Ballistic polycrystalline mining tool and method for making the same

Abstract

A cutting element for a mining or drilling tool provides a body that provides a recess for receiving a ballistic insert. The ballistic insert provides a top portion having a shape characterized by a first radius (R1) and a second radius (R2), and R1 and R2 have a tangential relationship. A sleeve may be positioned on the body to protect the body from erosion.

What is claimed is: 
     
         1 . A cutting element for mining a formation, the cutting element comprising:
 a ballistic insert that provides
 a top portion comprising a first section forming a tip of the ballistic insert and a second section below said first section, wherein the first section has a shape characterized by a first radius (R1), the second section has a shape characterized by a second radius (R2), and R1 and R2 have a tangential relationship, and 
 a bottom portion supporting the top portion. 
   
     
     
         2 . The cutting element of  claim 1 , further comprising a body providing a recess for receiving said ballistic insert. 
     
     
         3 . The cutting element of  claim 2 , further comprising a sleeve that is positioned on the body, wherein the sleeve protects the body from erosion. 
     
     
         4 . The cutting element of  claim 2 , wherein the body is steel. 
     
     
         5 . The cutting element of  claim 1 , wherein the ballistic insert is solid body comprising a mixture of polycrystalline diamond (PCD) and cubic boron nitride (CBN). 
     
     
         6 . The cutting element of  claim 1 , wherein the ballistic insert is polycrystalline diamond (PCD), cubic boron nitride (CBN), cobalt, carbide, tungsten, or a combination thereof. 
     
     
         7 . The cutting element of  claim 1 , wherein the top portion of said ballistic insert is polycrystalline diamond (PCD), cubic boron nitride (CBN), or a combination thereof. 
     
     
         8 . The cutting element of  claim 1 , wherein the bottom portion of said ballistic insert is a carbide substrate. 
     
     
         9 . The cutting element of  claim 3 , wherein the sleeve is a carbide. 
     
     
         10 . The cutting element of  claim 1 , wherein a tip of the top portion of said ballistic insert provides a concave apex. 
     
     
         11 . The cutting element of  claim 1 , wherein R2 is between 0.02 to 0.30 inches or 0.5 to 7.6 mm. 
     
     
         12 . The cutting element of  claim 1 , wherein R1 is between 1.2 to 10 inches or 30.5 to 254 mm. 
     
     
         13 . The cutting element of  claim 1 , wherein a ratio of R1 to R2 (R1/R2) is equal to or greater than 18. 
     
     
         14 . The cutting element of  claim 1 , wherein the ballistic insert provides one or more depressions for receiving an insert. 
     
     
         15 . The cutting element of  claim 2 , wherein the body provides one or more openings for receiving an insert. 
     
     
         16 . The cutting element of  claim 1 , wherein a height of said top portion is equal to or greater than 1 inch.