Cutting segment, method for manufacturing cutting segment, and cutting tool comprising the same

Abstract

A cutting segment for a cutting tool used for cutting or drilling brittle workpieces, such as stone, brick, concrete and asphalt, a method for manufacturing the segment, and a cutting tool comprising the segment are disclosed. The segment comprises layers of diamond particles and two kinds of plate-shaped metal matrix layers comprising soft and hard metal matrix layers having different ductility. The plate-shaped metal matrix layers are arranged perpendicular to a cutting surface while being parallel to a cutting direction, and are alternately stacked perpendicular to the cutting direction. The layers of diamond particles are suitably arranged in the plate-shaped soft and hard metal matrix layers. The segment and the cutting tool comprising the same have excellent cutting ability, and the manufacturing process thereof can be simplified, thereby remarkably enhancing productivity.

1 . A cutting segment, comprising: 
 a plurality of layers, each comprising layers of diamond particles and two kinds of plate-shaped metal matrix layers having different ductility,    wherein the two kinds of plate-shaped metal matrix layers are arranged perpendicular to a cutting surface while being parallel to a cutting direction, and are alternatively stacked perpendicular to the cutting direction, and    wherein each layer of diamond particles has diamond particles surrounded by the metal matrix layer having relatively high ductility among the metal matrix layers and positioned in a row of diamond particles on the cutting surface.    
   
   
       2 . The segment according to  claim 1 , wherein the plate-shaped metal matrix layers are constructed of a material selected from the group consisting of steel, aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       3 . The segment according to  claim 2 , wherein the plate-shaped metal matrix layers comprise at least one plate-shaped hard metal matrix layer and at least one plate-shaped soft metal matrix layer, the plate-shaped hard metal matrix layer is constructed of steel, and the plate-shaped soft metal matrix layer is constructed of a material selected from the group consisting of aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       4 . The segment according to any one of  claims 1  to  3 , wherein the plate-shaped metal matrix layers are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       5 . The segment according to  claim 4 , wherein the plate-shaped metal matrix layers are constructed of a rolled material.  
   
   
       6 . The segment according to  claim 5 , wherein the rolled material is a hot rolled steel plate or a cold rolled steel plate.  
   
   
       7 . A cutting segment, comprising: 
 a plurality of layers, each comprising layers of diamond particles, and two kinds of plate-shaped metal matrix layers comprising at least one soft metal matrix layer having relatively high ductility and at least one hard metal matrix layer having relatively low ductility,    wherein the two kinds of plate-shaped metal matrix layers are arranged perpendicular to a cutting surface while being parallel to a cutting direction, and are alternatively stacked perpendicular to the cutting direction, and    wherein each layer of diamond particles has diamond particles, a portion of each diamond particle being located in the soft metal matrix layer and the other portion of each diamond particle being located in the hard metal matrix layer, the diamond particles being positioned in a row of diamond particles on the cutting surface.    
   
   
       8 . The segment according to  claim 7 , wherein the portion of each diamond particle of one layer of diamond particles is located in each metal matrix layer.  
   
   
       9 . The segment according to  claim 8 , wherein the soft metal matrix layer has a thickness greater than that of the hard metal matrix layer.  
   
   
       10 . The segment according to  claim 8 , wherein the soft metal matrix layer has a thickness smaller than that of the hard metal matrix layer.  
   
   
       11 . The segment according to  claim 7 , wherein the portion of each diamond particle of two layers of diamond particles is located in each metal matrix layer.  
   
   
       12 . The segment according to any one of  claims 7  to  11 , wherein the plate-shaped metal matrix layers are constructed of a material selected from the group consisting of steel, aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       13 . The segment according to  claim 12 , wherein the plate-shaped hard metal matrix layer is constructed of steel, and the plate-shaped soft metal matrix layer is constructed of a material selected from the group consisting of aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       14 . The segment according to any one of  claims 7  to  11 , wherein the plate-shaped metal matrix layers are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       15 . The segment according to  claim 12 , wherein the plate-shaped metal matrix layers are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       16 . The segment according to  claim 14 , wherein the plate-shaped metal matrix layers are constructed of a rolled material.  
   
   
       17 . The segment according to  claim 15 , wherein the plate-shaped metal matrix layers are constructed of a rolled material.  
   
   
       18 . The segment according to  claim 16  or  17 , wherein the rolled material is a hot rolled steel plate or a cold rolled steel plate.  
   
   
       19 . A method for manufacturing a cutting segment, comprising the steps of: 
 preparing two kinds of plate-shaped metal matrices comprising plate-shaped soft metal matrices having relatively high ductility and plate-shaped hard metal matrices having relatively low ductility;    arranging diamond particles on a first soft metal matrix among the plate-shaped soft metal matrices such that the diamond particles are positioned in a row of diamond particles on a cutting surface;    stacking a second soft metal matrix on the diamond particles;    stacking a first hard metal matrix among the plate-shaped hard metal matrices on the second soft metal matrix;    stacking a third soft metal matrix on the first hard metal matrix, followed by arranging other diamond particles on the third soft metal matrix such that the other diamond particles are positioned in a row of diamond particles on the cutting surface, stacking a fourth soft metal matrix on the diamond particles, and stacking a second hard metal matrix on the fourth soft metal matrix;    repeating the above steps to prepare a stack having a desired thickness; and    heating and compressing the stack such that components constituting the stack are combined.    
   
   
       20 . The method according to  claim 19 , wherein the plate-shaped metal matrices are constructed of a material selected from the group consisting of steel, aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       21 . The method according to  claim 20 , wherein the plate-shaped hard metal matrices are constructed of steel, and the plate-shaped soft metal matrices are constructed of a material selected from the group consisting of aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       22 . The method according to  claim 19 , wherein the plate-shaped metal matrices are constructed of a rolled material, a sintered material, or a combination of the rolled material and the sintered material.  
   
   
       23 . The method according to  claim 22 , wherein the plate-shaped metal matrices are constructed of the rolled material.  
   
   
       24 . The method according to  claim 23 , wherein the rolled material is a hot rolled steel plate or a cold rolled steel plate.  
   
   
       25 . A method for manufacturing a cutting segment, comprising the steps of: 
 preparing two kinds of plate-shaped metal matrices comprising plate-shaped soft metal matrices having relatively high ductility and plate-shaped hard metal matrices having relatively low ductility;    arranging diamond particles on a first hard metal matrix among the plate-shaped hard metal matrices such that the diamond particles are positioned in a row of diamond particles on a cutting surface;    stacking a first soft metal matrix among the plate-shaped soft metal matrices on the diamond particles;    stacking a second hard metal matrix on the first soft metal matrix, followed by arranging other diamond particles on the second hard metal matrix such that the other diamond particles are positioned in a row of diamond particles on the cutting surface, and stacking a second soft metal matrix on the diamond particles;    repeating the above steps to prepare a stack having a desired thickness; and    heating and compressing the stack such that components constituting the stack are combined.    
   
   
       26 . The method according to  claim 25 , wherein each plate-shaped soft metal matrix layer of the stack has a thickness greater than that of each plate-shaped hard metal matrix layer of the stack.  
   
   
       27 . The method according to  claim 25 , wherein each plate-shaped soft metal matrix layer of the stack has a thickness smaller than that of each plate-shaped hard metal matrix layer of the stack.  
   
   
       28 . The method according to  claim 25 , wherein the plate-shaped metal matrices are constructed of a material selected from the group consisting of steel, aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       29 . The method according to  claim 28 , wherein the plate-shaped hard metal matrices are constructed of steel, and the plate-shaped soft metal matrices are constructed of a material selected from the group consisting of aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       30 . The method according to  claim 25 , wherein the plate-shaped metal matrices are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       31 . The method according to  claim 28 , wherein the plate-shaped metal matrices are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       32 . The method according to  claim 30 , wherein the plate-shaped metal matrices are constructed of a rolled material.  
   
   
       33 . The method according to  claim 31 , wherein the plate-shaped metal matrices are constructed of a rolled material.  
   
   
       34 . The method according to  claim 32 , wherein the rolled material is a hot rolled steel plate or a cold rolled steel plate.  
   
   
       35 . A method for manufacturing a cutting segment, comprising the steps of: 
 preparing two kinds of plate-shaped metal matrices comprising plate-shaped soft metal matrices having relatively high ductility and plate-shaped hard metal matrices having relatively low ductility;    arranging diamond particles on a first hard metal matrix among the plate-shaped hard metal matrices such that the diamond particles are positioned in a row of diamond particles on a cutting surface;    stacking a first soft metal matrix among the plate-shaped soft metal matrices on the diamond particles;    arranging other diamond particles on the first soft metal matrix such that the other diamond particles are positioned in a row of diamond particles on the cutting surface, followed by stacking a second hard metal matrix on the diamond particles, arranging other diamond particles on the second hard metal matrix such that the other diamond particles are positioned in a row of diamond particles on the cutting surface, and stacking a third soft metal matrix on the other diamond particles;    repeating the above steps to prepare a stack having a desired thickness; and    heating and compressing the stack such that components constituting the stack are combined.    
   
   
       36 . The method according to  claim 35 , wherein the plate-shaped metal matrices are constructed of a material selected from the group consisting of steel, aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       37 . The method according to  claim 36 , wherein the plate-shaped hard metal matrices are constructed of steel, and the plate-shaped soft metal matrices are constructed of a material selected from the group consisting of aluminum alloys, low melting point nickel alloys, copper alloys, silver alloys, and brass.  
   
   
       38 . The method according to  claim 35 , wherein the plate-shaped metal matrices are constructed of a rolled material, a sintered material, or a combination of a rolled material and a sintered material.  
   
   
       39 . The method according to  claim 38 , wherein the plate-shaped metal matrices are constructed of a rolled material.  
   
   
       40 . The method according to  claim 39 , wherein the rolled material is a hot rolled steel plate or a cold rolled steel plate.  
   
   
       41 . A cutting tool comprising the cutting segment according to  claim 1 .  
   
   
       42 . A cutting segment prepared according to the method of  claim 19 .  
   
   
       43 . A cutting tool comprising the cutting segment according to  claim 42.