Method for forming cutting elements

Abstract

The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed a ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

1 . A method for forming a cylindrical cutting element body of a predetermined diameter having a canted end surface, the method comprising the steps of: 
 forming a cylindrical work piece having a central axis and a diameter twice the predetermined diameter and a convex protrusion extending from an end of the cylindrical work piece; and    cutting the cylindrical body from the cylindrical work piece such that the outer surface of the cylindrical body is cut tangent to the outer surface of the cylindrical work piece.    
     
     
         2 . A method as recited in  claim 1  further comprising the step of cutting a second cylindrical body from the cylindrical work piece wherein the outer surface of the second cylindrical body is cut tangent to the outer surface of the cylindrical work piece.  
     
     
         3 . A method as recited in  claim 2  wherein the step of cutting a second cylindrical body comprises the step of cutting a second cylindrical body tangent to the first cylindrical body at the central axis of the work piece.  
     
     
         4 . A method for forming a cylindrical cutting element body of a predetermined diameter having a canted end surface, the method comprising the steps of: 
 forming a cylindrical work piece having a cylindrical outer surface and a longitudinal central axis and a diameter at least twice the predetermined diameter and a convex protrusion extending from an end of the cylindrical work piece; and    cutting the cylindrical body from the cylindrical work piece, wherein cylindrical body comprises a longitudinal central axis the central axis, wherein the longitudinal central axis of the workpiece is offset from the longitudinal central axis of the cylindrical body.    
     
     
         5 . A method as recited in  claim 4  further comprising the step of cutting a second cylindrical body from the cylindrical work piece wherein the second cylindrical body comprises a longitudinal central axis offset from the longitudinal central axis of the work piece.  
     
     
         6 . A method as recited in  claim 5  wherein the step of cutting a second cylindrical body comprises the step of cutting a second cylindrical body tangent to the first cylindrical body at the central axis of the work piece.  
     
     
         7 . A method as recited in  claim 4  wherein the step of cutting the first cylindrical body comprises the step of cutting the first cylindrical body having a cylindrical outer surface tangent to the outer cylindrical outer surface of the workpiece.  
     
     
         8 . A method as recited in  claim 7  further comprising the step of cutting a second cylindrical body from the cylindrical work piece, wherein the second cylindrical body comprises a longitudinal central axis offset from the central longitudinal axis of the workpiece and wherein the second cylindrical body outer surface is tangent to workpiece cylindrical outer surface.