Method for Manufacturing a Continuous Drill Ring for a Core Drill Bit

Abstract

A method for manufacturing a continuous drill ring for a core drill bit is disclosed. The method includes forming at least two green compacts in layers in a direction of formation between a bottom side and a top side by successively applying powder layers containing a powder mixture and diamond layers containing diamond particles that are arranged in a set pattern. The green compacts are shaped into ring segments under the effect of pressure. The ring segments are joined in a circular manner and they are sintered under the effect of heat so as to obtain a continuous drill ring.

Claims

1.-12. (canceled)

13. A method of manufacturing a continuous drill ring for a core drill bit, comprising the steps of: producing at least two green parts by successive applications of powder layers of a powder mixture and diamond layers with diamond particles disposed in a set pattern; forming the at least two green parts into respective ring segments under pressure; and annularly assembling the ring segments and sintering the ring segments under temperature action to form the continuous drill ring.

14. The method according to claim 13, wherein the continuous drill ring includes n≧1 first green parts which are formed into first ring segments and n second green parts which are formed into second ring segments and wherein the first and the second ring segments are disposed alternately one behind the other along a circumferential direction of the continuous drill ring.

15. The method according to claim 13, wherein the continuous drill ring includes first ring segments and second ring segments, wherein the first ring segments include a first powder mixture and first diamond particles, and wherein the second ring segments include a second powder mixture and second diamond particles.

16. The method according to claim 13, wherein the continuous drill ring includes a number of 2n, n≧1 equal green parts, wherein n green parts are formed under pressure action with a convex curvature to form first ring segments and n green parts are formed under pressure action with a concave curvature to form second ring segments.

17. The method according to claim 16, wherein an upper side of the first ring segments is disposed on an outer side of the continuous drill ring and wherein an upper side of the second ring segments is disposed on an inner side of the continuous drill ring, wherein the first and the second ring segments are disposed alternately one behind the other along a circumferential direction of the continuous drill ring.

18. The method according to claim 13, wherein a number of the diamond layers and a size of the diamond particles are set such that an average diamond diameter of the diamond particles is at least 45% of a quotient of a width of the continuous drill ring and the number of the diamond layers.

19. The method according to claim 13, wherein the at least two green parts are constructed from powder layers with rectangular base surfaces.

20. The method according to claim 13, wherein the at least two green parts are constructed from powder layers with pentagonal base surfaces and wherein the pentagonal base surfaces have a rectangle and a trapezoid with two right interior angles.

21. The method according to claim 13, wherein the at least two green parts are constructed from powder layers with hexagonal base surfaces and wherein the hexagonal base surfaces have a rectangle and an isosceles trapezoid.

22. The method according to claim 20, wherein a height of the trapezoid is between ⅓ and ⅚ of a total height of the respective green part.

23. The method according to claim 13, wherein the ring segments are subjected to pressure action during the sintering.

24. The method according to claim 23, wherein the ring segments are subjected to external shaping by the pressure action during the sintering.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 illustrates a core drill bit consisting of a drill ring, a cylindrical drill shaft and a receiving segment;

[0033] FIGS. 2A-C illustrate a first embodiment of a drill ring according to the invention, which is constructed from four ring segments, in a three-dimensional representation (FIG. 2A), in a cross-section perpendicular to the cylinder axis of the drill ring (FIG. 2B) and in a detail enlargement (FIG. 2C);

[0034] FIG. 3 illustrates a second embodiment of a drill ring according to the invention, which is constructed of four ring segments with water slots;

[0035] FIGS. 4A-D show the production of the drill ring of FIG. 3 of four identical green parts with a hexagonal base surface (FIG. 4A) wherein two green parts are formed into concave first ring portions and two green parts are formed into convex second ring segments (FIG. 4B), the first and second ring segments are arranged alternately one behind the other along a circumferential direction (FIG. 4C) and combined under temperature and pressure action to form a continuous drill ring (FIG. 4D); and

[0036] FIGS. 5A-C illustrate green parts with a rectangular base surface (FIG. 5A), a pentagonal base surface (FIG. 5B) and a hexagonal base surface (FIG. 5C).

DETAILED DESCRIPTION OF THE DRAWINGS

[0037] FIG. 1 shows a core drill bit 10 with a drill ring 11, a cylindrical drill shaft 12 and a receiving segment 13 with an insertion end 14. The core drill bit 10 is fastened via the insertion end 14 in the tool receptacle of a core drilling device and during drilling operation is driven by the core drilling device in a rotary direction 15 about a rotary axis 16, wherein the axis of rotation 16 is coaxial with the cylinder axis of the core drill bit 10.

[0038] The drill ring 11 is welded, brazed, or screwed to the drill shaft 12, or fixed to the drill shaft 12 in another suitable manner of attachment. In order to be able to weld the drill ring 11 with the drill shaft 12, the connecting area between the drill ring 11 and the drill shaft 12 must be made of a weldable material and must not contain diamond particle, as diamond particles cannot be welded.

[0039] FIGS. 2A-C show a first embodiment of a drill ring 21 according to the invention, which is composed of a plurality of ring segments and which can replace the drill ring 11 of the core drill bit 10 of FIG. 1. FIG. 2A shows the drill ring 21 in a three-dimensional representation, FIG. 2B shows the drill ring 21 in a cross-section perpendicular to the axis of rotation 16, and FIG. 2C shows a detail from the cross-section of FIG. 2B in the connection area between two ring segments.

[0040] The drill ring 21 is composed of four ring segments which are connected to one another at the side edges and form a closed ring in the circumferential direction (FIG. 2A). The ring segments of the drill ring 21 can be divided into two first ring segments 22.1, 22.2 and two second ring segments 23.1, 23.2 which are arranged alternately one behind the other along the circumferential direction of the drill ring 21. The first ring segments 22.1, 22.2 consist of a first powder mixture 24 and first diamond particles 25, and the second ring segments 23.1, 23.2 consist of a second powder mixture 26 and second diamond particles 27 (FIG. 2B).

[0041] FIG. 2C shows a detail from the cross-section of FIG. 2B in the connection region between the first ring segment 22.1 and the second ring segment 23.1. The first ring segment 22.1 is constructed of a number of m.sub.1 powder coatings of the first powder mixture 24 and m.sub.1 of diamond layers of the first diamond particles 25. The second ring segment 23.1 is constructed of a number of m.sub.2 powder coatings of the second powder mixture 26 and m.sub.2 diamond layers of the second diamond particles 27. In the exemplary embodiment of FIG. 2, the first ring segment 22.1 m.sub.1=3 powder layers 28.1, 29.1, 30.1 and m.sub.1=3 diamond layers 32.1, 33.1, 34.1 and the second ring segment 23.1 has m.sub.2=3 powder layers 35.1, 36.1, 37.1 and m.sub.2=3 diamond layers 38.1, 39.1, 40.1.

[0042] The first diamond particles 25 of the diamond layers 32.1-34.1 are arranged on three circular first ablation tracks 42.1, 43.1, 44.1 with different first radii of curvature R.sub.1i, i=1, 2, 3. The second diamond particles 27 of the diamond layers 38.1-40.1 are arranged on three circular second ablation tracks 45.1, 46.1, 47.1 with different second radii of curvature R.sub.2i, i=1, 2, 3. The selection of the materials for the first and second powder mixtures 24, 26, the selection of the diamond distribution and size for the first and second diamond particles 25, 27, and the number m.sub.1, m.sub.2 of the diamond layers and the ablation tracks make it possible to adapt the drill ring 21 to different substrates to be processed.

[0043] The ring segments 22.1, 22.2, 23.1, 23.2 are constructed in layers from three powder layers and three diamond layers. In a layered configuration, the powder mixture is filled into a matrix and forms the first powder layer. The diamond particles are placed in a set pattern as a first diamond layer on the first powder layer. In order to densify the layer structure, intermediate pressing can take place after placing the diamond particles. Subsequently, the powder mixture is filled into the matrix and forms the second powder layer. The diamond particles are placed in a set pattern as a second diamond layer on or in the second powder layer. This process is repeated until the desired height of the green part is reached. A diamond layer is used as the last layer.

[0044] FIG. 3 shows a second embodiment of a drill ring 51 according to the invention which consists of four ring segments and can replace the drill ring 11 of the core drill bit 10. Four water slots 52.1, 52.2, 52.3, 52.4 are formed between the ring segments, via which a cooling liquid is transported to the processing site. The ring segments are arranged in such a way that the drill ring 51 alternately has a diamond-coated area 55 and a diamond-free area 56 on the inside 53 and on the outside 54.

[0045] The water slots 52.1-52.4 extend over a height of approximately ⅔ of the total height of the drill ring 51. In order to ensure the operational capability of the drill ring 51 even if the water slots 52.1-52.4 are removed, two ring segments have a bore 57.1, 57.2 via which cooling liquid is transported to the processing site.

[0046] FIGS. 4A-D show the production of the drill ring 51 from four identical green parts 61 with a hexagonal base surface (FIG. 4A). Two green parts 61 are formed into concave first ring segments 62 and two green parts 61 are formed into convex second ring segments 63 (FIG. 4B). The first and second ring segments 62, 63 are arranged alternately one behind the other along a circumferential direction of the drill ring 51 (FIG. 4C) and sintered under a temperature and pressure action to form a continuous drill ring (FIG. 4D).

[0047] FIG. 4A shows the construction of the green part 61 which has been produced in powder layers from a powder mixture 64 and diamond layers of diamond particles 65. The green part 61 consists of an attachment area 66, which is also referred to as the footer zone, and a processing area 67, which is also referred to as the matrix zone. The attachment area 66 and the processing area 67 can be constructed jointly in layers, wherein no diamond particles 65 are placed in the connecting area. As an alternative, the attachment area can be produced as a separate area and can be connected to the processing area during sintering.

[0048] The base surface of the green parts 61 is hexagonal and consists of a rectangle 68 and an adjacent isosceles trapezoid 69, wherein the attachment area 66 of the green part 61 is located in the rectangle 68. In the region of the legs of the trapezoid, the water slots 52.1-52.4 are formed during sintering by additional pressure action, via which the cooling liquid is transported to the processing site. The height h of the trapezoid 69 in the green part defines the height of the water slot 52.1-52.4. In the exemplary embodiment, the height h of the trapezoid 69 corresponds to half the total height H of the green part 61.

[0049] FIG. 4B shows the first ring segment 62, which was created under pressure action with a convex curvature from the green part 61 of FIG. 4A, and the second ring segment 63, which was created under pressure action with a concave curvature from the green part 61 of FIG. 4A.

[0050] In the case of the first ring segment 62, the upper side of the green part 61, which is formed as a diamond layer, is arranged on the outer side 54, and in the second ring segment 63, the upper side of the green part 61 is arranged on the inner side 53.

[0051] The first ring segment 62 has first and second side edges 71, 72 which are joined to a first and second side edge 73, 74 of the second ring segment 63 during sintering. The first side edge 71 of the first ring segment 62 is connected to the second side edge 74 of the second ring segment 63, and the second side edge 72 of the first ring segment 62 is connected to the first side edge 73 of the second ring segment 63. In the drill ring 51 with two first and second ring segments 62.1, 62.2, 63.1, 63.2 the first and second side edges of the adjacent ring segments are connected to each other.

[0052] FIG. 4C shows the first ring segments 62.1, 62.2 and second ring segments 63.1, 63.2 arranged alternately one behind the other along a circumferential direction of the drill ring 51. The ring segments 62.1, 63.1, 62.2, 63.2 form a continuous drill ring and, in the embodiment shown in FIG. 4C, are processed further in a hot press. FIG. 4D shows the continuous drill ring after hot pressing. During hot pressing, the ring segments 62.1, 63.1, 62.2, 63.2 are subjected to temperature and pressure action. The temperature action ensures that the powder mixture is sintered in the ring segments and the ring segments are connected to one another at the side edges. Pressure in the axial direction, i.e., parallel to the axis of rotation of the drill ring, causes compression of the ring segments, which leads to densification of the ring segments. Hot pressing is carried out in a die which defines the final shape of the drill ring.

[0053] In the method according to the invention, a drill ring is constructed from a plurality of green parts, which are formed into ring segments and are sintered to form a continuous drill ring; polygonal base surfaces are a suitable geometry for the green parts. FIGS. 5A-C show green parts 81 with a rectangular base surface (FIG. 5A), green parts 82 with a pentagonal base surface (FIG. 5B) and green parts 83 with a hexagonal base surface (FIG. 5C).

[0054] The rectangular base surface 84 of the green parts 81 represents the simplest geometry for producing drill rings from a plurality of ring segments. In the exemplary embodiment of FIG. 5A, three identical green parts 81.1, 81.2, 81.3 are used to produce a continuous drill ring.

[0055] The pentagonal base surface of the green parts 82 can be divided into a rectangle 85 and a trapezoid 86 with two right interior angles. In the region of the inclined leg of the trapezoid, a water slot 87 is produced during sintering with the adjacent ring segment. A number of n water slots 87 are produced with such a pentagonal base surface for a drill ring with 2n, n≧1 ring segments.

[0056] The hexagonal base surface of the green parts 83 can be divided into a rectangle 88 and an isosceles trapezoid 89. In the region of the inclined trapezoidal legs, water slots 90 are produced during sintering with the adjacent ring segments. With such a hexagonal base surface, a number of n water slots 90 are generated in a drill ring with n, n≧2 ring segments.