METHOD FOR MANUFATURING OF POLYCRYSTALLINE SUPERHARD CUTTER UTILIZING INTERNAL FRAME

• US 20200130062A1
• Filed: 08/22/2019
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Active Application

• Current Assignee: Varel International Ind., LLC
• Original Assignee: Varel International Ind., LLC
• Inventors: BELLIN, FEDERICO
• Application Number:
  US16/547,808
• Publication Number:
  US 20200130062A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/62 by chemical means
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 10/66 by mechanical means
• CPC Class Codes: B22F 2003/244 Leaching
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 2302/406 Diamond
• CPC Class Codes: B22F 3/14 simultaneously
• CPC Class Codes: B22F 3/24 After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 5/00 Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B23B 2228/00 Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
• CPC Class Codes: B23B 27/148 Composition of the cutting inserts
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 26/00 Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: C22C 29/08 based on tungsten carbide
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method for manufacturing a cutter includes: placing a can into a press, the can comprising superhard powder, a metallic frame embedded in the superhard powder, and catalyst; operating the press to sinter the superhard powder, thereby forming a polycrystalline superhard cutting head; and exposing at least a portion of the polycrystalline superhard cutting head and the frame to acid for removing at least a portion of the catalyst from the polycrystalline superhard cutting head. The leaching frame comprises a plurality of branches. Each branch has an inner end located adjacent to a front face of the cutting head and an outer end located adjacent to a side of the cutting head. The acid tunnels into the polycrystalline superhard cutting head by dissolving the leaching frame.

Claims

1. A method for manufacturing a cutter, comprising:

placing a can into a press, the can comprising superhard powder, a leaching frame embedded in the superhard powder, and catalyst;

operating the press to sinter the superhard powder, thereby forming a polycrystalline superhard cutting head; and

exposing at least a portion of the polycrystalline superhard cutting head and the frame to acid for removing at least a portion of the catalyst from the polycrystalline superhard cutting head,

wherein;

the leaching frame comprises a plurality of branches,

each branch has an inner end located adjacent to a front face of the cutting head and an outer end located adjacent to a side of the cutting head, and

the acid tunnels into the polycrystalline superhard cutting head by dissolving the leaching frame.

2. The method of claim 1, further comprising:

forming the leaching frame;

loading the leaching frame into the can; and

loading superhard powder into the can.

3. The method of claim 1, further comprising grinding a base disk of the leaching frame from the polycrystalline superhard cutting head.

4. The method of claim 1, further comprising forming the leaching frame using an additive manufacturing system.

5. The method of claim 1, wherein the cutting head is a cutting table.

6. The method of claim 1, further comprising forming a chamfer in a periphery of the cutting head at the front face, wherein the outer end of each branch is behind the chamfer.

7. The method of claim 1, wherein:

the can comprises catalyst by loading a substrate into the can, and

the substrate is bonded to the polycrystalline superhard cutting table while operating the press.

8. A method for manufacturing a cutter, comprising:

forming a leaching frame;

applying catalyst to the leaching frame, thereby forming a composite frame;

placing a can into a press, the can comprising superhard powder and the composite frame embedded in the superhard powder;

operating the press to sinter the superhard powder, thereby forming polycrystalline superhard cutting head, wherein the catalyst portion of the frame melts and disperses within the superhard powder; and

exposing at least a portion of the polycrystalline superhard cutting head and the remaining leaching frame to acid for removing at least a portion of the catalyst from the polycrystalline superhard cutting head,

wherein the acid tunnels into the polycrystalline superhard cutting head by dissolving the remaining leaching frame.

9. The method of claim 8, further comprising applying the superhard powder as part of a slurry to the composite frame and curing the slurry to form a green cutting head.

10. The method of claim 9, wherein:

the superhard powder comprises a first powder having a first particle size and a second powder having a second particle size, and

the first particle size is less than the second particle size.

11. The method of claim 9, further comprising placing the green cutting head into a furnace and operating the furnace to debind the cured slurry and melt the catalyst, thereby forming a brown cutting head.

12. The method of claim 11, further comprising:

loading the brown cutting head into the can;

loading intermediate powder into the can; and

loading a substrate into the can.

13. The method of claim 12, wherein the intermediate powder is a mixture of superhard powder and ceramic or cermet powder.

14. A method for manufacturing a cutter, comprising:

placing a can into a press, the can comprising superhard powder and a catalyst frame embedded in the superhard powder; and

operating the press to sinter the superhard powder, thereby forming a polycrystalline superhard cutting head.

15. The method of claim 14, further comprising:

loading intermediate powder into the can; and

loading a substrate into the can.

16. The method of claim 15, wherein the intermediate powder is a mixture of superhard powder and ceramic or cermet powder.

17. The method of claim 14, further comprising applying the superhard powder as part of a slurry to the catalyst frame and curing the slurry to form a green cutting head.

18. The method of claim 17, wherein:

the superhard powder comprises a first powder having a first particle size and a second powder having a second particle size, and

the first particle size is less than the second particle size.

19. The method of claim 17, further comprising placing the green cutting head into a furnace and operating the furnace to debind the cured slurry and melt the catalyst frame, thereby forming a brown cutting head.

20. The method of claim 19, further comprising:

loading the brown cutting head into the can;

loading intermediate powder into the can; and

loading a substrate into the can.