Tool component

A tool for engaging a work material, comprising:

• a body defining a working surface;
• and
• a tool component including a cemented carbide support body having a top surface;
• and an abrasive compact bonded to the support body, and including a polycrystalline mass of ultra-hard abrasive particles bonded into a hard conglomerate and containing at least 70 percent by volume of ultra-hard abrasive particles, the polycrystalline mass including:
• (i) first and second major surfaces on opposite sides of the polycrystalline mass, the first major surface forming a cutting edge or point to engage and cut the work material, the second major surface being bonded to the support body, and
• (ii) upper and lower layers joined together by an interlocking, common boundary,
• the upper layer comprising ultra-hard abrasive particles, extending upward from said common boundary and over the top surface of the carbide support body, and forming the first major surface of the polycrystalline mass,
• the lower layer comprising particles selected from the group consisting of (a) ultra-hard abrasive particles coarser than the abrasive particles used to form the upper layer, and (b) a mixture of ultra-hard abrasive particles and carbide particles,
• the lower layer extending downward from said common boundary and forming the second major surface of the polycrystalline mass;
• wherein the tool component is recessed in the working surface with the cutting edge or point of the tool component located above the working surface, with the common boundary joining the upper and lower layers of the polycrystalline mass also located above the working surface and with the lower layer of the polycrystalline mass extending below the top surface of the support body and surrounding the support body beneath the working surface;
• wherein the working surface and the abrasive compact completely enclose the carbide support body to protect the carbide support body from cut pieces of the work material.