Manufacture of cutting elements having lobes

Abstract

An apparatus for forming a cutting insert. The apparatus may include compression device having a first sleeve with a bore therein. The first sleeve may receive a substantially hollow can. A plurality of solid particulates may be positioned within the can, and a substrate material or other punch may also be positioned in the can. A forming device of the compression device may be located adjacent an end of the can in which the solid particulates are located. The forming device may include at least one protrusion extending from an inner surface thereof into the bore. The protrusion may be adapted to deform the can while also forming the plurality of solid particulates into a solid mass having one or more reliefs and one or more lobes therein.

What is claimed is: 
     
         1 . A method for forming a cutting insert, comprising:
 inserting a plurality of solid particulates into a substantially hollow can;   inserting a substrate material into the substantially hollow can, the substrate material having a base portion and an extension portion;   inserting the substantially hollow can, substrate material, and plurality of solid particulates into a bore of a sleeve;   engaging the substantially hollow can with a forming device having at least one protrusion; and   applying a force to the substrate material within the substantially hollow can, the force causing the at least one protrusion to deform the substantially hollow can while the plurality of solid particulates and substrate material are therein, the force further causing the plurality of solid particulates to become press-fit to an outer surface of the extension portion while within the substantially hollow can.   
     
     
         2 . The method of  claim 1 , wherein inserting the plurality of solid particulates is performed prior to inserting the substrate material into the substantially hollow. 
     
     
         3 . The method of  claim 1 , wherein inserting the substrate material causes the plurality of solid particulates to become positioned between the substrate material and an interior surface of the deformable can. 
     
     
         4 . The method of  claim 1 , wherein the substrate material includes a carbide substrate. 
     
     
         5 . The method of  claim 1 , wherein applying the force further causes the at least one protrusion to deform the extension portion of the substrate material. 
     
     
         6 . The method of  claim 5 , wherein applying the force causes the at least one protrusion to form at least one relief and at least one lobe in the extension portion. 
     
     
         7 . The method of  claim 6 , further comprising:
 heating the substrate material and plurality of solid particulates to a temperature between about 1,200° C. and about 1,600° C. after the at least one relief has been formed in the extension portion.   
     
     
         8 . The method of  claim 1 , wherein applying the force includes applying a compressive force using a shaft arranged and designed to fit within the bore. 
     
     
         9 . The method of  claim 8 , wherein the shaft is part of a compression device, the compression device having a shoulder for restricting axial movement of the shaft within the bore. 
     
     
         10 . An apparatus for forming a cutting insert, comprising:
 a sleeve having a bore formed at least partially therethrough, the sleeve being arranged and designed to receive a substantially hollow can having a plurality of solid particulates therein; and   a forming device at a first end portion of the bore, the forming device including at least one protrusion extending into the bore, the at least one protrusion being arranged and designed to deform the can while the solid particulates are therein.   
     
     
         11 . The apparatus of  claim 10 , further comprising:
 a compression device at a second end portion of the bore, the compression device being arranged and designed to move in a direction parallel to, or coaxial with, a central longitudinal axis through the bore.   
     
     
         12 . The apparatus of  claim 11 , wherein the compression device and forming device are arranged and designed to be positioned within respective portions of the bore having differing sizes. 
     
     
         13 . The apparatus of  claim 10 , wherein the sleeve is made of polyurethane, epoxy, polyester, phenolic, or a combination thereof. 
     
     
         14 . The apparatus of  claim 10 , wherein the sleeve is a first sleeve, the apparatus further comprising:
 a second sleeve at least partially enclosing the first sleeve, the second sleeve being more rigid than the first sleeve.   
     
     
         15 . The apparatus of  claim 10 , wherein an inner surface of the forming device includes a curved surface having the at least one protrusion extending therefrom. 
     
     
         16 . The apparatus of  claim 15 , the curved surface having a radius of curvature from about 3 mm to about 20 mm. 
     
     
         17 . The apparatus of  claim 10 , the at least one protrusion including two or more protrusions that are circumferentially offset from one another about a central longitudinal axis through the forming device. 
     
     
         18 . A method for forming a cutting insert, comprising:
 inserting a plurality of diamond particles into a deformable can;   inserting a punch into the deformable can such that the plurality of diamond particles is between the punch and an interior surface of the can;   inserting the punch, the plurality of diamond particles, and the deformable can at least partially into a compression device, the compression device including a forming device with at least one protrusion; and   applying a compressive force to the punch, the compressive force causing the at least one protrusion to deform the can and the punch, the punch having at least one lobe and at least one relief formed in a deformed portion thereof, wherein the compressive force further causes the plurality of diamond particles to form a substantially solid layer press-fit to the deformed portion of the punch.   
     
     
         19 . The method of  claim 18 , wherein the punch comprises a carbide substrate. 
     
     
         20 . The method of  claim 19 , further comprising:
 heating the carbide substrate and the substantially solid layer to a temperature from about 1,200° C. to about 1,600° C.; and   exposing the carbide substrate and the substantially solid layer to a pressure from about 5 GPa to about 7 GPa.   
     
     
         21 . The method of  claim 18 , wherein applying the compressive force includes applying a compressive force from about 500 N to about 10,000 N.