Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: An abrasive tool insert if formed from a substrate having a face and a continuous abrasive layer having a center, a periphery forming a cutting edge, being integrally formed on the substrate, and defining an interface therebetween. The interface is formed in a sawtooth pattern of concentric rings extending from said center to the periphery. Radially outwardly sloping troughs extending from the center to the periphery are superimposed on the concentric rings. The profile of the interface slopes downwardly from the center to the periphery. The abrasive layer advantageously is diamond and the substrate advantageously is metal cemented carbide.

Abstract: A cutter for use on a rotary-type drag bit for earth boring is provided comprising a substantially rectangular diamond table attached to and supported by a substrate. A plurality of rod-like diamond pilings made of polycrystalline diamond is carried in the substrate, extending from the cutting face of the diamond table, through the diamond table, and into the substrate material. The diamond pilings are generally arranged in a mutually parallel configuration substantially transverse to the plane of the diamond table, and the forward ends of each diamond piling may coextensively terminate at the cutting face of the diamond table, may terminate within the diamond table, or may merely abut the rear of the diamond table. Further, the diamond table may be of smaller size than the transverse cross-section of the substrate, and at least a portion of the periphery of the substrate may then be forwardly and inwardly tapered to provide structural support to the diamond table.

Abstract: A cutting element comprises a diamond layer and a metal carbide substrate. The diamond layer and the metal carbide substrate form an egg-carton shaped interface.