprises a fracture plane disposed within the non-cutting surface.   
     
     
         2 . The cutting element of  claim 1 , wherein the fracture plane is disposed substantially linearly below a valley disposed in the cutting profile. 
     
     
         3 . The cutting element of  claim 2 , wherein the fracture plane comprises a groove. 
     
     
         4 . The cutting element of  claim 3 , wherein the groove comprises a V-shape. 
     
     
         5 . The cutting element of  claim 1 , further comprising a plurality of fracture planes disposed within the non-cutting surface. 
     
     
         6 . The cutting element of  claim 5 , wherein each of the fracture planes is disposed substantially linearly below a respective valley disposed in the cutting profile. 
     
     
         7 . The cutting element of  claim 6 , wherein the cutting surface comprises a top surface and the non-cutting surface comprises a bottom surface disposed opposite the top surface,
 wherein the cutting element further comprises at least three side surfaces disposed between the top surface and the bottom surface, and   wherein at least one of the at least three side surfaces comprise a side surface fracture plane, the side surface fracture plane being substantially perpendicular to at least one of the plurality of fracture planes disposed within the bottom surface.   
     
     
         8 . The cutting element of  claim 1 , wherein the cutting surface comprises a top surface and the non-cutting surface comprises a bottom surface disposed opposite the top surface,
 wherein the cutting element further comprises a front surface, a back surface disposed opposite the front surface, a first side surface, and a second side surface disposed opposite the first side surface, the front surface, back surface, first side surface, and second side surface being disposed between the top surface and the bottom surface, and   wherein the first side surfaces comprises a side surface fracture plane, the side surface fracture plane being substantially perpendicular to the fracture plane disposed within the bottom surface.   
     
     
         9 . A cutting element comprising:
 two or more segments, at least one of the two or more segments comprising a top cutting profile and a front side, the front side comprising a horizontal groove disposed opposite the top cutting profile, the horizontal groove providing a fracture plane,   wherein the two or more segments are initially disposed adjacent and affixed to each other along the fracture plane, and   wherein, after sufficient wear of one of the two or more segments, one of the two or more segments breaks apart from the remaining one or more segments along the fracture plane.   
     
     
         10 . The cutting element of  claim 9 , wherein the fracture plane comprises an apex that is disposed substantially linearly below a valley disposed in the top cutting profile. 
     
     
         11 . The cutting element of  claim 10 , wherein the horizontal groove comprises a V-shape. 
     
     
         12 . The cutting element of  claim 9 , the front side of at least one of the two or more segments comprises a vertical groove disposed substantially perpendicular to and connected to the horizontal groove. 
     
     
         13 . The cutting element of  claim 9 , wherein the horizontal groove comprises a material disposed within the horizontal groove, the material being weaker in strength as compared to a cutting element material forming the remainder of the one or more segments. 
     
     
         14 . A cutting tool comprising:
 a body having a first end for connection with a rotating component; and   a cutting end for rotation in unison with the body, the cutting end comprising a cutting element, the cutting element comprising a cutting surface having a cutting profile and a non-cutting surface, wherein the non-cutting surface comprises a fracture plane disposed within the non-cutting surface,   wherein after sufficient use of the cutting tool, the cutting element breaks along the fracture plane.   
     
     
         15 . The cutting element of  claim 14 , wherein the fracture plane is disposed substantially linearly below a valley disposed in the cutting profile. 
     
     
         16 . The cutting element of  claim 14 , wherein the cutting surface comprises a top surface and the non-cutting surface comprises a bottom surface disposed opposite the top surface,
 wherein the cutting element further comprises at least three side surfaces disposed between the top surface and the bottom surface, and   wherein at least one of the at least three side surfaces comprise a side surface fracture plane, the side surface fracture plane being substantially perpendicular to the fracture plane disposed within the bottom surface.   
     
     
         17 . A method of cutting an object, the method comprising the steps of:
 (a) providing a cutting tool, the cutting tool comprising a cutting element having a cutting surface and a non-cutting surface, wherein the non-cutting surface comprises a fracture plane disposed within the non-cutting surface wherein after sufficient use of the cutting tool, the cutting element breaks along the fracture plane;   (b) contacting the cutting element with an object to be cut;   (c) rotating the cutting element against the object; and   (d) during step (c), breaking the cutting element along the fracture plane to remove a portion of the cutting element from the cutting tool.   
     
     
         18 . The method of  claim 17 , wherein the fracture plane is formed in the non-cutting surface by cutting a groove within the non-cutting surface. 
     
     
         19 . The method of  claim 18 , wherein the fracture plane is formed in the non-cutting surface by heating a portion of the non-cutting surface with a laser.