On the mechanism of rock fracture with tools made of hard alloys and polycrystalline superhard materials

Abstract

When studying the process of rock fracture with tools equipped with polycrystalline superhard materials (PSHM) and hard alloys, the main regularities of the fracture mechanism, despite the significant differences in physical and mechanical properties of the used tool materials, are assumed to be identical. This approach not only reduces the efficiency of using the created rock-destroying tools, but also limits the scope of application of polycrystalline superhard materials. Experimental studies using various methods of obtaining information shown significant differences in the mechanism of rock fracture by hard alloys and polycrystalline superhard materials. The study of the zone of the pre-destroyed surface showed that when cutting rocks with PSTM, the process of destruction is carried out not only by the entire polycrystalline plate, but also by ridged diamond formed on the cutting edge and rear surface of the tool. At the same time ridged diamonds, when embedded in the rock, create high contact stresses and an additional network of microcracks interacting with microcracks formed due to the embedding of the entire cutting edge of the plate. The impact of two independent indenters simultaneously increases the zone of the pre-destruction layer in the rock mass, which leads to a more significant decrease in its strength and, as a consequence, to the intensification of the process of rock destruction by the PSTM tool. In case of wrong choice of PSTM application area and operation modes, errors in tool design and insufficient cooling, ridges are not formed on the cutting edge and back surface of the polycrystal. As a result, the polycrystalline insert works as a carbide insert and the efficiency of the PSHM tool is sharply reduced. The use of knowledge obtained as a result of the conducted research makes it possible to create tools equipped with diamond-hard-alloyed inserts, the wear resistance of which is dozens of times higher than that of similar tools made of hard alloy. For example, effective tools equipped with diamond-hard-alloyed inserts have been created and widely introduced into practice for rotary drilling of boreholes, degassing wells, anchoring of mine workings, saw stone cutting, drilling of abrasive permafrost soils and others. Keywords: polycrystalline diamonds cutters (PDC), hard alloys, pre-destruction zone, rock breaking tools, rock destruction.