Thick Pointed Superhard Material

Abstract

In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius measured from a direction substantially perpendicular to a central axis of the tool. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface.

Description

BACKGROUND OF THE INVENTION

The invention relates to a high impact resistant tool that may be used in machinery such as crushers, picks, grinding mills, roller cone bits, rotary fixed cutter bits, earth boring bits, percussion bits or impact bits, and drag bits. More particularly, the invention relates to inserts comprised of a carbide substrate with a non-planar interface and an abrasion resistant layer of super hard material affixed thereto using a high pressure high temperature press apparatus. Such inserts typically comprise a super hard material layer or layers formed under high temperature and pressure conditions, usually in a press apparatus designed to create such conditions, cemented to a carbide substrate containing a metal binder or catalyst such as cobalt. The substrate is often softer than the super hard material to which it is bound. Some examples of super hard materials that high pressure high temperature (HPHT) presses may produce and sinter include cemented ceramics, diamond, polycrystalline diamond, and cubic boron nitride. A cutting element or insert is normally fabricated by placing a cemented carbide substrate into a container or cartridge with a layer of diamond crystals or grains loaded into the cartridge adjacent one face of the substrate. A number of such cartridges are typically loaded into a reaction cell and placed in the high pressure high temperature press apparatus. The substrates and adjacent diamond crystal layers are then compressed under HPHT conditions which promotes a sintering of the diamond grains to form the polycrystalline diamond structure. As a result, the diamond grains become mutually bonded to form a diamond layer over the substrate interface. The diamond layer is also bonded to the substrate interface.

Such inserts are often subjected to intense forces, torques, vibration, high temperatures and temperature differentials during operation. As a result, stresses within the structure may begin to form. Drill bits for example may exhibit stresses aggravated by drilling anomalies during well boring operations such as bit whirl or bounce often resulting in spalling, delamination or fracture of the super hard abrasive layer or the substrate thereby reducing or eliminating the cutting elements efficacy and decreasing overall drill bit wear life. The superhard material layer of an insert sometimes delaminates from the carbide substrate after the sintering process as well as during percussive and abrasive use. Damage typically found in percussive and drag bits may be a result of shear failures, although non-shear modes of failure are not uncommon. The interface between the superhard material layer and substrate is particularly susceptible to non-shear failure modes due to inherent residual stresses.

U.S. Pat. No. 5,544,713 by Dennis, which is herein incorporated by reference for all that it contains, discloses a cutting element which has a metal carbide stud having a conic tip formed with a reduced diameter hemispherical outer tip end portion of said metal carbide stud. The tip is shaped as a cone and is rounded at the tip portion. This rounded portion has a diameter which is 35-60% of the diameter of the insert.

U.S. Pat. No. 6,408,959 by Bertagnolli et al., which is herein incorporated by reference for all that it contains, discloses a cutting element, insert or compact which is provided for use with drills used in the drilling and boring of subterranean formations.

U.S. Pat. No. 6,484,826 by Anderson et al., which is herein incorporated by reference for all that it contains, discloses enhanced inserts formed having a cylindrical grip and a protrusion extending from the grip.

U.S. Pat. No. 5,848,657 by Flood et al, which is herein incorporated by reference for all that it contains, discloses domed polycrystalline diamond cutting element wherein a hemispherical diamond layer is bonded to a tungsten carbide substrate, commonly referred to as a tungsten carbide stud. Broadly, the inventive cutting element includes a metal carbide stud having a proximal end adapted to be placed into a drill bit and a distal end portion. A layer of cutting polycrystalline abrasive material disposed over said distal end portion such that an annulus of metal carbide adjacent and above said drill bit is not covered by said abrasive material layer.

U.S. Pat. No. 4,109,737 by Bovenkerk which is herein incorporated by reference for all that it contains, discloses a rotary bit for rock drilling comprising a plurality of cutting elements mounted by inference-fit in recesses in the crown of the drill bit. Each cutting element comprises an elongated pin with a thin layer of polycrystalline diamond bonded to the free end of the pin.

US Patent Application Serial No. 2001/0004946 by Jensen, although now abandoned, is herein incorporated by reference for all that it discloses. Jensen teaches that a cutting element or insert with improved wear characteristics while maximizing the manufacturability and cost effectiveness of the insert. This insert employs a superabrasive diamond layer of increased depth and by making use of a diamond layer surface that is generally convex.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a high impact resistant tool has a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. At the interface, the substrate has a tapered surface starting from a cylindrical rim of the substrate and ending at an elevated flatted central region formed in the substrate. The superhard material has a pointed geometry with a sharp apex having 0.050 to 0.125 inch radius of curvature. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the flatted central region of the substrate. In other embodiments, the substrate may have a non-planar interface. The interface may comprise a slight convex geometry or a portion of the substrate may be slightly concave at the interface.

The substantially pointed geometry may comprise a side which forms a 35 to 55 degree angle with a central axis of the tool. The angle may be substantially 45 degrees. The substantially pointed geometry may comprise a convex and/or a concave side. In some embodiments, the radius may be 0.090 to 0.110 inches. Also in some embodiments, the thickness from the apex to the non-planar interface may be 0.125 to 0.275 inches.

The substrate may be bonded to an end of a carbide segment. The carbide segment may be brazed or press fit to a steel body. The substrate may comprise a 1 to 40 percent concentration of cobalt by weight. A tapered surface of the substrate may be concave and/or convex. The taper may incorporate nodules, grooves, dimples, protrusions, reverse dimples, or combinations thereof. In some embodiments, the substrate has a central flatted region with a diameter of 0.125 to 0.250 inches.

The superhard material and the substrate may comprise a total thickness of 0.200 to 0.700 inches from the apex to a base of the substrate. In some embodiments, the total thickness may be up to 2 inches. The superhard material may comprise diamond, polycrystalline diamond, natural diamond, synthetic diamond, vapor deposited diamond, silicon bonded diamond, cobalt bonded diamond, thermally stable diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, infiltrated diamond, layered diamond, monolithic diamond, polished diamond, course diamond, fine diamond, cubic boron nitride, diamond impregnated matrix, diamond impregnated carbide, metal catalyzed diamond, or combinations thereof A volume of the superhard material may be 75 to 150 percent of a volume of the carbide substrate. In some embodiments, the volume of diamond may be up b twice as much as the volume of the carbide substrate. The superhard material may be polished. The superhard material may be a polycrystalline superhard material with an average grain size of 1 to 100 microns. The superhard material may comprise a 1 to 40 percent concentration of binding agents by weight. The tool of the present invention comprises the characteristic of withstanding impacts greater than 80 joules.

The high impact tool may be incorporated in drill bits, percussion drill bits, roller cone bits, shear bits, milling machines, indenters, mining picks, asphalt picks, cone crushers, vertical impact mills, hammer mills, jaw crushers, asphalt bits, chisels, trenching machines, or combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective diagram of an embodiment of a high impact resistant tool.

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

FIG. 2 a is a cross-sectional diagram of another embodiment of a superhard geometry.

FIG. 3 is a cross-sectional diagram of an embodiment of a superhard geometry.

FIG. 3 a is a diagram of an embodiment of test results.

FIG. 3 b is diagram of an embodiment of Finite Element Analysis of a superhard geometry.

FIG. 3 c is diagram of an embodiment of Finite Element Analysis of a pointed geometry.

FIG. 4 is a cross-sectional diagram of another embodiment of a pointed geometry.

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

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

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

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

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

FIG. 10 is a cross-sectional diagram of another embodiment of a pointed geometry.

FIG. 11 is a cross-sectional diagram of another embodiment of a pointed geometry.

FIG. 12 is a cross-sectional diagram of another embodiment of a high impact resistant tool.

FIG. 13 is a cross-sectional diagram of another embodiment of a high impact resistant tool.

FIG. 14 is a cross-sectional diagram of another embodiment of a high impact resistant tool.

FIG. 14 a is a perspective diagram of an embodiment of high impact resistant tools.

FIG. 15 is a cross-sectional diagram of an embodiment of an asphalt milling machine.

FIG. 16 is an orthogonal diagram of an embodiment of a percussion bit.

FIG. 17 is a cross-sectional diagram of an embodiment of a roller cone bit.

FIG. 18 is a perspective diagram of an embodiment of a mining bit.

FIG. 19 is an orthogonal diagram of an embodiment of a drill bit.

FIG. 20 is a perspective diagram of another embodiment of a trenching machine.

FIG. 21 is a cross-sectional diagram of an embodiment of a jaw crusher.

FIG. 22 is a cross-sectional diagram of an embodiment of a hammer mill.

FIG. 23 is a cross-sectional diagram of an embodiment of a vertical shaft impactor.

FIG. 24 is a perspective diagram of an embodiment of a chisel.

FIG. 25 is a perspective diagram of another embodiment of a moil.

FIG. 26 is a cross-sectional diagram of an embodiment of a cone crusher.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 discloses an embodiment of a high impact resistant tool 100 which may be used in machines in mining, asphalt milling, or trenching industries. The tool 100 may comprise a shank 101 and a body 102, the body 102 being divided into first and second segments 103, 104. The first segment 103 may generally be made of steel, while the second segment 104 may be made of a harder material such as a cemented metal carbide. The second segment 104 may be bonded to the first segment 103 by brazing to prevent the second segment 104 from detaching from the first segment 103.

The shank 101 may be adapted to be attached to a driving mechanism. A protective spring sleeve 105 may be disposed around the shank 101 both for protection and to allow the high impact resistant tool to be press fit into a holder while still being able to rotate. A washer 106 may also be disposed around the shank 101 such that when the high impact resistant tool 100 is inserted into a holder, the washer 106 protects an upper surface of the holder and also facilitates rotation of the tool. The washer 106 and sleeve 105 may be advantageous since they may protect the holder which may be costly to replace.

The high impact resistant tool 100 also comprises a tip 107 bonded to a frustoconical end 108 of the second segment 104 of the body 102. The tip 107 comprises a superhard material 109 bonded to a cemented metal carbide substrate 110 at a non-planar interface. The tip may be bonded to the substrate through a high temperature high pressure process. The superhard material 109 may comprise diamond, polycrystalline diamond, natural diamond, synthetic diamond, vapor deposited diamond, silicon bonded diamond, cobalt bonded diamond, thermally stable diamond, polycrystalline diamond with a binder concentration of 1 to 40 weight percent, infiltrated diamond, layered diamond, monolithic diamond, polished diamond, course diamond, fine diamond, cubic boron nitride, diamond impregnated matrix, diamond impregnated carbide, non-metal catalyzed diamond, or combinations thereof.

The superhard material 109 may be a polycrystalline structure with an average grain size of 10 to 100 microns. The cemented metal carbide substrate 110 may comprise a 1 to 40 percent concentration of cobalt by weight, preferably 5 to 10 percent. During high temperature high pressure (HTHP) processing, some of the cobalt may infiltrate into the superhard material such that the substrate comprises a slightly lower cobalt concentration than before the HTHP process. The superhard material may preferably comprise a 1 to 5 percent cobalt concentration by weight after the cobalt or other binder infiltrates the superhard material. The superhard material may also comprise a 1 to 5 percent concentration of tantalum by weight as a binding agent. Other binders that may be used with the present invention include iron, cobalt, nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide, phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate, hydrogen phosphate, phosphorus carbonate, alkali metals, ruthenium, rhodium, niobium, palladium, chromium, molybdenum, manganese, tantalum or combinations thereof. In some embodiments, the binder is added directly to the superhard material's mixture before the HTHP processing and do not rely on the binder migrating from the substrate into the mixture during the HTHP processing.

Now referring to FIG. 2, the substrate 110 comprises a tapered surface 200 starting from a cylindrical rim 250 of the substrate and ending at an elevated, flatted, central region 201 formed in the substrate. The superhard material 109 comprises a substantially pointed geometry 210 with a sharp apex 202 comprising a radius of 0.050 to 0.125 inches. In some embodiments, the radius is 0.900 to 0.110 inches. It is believed that the apex 202 is adapted to distribute impact forces across the flatted region 201, which may help prevent the superhard material 109 from chipping or breaking. The superhard material 109 may comprise a thickness 203 of 0.100 to 0.500 inches from the apex to the flatted region or non-planar interface, preferably from 0.125 to 0.275 inches. The superhard material 109 and the substrate 110 may comprise a total thickness 204 of 0.200 to 0.700 inches from the apex 202 to a base 205 of the substrate 110. The sharp apex 202 may allow the high impact resistant tool to more easily cleave asphalt, rock, or other formations.

The pointed geometry of the superhard material 109 may comprise a side which forms a 35 to 55 degree angle 150 with a central axis of the tool, though the angle 150 may preferably be substantially 45 degrees. The included angle may be a 90 degree angle, although in some embodiments, the included angle is 85 to 95 degrees.

The pointed geometry may also comprise a convex side or a concave side. The tapered surface of the substrate may incorporate nodules 207 at the interface between the superhard material and the substrate, which may provide more surface area on the substrate to provide a stronger interface. The tapered surface may also incorporate grooves, dimples, protrusions, reverse dimples, or combinations thereof. The tapered surface may be convex, as in the current embodiment, though the tapered surface may be concave.

Comparing FIGS. 2 and 3, the advantages of having a pointed apex 202 as opposed to a blunt apex 300 may be seen. FIG. 2 is a representation of a pointed geometry which was made by the inventors of the present invention, which has a 0.094 inch radius apex and a 0.150 inch thickness from the apex to the non-planar interface. FIG. 3 is a representation of another geometry also made by the same inventors comprising a 0.160 inch radius apex and 0.200 inch thickness from the apex to the non-planar geometry. The superhard geometries were compared to each other in a drop test performed at Novatek International, Inc. located in Provo, Utah. Using an Instron Dynatup 9250G drop test machine, the tools were secured to a base of the machine and weights comprising tungsten carbide targets were dropped onto the superhard geometries. The pointed apex 202 of FIG. 2 surprisingly required about 5 times more joules to break than the thicker geometry of FIG. 3.

It was shown that the sharper geometry of FIG. 2 penetrated deeper into the tungsten carbide target, thereby allowing more surface area of the superhard material to absorb the energy from the falling target by beneficially buttressing the penetrated portion of the superhard material effectively converting bending and shear loading of the diamond substrate into a more beneficial quasi-hydrostatic type compressive forces drastically increasing the load carrying capabilities of the superhard material. On the other hand since the embodiment of FIG. 3 is blunter the apex hardly penetrated into the tungsten carbide target thereby providing little buttress support to the diamond substrate and caused the superhard material to fail in shear/bending at a much lower load with larger surface area using the same grade of diamond and carbide. The average embodiment of FIG. 2 broke at about 130 joules while the average geometry of FIG. 3 broke at about 24 joules. It is believed that since the load was distributed across a greater surface area in the embodiment of FIG. 2 it was capable of withstanding a greater impact than that of the thicker embodiment of FIG. 3.

Surprisingly, in the embodiment of FIG. 2, when the superhard geometry finally broke, the crack initiation point 251 was below the radius. This is believed to result from the tungsten carbide target pressurizing the flanks of the pointed geometry in the penetrated portion, which results in the greater hydrostatic stress loading in the pointed geometry. It is also believed that since the radius was still intact after the break, that the pointed geometry will still be able to withstand high amounts of impact, thereby prolonging the useful life of the pointed geometry even after chipping.

FIG. 3 a illustrates the results of the tests performed by Novatek, International, Inc. As can be seen, three different types of pointed insert geometries were tested. This first type of geometry is disclosed in FIG. 2a which comprises a 0.035 inch thick superhard geometry and an apex with a 0.094 inch radius. This type of geometry broke in the 8 to 15 joules range. The blunt geometry with the radius of 0.160 inches and a thickness of 0.200, which the inventors believed would outperform the other geometries broke in the 20-25 joule range. The pointed geometry with the 0.094 thickness and the 0.150 inch thickness broke at about 130 joules. The impact force measured when the superhard geometry with the 0.160 inch radius broke was 75 kilo-newtons. Although the Instron drop test machine was only calibrated to measure up to 88 kilo-newtons, which the pointed geometry exceeded when it broke, the inventors were able to extrapolate that the pointed geometry probably experienced about 105 kilo-newtons when it broke.

As can be seen, superhard material having the feature of being thicker than 0.100 inches or having the feature of a 0.075 to 0.125 inch radius is not enough to achieve the superhard material's optimal impact resistance, but it is synergistic to combine these two features. In the prior art, it was believed that a sharp radius of 0.075 to 0.125 inches of a superhard material such as diamond would break if the apex were too sharp, thus rounded and semispherical geometries are commercially used today.

The performance of the present invention is not presently found in commercially available products or in the prior art. Inserts tested between 5 and 20 joules have been acceptable in most commercial applications, but not suitable for drilling very hard rock formations

After the surprising results of the above test, Finite Element Analysis (FEA) was performed, the results of which are shown in FIGS. 3b and 3c. FIG. 3b discloses the superhard geometry, with a radius of 0.160 inches and a thickness of 0.200 inches under the load in which it broke while FIG. 3c discloses the pointed geometry with the 0.094 radius and the 0.150 inch thickness under the load that it broke under. As illustrated, each embodiment comprises a superhard material 109, a substrate 110 and a tungsten carbide segment 103. Both embodiments broke at the same stress, but due to the geometries of the superhard material 109, that VonMises level was achieved under significantly different loads since the pointed apex 202 distributed the stresses more efficiently than the blunt apex 300. In FIGS. 3b and 3c stress concentrations are represented by the darkness of the regions, the lighter regions represent lower the stress concentrations and the darker regions represent greater VonMises stress concentration. As can be seen the stress in the embodiment of FIG. 3b is concentrated near the apex and are both larger and higher in bending and shear, while the stress in FIG. 3c distributes the stresses lower and more efficiently due to their hydrostatic nature.

Since high and low stresses are concentrated in the superhard material transverse rupture is believed to actually occur in the superhard material, which is generally more brittle than the softer carbide substrate. The embodiment of FIG. 3c however has the majority of high stress in the superhard material while the lower stresses are actually in the carbide substrate which is more capable of handling the transverse rupture. Thus, it is believed that the geometry's thickness is critical to its ability to withstand greater impact forces; if it is too thick the transverse rupture will occur, but if it is too thin the superhard material will not be able to support itself and break at lower impact forces.

FIGS. 4 through 10 disclose various possible embodiments comprising different combinations of tapered surface 200 and conical surface 210 geometries. FIG. 4 illustrates the pointed geometry with a concave side 450 and a continuous convex substrate geometry 451 at the interface 200. FIG. 5 comprises an embodiment of a thicker superhard material 550 from the apex to the non-planar interface, while still maintaining this radius of 0.075 to 0.125 inches at the apex. FIG. 6 illustrates grooves 650 formed in the substrate to increase the strength of interface. FIG. 7 illustrates a slightly concave geometry at the interface with concave sides 750. FIG. 8 discloses slightly convex sides 850 of the pointed geometry while still maintaining the 0.075 to 0.125 inch radius. FIG. 9 discloses a flat sided pointed geometry 950. FIG. 10 discloses concave and convex portions 1050, 1051 of the substrate with a generally flatted central portion.

Now referring to FIG. 11, the superhard material 109 (number not shown in the fig.) may comprise a convex surface comprising different general angles at a lower portion 1100, a middle portion 1101, and an upper portion 1102 with respect to the central axis of the tool. The lower portion 1100 of the side surface may be angled at substantially 25 to 33 degrees from the central axis, the middle portion 1101, which may make up a majority of the convex surface, may be angled at substantially 33 to 40 degrees from the central axis, and the upper portion 1102 of the side surface may be angled at about 40 to 50 degrees from the central axis.

FIG. 12 discloses the second segment 104 may be press fit into a bore 1200 of the first segment 103. This may be advantageous in embodiments which comprise a shank 101 coated with a hard material. A high temperature may be required to apply the hard material coating to the shank, which may affect a brazed bond between the first and second segments 103, 104 when the segments have been brazed together beforehand. The same may occur if the segments are brazed together after the coating is applied, wherein a high temperature braze may affect the hard material coating. A press fit may allow the second segment 104 to be attached to the first segment 103 without affecting any other coatings or brazes on the tool 100. The depth of the bore 1200 and size of the second segment 104 may be adjusted to optimize wear resistance and cost effectiveness of the tool in order to reduce body wash and other wear to the first segment 103.

FIG. 13 discloses the tool 100 may comprise one or more rings 1300 of hard metal or superhard material disposed around the first segment, as in the embodiment of FIG. 13. The ring 1300 may be inserted into a groove 1301 or recess formed in the first segment. The ring 1300 may also comprise a tapered outer circumference such that the outer circumference is flush with the first segment 103. The ring 1300 may protect the first segment 103 from excessive wear that could affect the press fit of the second segment 104 in the bore 1200 of the first segment. The first segment 103 may also comprise carbide buttons or other strips adapted to protect the first segment 103 from wear due to corrosive and impact forces. Silicon carbide, diamond mixed with braze material, diamond grit, or hard facing may also be placed in groove or slots formed in the first segment of the tool to prevent the segment from wearing. In some embodiments, epoxy with silicon carbide or diamond may be used.

The high impact resistant tool 100 may be rotationally fixed during an operation, as in the embodiment of FIG. 14. A portion of the shank 101 may be threaded to provide axial support to the tool, and so that the tool may be inserted into a holder in a trenching machine, a milling machine, or a drilling machine. The planar surface of the second segment may be formed such that the tip 107 is presented at an angle with respect to a central axis 1400 of the tool.

FIG. 14 a discloses several pointed insert of superhard material disposed along a row. The pointed inserts 210 comprise flats 1450 on their periphery to allow their apexes 202 to get closer together. This may be beneficial in applications where it is desired to minimize the amount of material that flows between the pointed inserts.

The high impact resistant tool 100 may be used in many different embodiments. The tool may be a pick in an asphalt milling machine 1500, as in the embodiment of FIG. 15. The pointed inserts as disclosed herein have been tested in locations in the United States and have shown to last 10 to 15 time the life of the currently available milling teeth.

The tool may be an insert in a drill bit, as in the embodiments of FIGS. 16 through 19. In percussion bits, the pointed geometry may be useful in central locations 1651 on the bit face 1650 or at the gauge 1652 of the bit face. Further the pointed geometry may be useful in roller cone bits, where the inserts typically fail the formation through compression. The pointed geometries may be angled to enlarge the gauge well bore. FIG. 18 discloses a mining bit that may also be incorporated with the present invention. FIG. 19 discloses a drill bit typically used in horizontal drilling.

The tool may be used in a trenching machine 2000, as in the embodiment of FIG. 20. The tools may be placed on a chain that rotates around an arm 2050.

Milling machines may also incorporate the present invention. The milling machines may be used to reduce the size of material such as rocks, grain, trash, natural resources, chalk, wood, tires, metal, cars, tables, couches, coal, minerals, chemicals, or other natural resources.

A jaw crusher 2100 may comprise fixed plate 2150 with a wear surface and pivotal plate 2151 with another wear surface. Rock or other materials are reduced as they travel downhole the wear plates. The inserts may be fixed to the wear plates 2152 and may be in larger size as the tools get closer to the pivotal end of the wear plate. Hammer mills 2200 may incorporate the tool at on the distal end 2250 of the hammer bodies 2251. Vertical shaft impactors 2300 may also use the pointed inserts of superhard materials. They may use the pointed geometries on the targets or on the edges of a central rotor.

Chisels 2400 or rock breakers may also incorporate the present invention. At least one tool with a pointed geometry may be placed on the impacting end 2450 of a rock breaker with a chisel 2400 or moil geometry 2500. In some embodiments, the sides of the pointed geometry may be flatted.

A cone crusher, as in the embodiment of FIG. 26, may also incorporate the pointed geometries of superhard material. The cone crusher may comprise a top and bottom wear plate 2650, 2651 that may incorporate the present invention.

Other applications not shown, but that may also incorporate the present invention include rolling mills; cleats; studded tires; ice climbing equipment; mulchers; jackbits; farming and snow plows; teeth in track hoes, back hoes, excavators, shovels; tracks, armor piercing ammunition; missiles; torpedoes; swinging picks; axes; jack hammers; cement drill bits; milling bits; drag bits; reamers; nose cones; and rockets.

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 high impact resistant tool, comprising a sintered polycrystalline diamond material bonded to a cemented metal carbide substrate at a non-planar interface;the diamond material comprises a substantially pointed geometry with an apex comprising 0.050 to 0.125 inch radius of curvature measured from a direction substantially perpendicular to a central axis of the tool;the diamond material comprises a 0.100 to 0.500 inch thickness from the apex to the non-planar interface; andthe central axis intersects the interface between the diamond material and substrate.

2. The tool of claim 1, wherein the substantially pointed surface comprises a side which forms a 35 to 55 degree angle with a central axis of the tool.

3. The tool of claim 2, wherein the angle is substantially 45 degrees.

4. The tool of claim 1, wherein the substantially pointed geometry comprises a convex side.

5. The tool of claim 1, wherein the substantially pointed geometry comprises a concave side.

6. The tool of claim 1, wherein at the interface the substrate comprises a tapered surface starting from a cylindrical rim of the substrate and ending at an elevated flatted central region formed in the substrate.

7. The tool of claim 6, wherein the flatted region comprises a diameter of 0.125 to 0.250 inches.

8. The tool of claim 6, wherein the tapered surface incorporates nodules, grooves, dimples, protrusions, reverse dimples, or combinations thereof.

9. The tool of claim 1, wherein the radius is 0.090 to 0.110 inches.

10. The tool of claim 1, wherein the thickness from the apex to the non-planar interface is 0.125 to 0.275 inches.

11. The tool of claim 1, wherein the diamond material and the substrate comprise a total thickness of 0.200 to 0.700 inches from the apex to a base of the substrate.

12. The tool of claim 1, wherein a volume of the diamond material is 75 to 150 percent of a volume of the carbide substrate.

13. The tool of claim 1, wherein the high impact tool is incorporated in drill bits, percussion drill bits, roller cone bits, shear bits, milling machines, indenters, mining picks, asphalt picks, cone crushers, vertical impact mills, hammer mills, jaw crushers, asphalt bits, chisels, trenching machines, or combinations thereof.

14. The tool of claim 1, wherein the substrate is bonded to an end of a carbide segment.

15. The tool of claim 1, wherein the diamond material is a polycrystalline structure with an average grain size of 1 to 100 mircons.

16. The tool of claim 1, wherein the diamond material comprises a 1 to 5 percent concentration of binding agents by weight.

17. The tool of claim 1, wherein the substrate comprises a 5 to 10 percent concentration of cobalt by weight.

18. The tool of claim 1, wherein the tool comprises the characteristic of withstanding impacts of 130 joules.

19. The tool of claim 1, wherein the central axis also substantially intersects the apex of the diamond material.