Selectively leached cutter
First Claim
1. A method of manufacturing a polycrystalline diamond (PCD) cutting element comprising:
- identifying a portion of a cutting surface of a PCD body in a PCD cutting element as a cutting area which, during use of the PCD cutting element, is heated by a cutting action of the cutting element;
leaching the PCD body to remove substantially all of a binder-catalyzing material from the cutting area to a first depth; and
leaching the PCD body to remove substantially all of the binder-catalyzing material from at least a portion of the cutting surface surrounding the cutting area to a second depth,wherein the first depth is greater than the second depth, andwherein the PCD body is substantially cylindrical and no leaching occurs at a portion of the cutting surface central to a cylindrical axis of the PCD body.
2 Assignments
0 Petitions
Accused Products
Abstract
The present disclosure provides a method of manufacturing a polycrystalline diamond (PCD) cutting element used as drill bit cutting elements (10). The method includes leaching a PCD body formed from diamond particles (202) using a binder-catalyzing material so as to remove substantially all of the binder-catalyzing material from portions of a cutting surface of the PCD body. A portion (24) of the cutting surface is identified as a cutting area which, in use of the cutting element to cut material, is heated by the cutting action of the cutting element. Leaching of the PCD body includes performing a relatively deep leach in the portion of the cutting surface identified as the cutting area and performing a relatively shallow leach in at least the portion (26) of the cutting surface surrounding the identified cutting area.
8 Citations
19 Claims
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1. A method of manufacturing a polycrystalline diamond (PCD) cutting element comprising:
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identifying a portion of a cutting surface of a PCD body in a PCD cutting element as a cutting area which, during use of the PCD cutting element, is heated by a cutting action of the cutting element; leaching the PCD body to remove substantially all of a binder-catalyzing material from the cutting area to a first depth; and leaching the PCD body to remove substantially all of the binder-catalyzing material from at least a portion of the cutting surface surrounding the cutting area to a second depth, wherein the first depth is greater than the second depth, and wherein the PCD body is substantially cylindrical and no leaching occurs at a portion of the cutting surface central to a cylindrical axis of the PCD body. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A polycrystalline diamond (PCD) cutting element comprising:
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a PCD body comprising a cutting area and a cutting surface surrounding the cutting area, wherein the cutting area comprises substantially no binder-catalyzing material to a depth of not less than about 0.15 mm, and wherein at least a portion of the cutting surface surrounding the cutting area comprises substantially no binder-catalyzing material to a depth of not less than about 0.01 mm and not more than about 0.12 mm, and wherein the PCD body is substantially cylindrical with a binder-catalyzing material at a portion of the cutting surface central to a cylindrical axis of the PCD body. - View Dependent Claims (17)
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18. An earth-boring drill bit comprising a diamond (PCD) cutting element comprising:
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a bit body; and a PCD body inserted into the bit body and comprising a cutting area and a cutting surface surrounding the cutting area, wherein the cutting area comprises substantially no binder-catalyzing material to a depth of not less than about 0.15 mm, and wherein at least a portion of the cutting surface surrounding the cutting area comprises substantially no binder-catalyzing material to a depth of not less than about 0.01 mm and not more than about 0.12 mm, and wherein the PCD body is substantially cylindrical with a binder-catalyzing material at a portion of the cutting surface central to a cylindrical axis of the PCD body. - View Dependent Claims (19)
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Specification