Retention System

Abstract

A retention assembly, comprises a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft. Wherein, the inserted end is brazed to an inner surface of the cavity.

Description

BACKGROUND OF THE INVENTION

In the road construction and mining industries, rocks and pavement are degraded using attack tools. Often, a drum with an array of attack tools attached to it may be rotated and moved so that the attack tools engage a paved surface or rock to be degraded. Because attack tools engage materials that may be abrasive, the attack tools may be susceptible to wear.

U.S. Pat. No. 6,733,087 to Hall et al., which is herein incorporated by reference for all that it contains, discloses an attack tool for working natural and man-made materials that is made up of one or more segments, including a steel alloy base segment, an intermediate carbide wear protector segment, and a penetrator segment comprising a carbide substrate that is coated with a super hard material. The segments are joined at continuously curved interfacial surfaces that may be interrupted by grooves, ridges, protrusions, and posts. At least a portion of the curved surfaces vary from one another at about their apex in order to accommodate ease of manufacturing and to concentrate the bonding material in the region of greatest variance.

Examples of degradation assemblies from the prior art are disclosed in U.S. Pat. No. 6,824,225 to Stiffler, US Pub. No. 20050173966 to Mouthaan, U.S. Pat. No. 6,692,083 to Latham, U.S. Pat. No. 6,786,557 to Montgomery, Jr., US. Pub. No. 20030230926, U.S. Pat. No. 4,932,723 to Mills, US Pub. No. 20020175555 to Merceir, U.S. Pat. No. 6,854,810 to Montgomery, Jr., U.S. Pat. No. 6,851,758 to Beach, which are all herein incorporated by reference for all they contain.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention a retention assembly has a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft and the inserted end is brazed to an inner surface of the cavity.

The shaft may be in mechanical communication with the loaded end through a threaded nut. The threaded nut may engage a shoulder of the shank. The brazed joint may comprise a braze material comprising copper, brass, lead, tin, silver or combinations thereof. The inserted end of the shaft may be interlocked inside the cavity. The shaft, the carbide bolster and the shank may be coaxial. The inserted end of the shaft may be brazed with the inner surface of the cavity of the bolster. The inserted end of the shaft may be adapted to compliment the ceiling of the bolster. The cavity may comprise a concave surface adapted to receive the shaft. The retention assembly may be incorporated into drill bits, shear bits, cone crushers, picks, hammer mills or combinations thereof. The cavity of the bolster may comprise a thermal expansion relief groove. The interface between the inserted end of the shaft and the bolster may be non-planar. The inserted end of the shaft may comprise a 1 to 15 degree taper. The inserted end of the shaft may comprise at least one thermal expansion relief groove. The thermal expansion relief grooves in the inserted end of the shaft may be adapted to receive the thermal expansion relief grooves in the cavity of the bolster. The inserted end of the shaft may be brazed to a top of the cavity. A tip made of carbide and diamond may be brazed to the bolster. An insert may be brazed into the cavity and the insert may retain the inserted end of the shaft. The insert and the inserted end may comprise a rounded interface. The retention assembly may be incorporated into a driving mechanism, a drum, a chain, or combinations thereof. The bolster may comprise an assembly brazed into the cavity and the assembly may comprise a pocket adapted to hold the inserted portion of the shaft.

In another aspect of the invention a retention assembly has a carbide bolster comprising a cavity formed in its base end. A shaft comprises an inserted end disposed within the cavity. The shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft and the inserted end is interlocked within the geometry of the cavity by a casting.

The cast material may comprise metals like zinc, aluminum, magnesium; thermosetting plastics, Bakelite, melamine resin, polyester resin, vulcanized rubber or combination thereof. The shaft may be in mechanical communication with the loaded end through a threaded nut. The threaded nut may engage a shoulder of the shank. The inserted end of the shaft may comprise a 1 to 15 degree taper. The inserted end of the shaft may comprise an increase in diameter. The shaft, the carbide bolster and the shank may be coaxial. The inserted end of the shaft may compromise at least one groove formed in its surface. The retention assembly may be incorporated into drill bits, shear bits, hammer mills, cone crushers, or combinations thereof.

The inserted end of the shaft may compromise a shaft geometry adapted to interlock with the casting. The inner surface of the cavity of the bolster may comprise a cavity geometry adapted to interlock with the casting. The cavity geometry may comprise a taper narrowing towards an opening of the cavity formed in the base end. The diameter of the opening of the cavity formed in the base end is slightly smaller than the diameter of a tapered end of the shaft. The cavity geometry may comprise a lip. The inserted end of the shaft may be in contact with the cavity of the bolster. A tip of carbide and diamond may be brazed to the bolster. The retention assembly may be incorporated into a driving mechanism, a drum, a chain, a rotor, or combination thereof. The casting may submerge at least the tapered end of the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality of picks suspended underside of a pavement milling machine.

FIG. 2 is a cross-sectional diagram of an embodiment of a pick

FIG. 3 is an exploded diagram of an embodiment of a pick.

FIG. 4 is a cross-sectional diagram of an embodiment of a pick.

FIG. 5 is a cross-sectional diagram of another embodiment of a pick.

FIG. 6 is a cross-sectional diagram of another embodiment of a pick.

FIG. 7 is a cross-sectional diagram of another embodiment of a pick.

FIG. 8 is a cross-sectional diagram of another embodiment of a pick.

FIG. 9 is a cross-sectional diagram of another embodiment of a pick.

FIG. 10 is a cross sectional diagram of an embodiment of an insert brazed in a cavity.

FIG. 11 is a perspective diagram of another embodiment of an insert brazed in the cavity.

FIG. 12 is a cross-sectional diagram of another embodiment of a pick.

FIG. 13 is a cross-sectional diagram of an embodiment of a casting process.

FIG. 14 is a cross-sectional diagram of another embodiment of a pick.

FIG. 15 is a cross-sectional diagram of another embodiment of a pick.

FIG. 16 is a cross-sectional diagram of another embodiment of a pick.

FIG. 17 is a cross-sectional diagram of another embodiment of a pick.

FIG. 18 is a cross-sectional diagram of an embodiment of a retention assembly.

FIG. 19 is a cross-sectional diagram of another embodiment of a pick.

FIG. 20 is a cross-sectional diagram of another embodiment of a pick.

FIG. 21 is a cross-sectional diagram of another embodiment of a pick.

FIG. 22 is a cross-sectional diagram of another embodiment of a pick.

FIG. 23 is a cross-sectional diagram of another embodiment of a pick.

FIG. 24 is a cross-sectional diagram of another embodiment of a pick.

FIG. 25 is a cross-sectional diagram of another embodiment of a pick.

FIG. 26 is a cross-sectional diagram of another embodiment of a pick.

FIG. 27 is a cross-sectional diagram of another embodiment of a pick.

FIG. 28 is a cross-sectional diagram of another embodiment of a pick.

FIG. 29 is a cross-sectional diagram of another embodiment of a pick.

FIG. 30 is a cross-sectional diagram of an embodiment of a trencher.

FIG. 31 is a cross-sectional diagram of another embodiment of a trencher.

FIG. 32 is a cross-sectional diagram of an embodiment of a percussion bit.

FIG. 33 is a cross-sectional diagram of an embodiment of a fixed cutter bit.

FIG. 34 is a cross-sectional diagram of an embodiment of a roller cone.

FIG. 35 is a cross-sectional diagram of another embodiment of a retention assembly.

FIG. 36 is a cross-sectional diagram of another embodiment of a retention assembly

FIG. 37 is a cross-sectional diagram of another embodiment of a retention assembly

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of embodiments of the methods of the present invention, as represented in the Figures is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected embodiments of the invention.

The illustrated embodiments of the invention will best be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the methods described herein may easily be made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected embodiments consistent with the invention as claimed herein.

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality of picks 101 attached to a rotating drum 102 connected to the underside of a pavement milling machine 103. The milling machine 103 may be a cold planer used to degrade man-made formations such as pavement 104 prior to the placement of a new layer of pavement. Picks 101 may be attached to the drum 102 bringing the picks 101 into engagement with the formation.

FIG. 2 is an orthogonal diagram of an embodiment of a pick 101. The pick 101 comprises a cemented metal carbide bolster 201 attached to a hollow shank 202 at a carbide base 203 of the bolster 201. The carbide bolster 201 may comprise tungsten carbide, calcium carbide, silicon carbide, cementite, boron carbide, tantalum carbide, titanium carbide or combination thereof. The shank 202 may be substantially cylindrical and/or tapered. The impact tip 205 may comprise a super hard material 207 bonded to a carbide substrate at a non-planar interface. Preferably the carbide substrate has an axial thickness less than 6 mm. In some embodiments, the carbide substrate ranges between 10 and 1 mm. The superhard material may be at least 0.100 inches thick axially, in some embodiments it may be over 0.250 inches. The superhard material may be formed in a substantially conical shape.

The super hard material 207 may comprise diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, cubic boron nitride, refractory metal bonded diamond, silicon bonded diamond, layered diamond, infiltrated diamond, thermally stable diamond, natural diamond, vapor deposited diamond, physically deposited diamond, diamond impregnated matrix, diamond impregnated carbide, monolithic diamond, polished diamond, course diamond, fine diamond, nonmetal catalyzed diamond, cemented metal carbide, chromium, titanium, aluminum, tungsten, or combinations thereof.

The impact tip 205 may comprise a carbide substrate 305 bonded to the super hard material 207. Typically the substrate of the impact tip 205 is brazed to the carbide bolster 201 at a planar interface 306. The tip 205 and the bolster 201 may be brazed together with a braze material comprising a melting temperature from 700 to 1200 degrees Celsius. The super hard material 207 may be bonded to the carbide substrate 305 through a high temperature high pressure process (HTHP).

A cavity 307 may be formed at the end base of the bolster 201. An inserted end 204 of a shaft 301 may be inserted into the cavity 307. The other end 250 of the shaft 301 may be in mechanical communication with the loaded end 251 of the shank 202. The other end 250 of the shaft may comprise at least one thread 252 adapted to receive the threaded nut 302. The nut diameter may be bigger than the shaft diameter but smaller than the shank diameter.

The inserted end 204 of the shaft 301 may be brazed within the cavity 307 of the bolster 201. Preferably, the head of the inserted end comprises a geometry that compliments the geometry of the cavity. Preferably, the head of the inserted end is brazed directly to a ceiling 253 of the cavity. In other embodiments, the shaft is brazed to a side wall of the cavity.

Referring now to FIG. 3, the substrate 305 and the bolster 201 may be brazed together at high temperature at the same time the inserted end 204 of the shaft 301 is brazed to the cavity 307. The shaft 301 and the cavity 307 may be brazed at a non-planar interface. In some embodiments, the braze joints may be brazed at different times. In some embodiments, both braze joints utilize substantially similar braze materials 410. After brazing the inserted end of the shaft into the cavity, the other end of the shaft may be tensioned through the hollow shank and anchored while under tension with the threaded nut. This tension loads the other end of the hollow shank and snuggly holds the bolster against the hollow shank.

In FIG. 4, the inserted end 204 of the shaft 301 is tapered, which is adapted to abut a taper of the cavity. The shaft taper and the cavity taper may be brazed together.

In the embodiment of FIG. 5, the inserted end 204 of the shaft 301 is brazed to the ceiling 253 of the cavity 307. The diameter of the inserted end is larger than an opening constricted by a protruding lip 601 formed in the cavity. The geometry of the inserted end is adapted to flex upon insertion and snap out once past the lip 601. The inserted end 204 of the shaft 301 may be interlocked inside the cavity 307 of the bolster. The geometry of the inserted end 204 of the shaft 301 may allow enough space for thermal expansion while brazing the inserted end to the cavity.

Referring now to FIG. 6, the inserted end 204 of the shaft 301 may comprise at least one relief groove 650 to allow space for thermal expansion during brazing. This may reduce residual stress that may develop during brazing.

Referring now to FIG. 7, the ceiling 253 of the cavity 307 of the bolster 201 may comprise at least one relief groove 701 to allow for thermal expansion during brazing. They may reduce residual stress that may develop during brazing. The inserted end 204 of the shaft 301 may be partially brazed with the ceiling 253 of the cavity 307 of the bolster 201.

In FIG. 8 another embodiment of the invention is disclosed in which the pick 101 may comprise at least one groove 701 in the ceiling 253 of the cavity 307 of the bolster 201 adapted to receive protrusions in the inserted end 204 of the shaft 301. The ceiling 253 may be irregular and non-planar. The grooves 701 may form an interlocking mechanism. The grooves 701 may increase the surface area of the inserted end 204 and ceiling allowing a larger braze joint.

FIG. 9 is a cross-sectional diagram of another embodiment of the pick 101. A relief opening 802 may be formed in the inserted end 204 of the shaft 301. The purpose of the opening 802 may be to allow enough space for thermal expansion while brazing.

Referring now to FIG. 10, an insert may be brazed into the cavity of the bolster. The insert may be adapted to retain the inserted end of the shaft, preferably in ball and socket type of joint, although in some embodiments the joint may be tapered or interlocked. A cap 505 may be used in some embodiment to prevent a brazing material from flowing into the insert and interfering with the joint. The solidification of the brazing material may restrict the compliancy of the joint during a bending moment induced in the bolster while in operation and create stress risers. The insert and the inserted end 204 of the shaft may comprise a rounded interface.

In FIG. 11, another embodiment of an inserted brazed within the cavity is shown.

FIG. 12 is a cross-sectional diagram of another embodiment of the pick 101. The inserted end 204 of the shaft 301 may be interlocked within the cavity of the bolster 201 by casting. The casting may comprise zinc, a braze material, a plastic, lead, or combinations thereof. Zinc may be the preferred casting material since zinc will not significantly bond to the carbide and zinc demonstrates a high compressive strength. In some embodiment a non-wetting agent may be applied to the head of the shaft to prevent the zinc from forming a strong bond with the shaft.

In FIG. 13, a cross-sectional diagram of depicting a casting process. The tapered inserted end 204 of the shaft 301 may be brought into the cavity 307 and molten cast material 401 may be poured inside the cavity 307. The molten cast material 401 may be left to be cooled and solidify. The cooling rate may vary according to the cast material. The rate at which a casting cools may affect its microstructure, quality and properties of the casting and the mechanical interlocking of the cast with the shaft and the geometry of the cavity. The geometry of the cavity 307 of the bolster 201 may provide additional support in keeping the inserted end 204 of the shaft 301 interlocked within the cavity 307. In other embodiments, casting material granules, balls, shavings, segments, dust or combinations thereof may be placed in the cavity with the inserted end of the shaft and melted in place. The casting material may be heated in an oven, or a heating source such as a torch or radiant heater may be applied within the cavity or applied to the outside of the bolster.

FIG. 14 is an embodiment of the shaft casted within the cavity. The shaft may comprise an increase in diameter adapted to substantially contact an inner diameter of the hollow shank.

FIG. 15 is a cross-sectional diagram of another embodiment of the pick 101. The inserted end 204 of the shaft 301 may or may not touch the ceiling 253 of the cavity. The casting may form around the entire surface of the head of the inserted end.

In FIG. 16, the inserted end 204 of the shaft 301 may be tapered to increase its surface area with the casting. In some embodiments, the taper is gradual and distributes the load substantially equally across an interface between the casting and the inserted end. Another benefit of casting the shaft in place is distributing the loads across substantially the entire inner surface of the cavity.

Referring now to FIG. 17, the inserted end may comprise at least one groove 1001, and may be tapered. The grooves 1001 may increase the grip between the inserted end and the casting.

FIG. 18 is a cross-sectional diagram of an embodiment of a degradation assembly inserted into a blind hole 2020 of a tool, such as a fixed cutter drill bit, percussion bit, roller cone bit, miller, crusher and/or mill. The inserted end of the shaft 301 may be brought together with the cavity 307 of the bolster 201 by casting.

FIG. 19 is another embodiment of a pick 101. The bolster 201 comprises a first and second segment 2000, 2001. Since carbide is a brittle material and the shaft 301 is tensioned and therefore loading at least a portion of the carbide a thick carbide lip 2002 is incorporated into this embodiment. The bolster 201 is formed in two segments to allow insertion of the bolster from the opposing end of the shaft. A diameter increase of the inserted end 204 interlocks with the lip 2002 of the first carbide segment. The second segment of the bolster is brazed to the first after the inserted end is in place. Both segments are made of similar materials reducing thermal stresses that are common in traditional picks. In some embodiments, the second carbide segment 2001 overhangs the first segment 2000, directing debris away from the braze joint 2005 during a milling operation. The interface between the lip of the cavity and the inserted end of the shaft in some embodiments forms a joint that allows the inserted end to swivel within the cavity 307. This reduces the transfer of stress induced in the bolster during a bending moment to the shaft. In some embodiments, the shaft may be casted, brazed, bonded, or combinations thereof in the cavity after insertion. In some embodiments, the inserted end may be brazed in place while the bolster segments are brazed together. In other embodiments, the while brazing the segments together the flow of the braze material is controlled to prevent the braze material from inferring with the shaft. In some embodiments, the inserted end of the shaft is coated with boron nitride or another non0wetting agent to prevent the braze material from bonding to itself. In some embodiments, the segments may be made of different carbide grades. The first segment may comprise a more wear resistant carbide grade while the second segment may comprise a tougher grade or vice versa.

FIG. 20 discloses a rearward sloping braze joint 2006 between the carbide segments, while FIG. 21 discloses a frontward sloping braze joint 2007 between the carbide segments. FIG. 22 discloses a third bolster segment 2008.

In some embodiments, the space within the cavity may be lubricated. One such embodiment is disclosed in FIG. 23 where a port 2009 is formed in the shaft 301 to accommodate a flow of lubricate from a lubricant reservoir to the cavity 307. FIG. 24 discloses carbide segments bonded to another along an axial braze joint 2010. FIG. 25 disclosed a wear resistant coating 2011 deposited on the inserted end to prevent wear. FIG. 26 discloses a braze joint 2012 between the lip 2002 and underside 2013 of the inserted end of the shaft.

FIGS. 27 and 28 both disclose embodiments where the bolster is adapted to rotate around the inserted end of the shaft. In such embodiments, an o-ring 2014 may be place between the hollow shank and the base end of the bolster. The shaft may be press fit into the hollow shank. In some embodiments the shaft protrudes out of a solid shank. Wear resistant material and lubricants may be applied to the rotating surfaces. In FIG. 27, the shaft is press fit within the hollow shank. In FIG. 28, the shaft is tensioned and secured through a threaded nut 2015 on the loaded end. A hardened washer 2016 is attached to the hollow shank and abutting the base end of the bolster to provide a bearing surface on which the bolster may rotate. The bolster also forms an overhang 2017 over the hollow shank to direct debris away from the rotating interface 2018.

FIG. 29 is another embodiment of a segment bolster and the inserted end 204 of the shank 301 is casted in place.

FIG. 30 is a perspective diagram of an embodiment of a pick on a rock wheel trenching machine 130 and FIG. 20 discloses an embodiment of the pick 101 on a chain trenching machine. The picks 101 may be placed on a chain that rotates around an arm 1402 of a chain trenching machine 1401.

In FIG. 32, a cross-sectional diagram of an embodiment of a percussion bit 1400 having a bit body with slots for receiving the picks 101. The picks may be anchored in the slots through a press fit, barbs, hooks, snap rings, or combinations thereof. FIG. 33 discloses the picks in a fixed cutter bit 1500 and FIG. 34 discloses the picks 101 in a cone 5004 of a roller cone bit.

FIG. 35 is a cross-sectional diagram of another embodiment of the retention assembly. The retention assembly 2600 may be used to bring two parts together such as two parts 2500 and 2501 of a chair.

Referring now to FIG. 25, the retention assembly 2006 may be used to connect two blocks 5005 and 5006 together.

In FIG. 26 the retention assembly 2006 may be used to attach a block 2601 with the other block 2602.

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

1. A retention assembly, comprising: carbide bolster comprising a cavity formed in its base end;a shaft comprising an inserted end disposed within the cavity;the shaft is disposed within a hollow shank which comprises a first end contacting the bolster and a loaded end in mechanical communication with the shaft;wherein the inserted end is secured within an inner surface of the cavity through a braze joint.

1. The assembly of claim 1, wherein the shaft is in mechanical communication with the loaded end through a threaded nut.

2. The assembly of claim 2, wherein the threaded nut engages a shoulder of the shank.

3. The assembly of claim 1, wherein the brazed joint comprises a braze material comprising copper, brass, lead, tin, silver or combinations thereof.

4. The assembly of claim 1, wherein the inserted end of the shaft is interlocked inside the cavity.

5. The assembly of claim 1, wherein the shaft, the carbide bolster and the shank are coaxial.

6. The assembly of claim 1, wherein the retention assembly is incorporated into drill bits, shears bits, cone crushers, picks, hammer mills, or combinations thereof.

7. The assembly of claim 1, wherein the cavity of the bolster comprises a thermal expansion relief groove.

8. The assembly of claim 1, wherein the inserted end of the shaft comprises a 1 to 15 degree taper.

9. The assembly of claim 1, wherein the inserted end of the shaft comprises at least one thermal expansion relief groove.

10. The assembly of claim 1, wherein the inserted end of the shaft is brazed to a top of the cavity.

11. The assembly of claim 1, wherein the inserted end of the shaft is brazed to a side of the cavity.

12. The assembly of claim 1, wherein a tip made of carbide and diamond is brazed to the bolster.

13. The assembly of claim 1, wherein an insert is brazed into the cavity and the insert retains the inserted end of the shaft.

14. The assembly of claim 14, wherein the insert and inserted end comprise a rounded interface.

15. The assembly of claim 1, wherein the assembly comprises the characteristic of the shaft being substantially isolated from bending moments induced in the bolster.

16. The assembly of claim 1, wherein the retention assembly is incorporated into a driving mechanism, a drum, a chain, a rotor, or combinations thereof.

17. The assembly of claim 1, wherein the bolster comprises an assembly brazed into the cavity, the assembly comprises a pocket adapted to hold the inserted portion of the shaft.

18. The assembly of claim 1, wherein the cavity is formed by at least two segments of the carbide bolster.

19. A pick, comprising: carbide bolster comprising a cavity formed in its base end;a shaft comprising an inserted end disposed within the cavity; andthe inserted end is secured within the cavity through a braze joint.