Abstract:
A cutter assembly and a method of making the cutter assembly are disclosed. A method of fabricating a cutting element having at least one island structure in at least one pocket of a substrate may comprise steps of building a substrate green body with at least one pocket; building at least one island green body; assembling the at least one island green body and the substrate green body with at least one pocket in the substrate green body to form a green body assembly; and subjecting the green body assembly to a final fabrication process to form the said cutting element.

Description:
FIELD 
       [0001]    The present disclosure relates to a cutter assembly with at least one island. 
         [0002]    More particularly, the present disclosure relates a cutter assembly that can include a substrate and at least one island disposed in the substrate. 
       BACKGROUND 
       [0003]    In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicants expressly reserve the right to demonstrate that such structures and/or methods do not qualify as prior art. 
         [0004]    Cutters can be subject to abrasion which can shorten the working life of the cutter. Thus, there is a need in the art for a cutter assembly that can provide higher abrasion resistance or longer cutter life. 
       SUMMARY 
       [0005]    Exemplary embodiments provide a cutter assembly and a method of manufacturing a cutter assembly. The cutter assembly includes a substrate and at least one island. The substrate includes a surface circumscribed by a peripheral edge, a flank surface extending from the peripheral edge, and at least one pocket with an opening on the surface and spaced apart from the peripheral edge. The at least one pocket extends from the opening towards an interior of the substrate. The at least one island is in the at least one pocket, and the at least one island includes a cutting surface that is exposed by the opening of the at least one pocket. 
         [0006]    In another construction, the cutter assembly includes a substrate and at least one island. The substrate includes a surface circumscribed by a peripheral edge, a flank surface extending from the peripheral edge, and at least one pocket with an opening on the surface and the flank surface. The at least one pocket extends from the opening towards an interior of the substrate, and the at least one island is in the at least one pocket so that the at least one island protrudes beyond the flank surface. The at least one island includes a cutting surface that is exposed by the opening of the at least one pocket. 
         [0007]    In another construction, the cutter assembly includes a substrate and at least one island. The substrate includes a surface circumscribed by a peripheral edge, a flank surface extending from the peripheral edge, and at least one pocket disposed in the substrate away from the surface and the flank surface. The at least one island is disposed in the at least one pocket, and the at least one island includes a cutting surface. 
         [0008]    The method of manufacturing a cutter assembly includes: providing at least one island; treating the at least one island; providing a substrate; forming a surface circumscribed by a peripheral edge on the substrate; forming at least one pocket with an opening disposed on the surface and spaced apart from the peripheral edge, the at least one pocket extending from the opening towards an interior of the substrate and having a shape that engages with the at least one island; disposing the at least one island in the at least one pocket; and coupling the at least island to the at least one pocket. 
         [0009]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0010]    The following detailed description can be read in connection with the accompanying drawings in which like numerals designate like elements and in which: 
           [0011]      FIG. 1  is a perspective view of a cutter assembly with at least one island in accordance with an embodiment. 
           [0012]      FIG. 2   a  is a side view of the cutter assembly with at least one island shown in  FIG. 1  according to one embodiment. 
           [0013]      FIG. 2   b  is a side view of the cutter assembly with at least one island shown in  FIG. 1  according to another embodiment. 
           [0014]      FIG. 3   a  is a sectional side view of the cutter assembly with at least one island shown in  FIG. 1  according to one embodiment. 
           [0015]      FIG. 3   b  is a sectional side view of the cutter assembly with at least one island shown in  FIG. 1  according to another embodiment. 
           [0016]      FIG. 4  is a top view of the cutter assembly with at least one island shown in  FIG. 1 . 
           [0017]      FIG. 5  is a perspective view of a cutter assembly with at least one island of an alternate construction. 
           [0018]      FIG. 6  is a side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 5 . 
           [0019]      FIG. 7  is a sectional side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 5 . 
           [0020]      FIG. 8  is a perspective view of a cutter assembly with at least one island of an alternate construction. 
           [0021]      FIG. 9  is a side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 8 . 
           [0022]      FIG. 10  is a sectional side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 8 . 
           [0023]      FIG. 11  is a perspective view of a cutter assembly with at least one island of an alternate construction. 
           [0024]      FIG. 12  is a side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 11 . 
           [0025]      FIG. 13  is a sectional side view of the cutter assembly with at least one island of an alternate construction shown in  FIG. 11 . 
           [0026]      FIG. 14  is a top view of a cutter assembly with at least one island of an alternate construction. 
           [0027]      FIG. 15  is a top view of a cutter assembly with at least one island of an alternate construction. 
           [0028]      FIG. 16  is a top view of a cutter assembly with at least one island of an alternate construction. 
           [0029]      FIG. 17  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction, 
           [0030]      FIG. 18  is a side view of the cutter assembly with at least one island shown in  FIG. 17 . 
           [0031]      FIG. 19  is a sectional side view of the cutter assembly with at least one island shown in  FIG. 17 . 
           [0032]      FIG. 20  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0033]      FIG. 21  is a side view of the cutter assembly with at least one island shown in  FIG. 20 . 
           [0034]      FIG. 22  is a sectional side view of the cutter assembly with at least one island shown in  FIG. 20 . 
           [0035]      FIG. 23  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0036]      FIG. 24  is a side view of the cutter assembly with at least one island shown in  FIG. 23 . 
           [0037]      FIG. 25  is a sectional side view of the cutter assembly with at least one island shown in  FIG. 23 . 
           [0038]      FIG. 26  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0039]      FIG. 27  is a side view of the cutter assembly with at least one island shown in  FIG. 26 . 
           [0040]      FIG. 28  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 26 . 
           [0041]      FIG. 29  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0042]      FIG. 30  is a side view of the cutter assembly with at least one island shown in  FIG. 29 . 
           [0043]      FIG. 31  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 29 . 
           [0044]      FIG. 32  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0045]      FIG. 33  is a side view of the cutter assembly with at least one island shown in  FIG. 32 . 
           [0046]      FIG. 34  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 32 . 
           [0047]      FIG. 35  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0048]      FIG. 36  is a side view of the cutter assembly with at least one island shown in  FIG. 35 . 
           [0049]      FIG. 37  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 35 . 
           [0050]      FIG. 38  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0051]      FIG. 39  is a side view of the cutter assembly with at least one island shown in  FIG. 38 . 
           [0052]      FIG. 40  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 38 . 
           [0053]      FIG. 41  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0054]      FIG. 42  is a side view of the cutter assembly with at least one island shown in  FIG. 41 . 
           [0055]      FIG. 43  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 41 . 
           [0056]      FIG. 44  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0057]      FIG. 45  is a side view of the cutter assembly with at least one island shown in  FIG. 44 . 
           [0058]      FIG. 46  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 44 . 
           [0059]      FIG. 47  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0060]      FIG. 48  is a side view of the cutter assembly with at least one island shown in  FIG. 47 . 
           [0061]      FIG. 49  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 47 . 
           [0062]      FIG. 50  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0063]      FIG. 51  is a side view of the cutter assembly with at least one island shown in  FIG. 50 . 
           [0064]      FIG. 52  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 50 . 
           [0065]      FIG. 53  is a perspective view of a cutter assembly with at least one island in accordance with an alternate construction. 
           [0066]      FIG. 54  is a side view of the cutter assembly with at least one island shown in  FIG. 53 . 
           [0067]      FIG. 55  is an exploded, sectional side view of the cutter assembly with at least one island shown in  FIG. 53 . 
           [0068]      FIG. 56  is a flowchart of a method of manufacturing a cutter with at least one island in accordance with an embodiment. 
           [0069]      FIG. 5  is a flowchart of a method of manufacturing a cutter with at least one island in accordance with an alternate construction. 
       
    
    
     DETAILED DESCRIPTION 
       [0070]    Referring to  FIGS. 1-56 , embodiments can provide a cutter assembly  100 ,  200 ,  300 ,  400 ,  500 ,  600 ,  700 ,  800 ,  900 ,  1000 ,  1100 ,  1200 ,  1300 ,  1400 ,  1500 ,  1600 ,  1700 ,  1800 , and  1900  with higher abrasion resistance, longer life, better toughness, and/or thermal stability. Embodiments can utilize, for example, fully leached polycrystalline diamond, which can have significantly better thermal stability up to approximately 1,000° C. When fully leached polycrystalline diamond is used and coupled with, for example, a cobalt-tungsten carbide, embodiments can also provide higher strength at the interface between fully leached polycrystalline diamond and cobalt-tungsten carbide. Embodiments can also provide a method of manufacturing a cutter assembly  100  . . .  1900 , that includes, for example, a fully leached polycrystalline diamond, which is coupled to, for example, cobalt-tungsten carbide securely and economically. 
         [0071]    The cutter assembly  100  . . .  1900  can comprise a substrate  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 ,  802 ,  902 ,  1002 ,  1102 ,  1202 ,  1302 ,  1402 ,  1502 ,  1602 ,  1702 ,  1802 , and  1902  at least one island  150   a,    150   b,    250 ,  350 ,  450 ,  550 ,  650 ,  750 ,  850 ,  950 ,  1050 ,  1150 ,  1250 ,  1350 ,  1450 ,  1550 ,  1650 ,  1750 ,  1850 , and  1950  disposed in the substrate  102  . . .  1902 . 
         [0072]    The at least one island  150   a  . . .  1950  can be disposed in the substrate  102  . . .  1902 . The substrate  102  . . .  1902  can have a surface  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804 ,  904 ,  1004 ,  1104 ,  1204 ,  1304 ,  1404 ,  1504 ,  1604 ,  1704 ,  1804 , and  1904 . The surface  104  . . .  1904  can receive one or more of the islands  150   a  . . .  1950 . In other constructions of the cutter assembly  100  . . .  1900 , the substrate  102  . . .  1902  can have a plurality of surfaces  104  . . .  1904 , and each one of the plurality of surfaces  104  . . .  1904  can receive one or more of the islands  150   a  . . .  1950 . 
         [0073]    The at least one island  150   a  . . .  1950  can be disposed in the substrate  102  . . .  1902  such that the at least one island  150   a  . . .  1950  is spaced apart from another island  150   a  . . .  1950 . 
         [0074]    The substrate  102  . . .  1902  can be made from tungsten carbide cobalt (W—Co), a diamond-silicon carbide composite material, binderless carbide, or some other suitable materials. One example of a diamond-silicon carbide composite material is commercially available as Versimax. Binderless can refer to tungsten carbide composites with less amount of metal binder phase than a metal-WC composite cermet material, such as Co—WC composite cermet material, Ni—WC composite cermet material, Fe—WC composite cermet material, and the like. Examples of binderless carbide can include a cermet of tungsten carbide binded with a molybdenum metal and a low metal content of about 1 wt % to about 2 wt %. Binderless carbide can also include a type of tungsten carbide sintered with low metal content, such as about 1 wt % to about 2 wt %, and a binding phase that is mainly eta-phase (Co 3 W 3 O 6 ). 
         [0075]    The at least one island  150   a  . . .  1950  can be made from polycrystalline diamond (PCD), diamond, cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), or a diamond-silicon carbide composite material. One example of a diamond-silicon carbide composite material is commercially available as Versimax. 
         [0076]    The at least one island  150   a  . . .  1950  can be a thermally stable material. However, in other constructions of the cutter assembly  100  . . .  1900 , the at least one island  150   a  . . .  1950  can be made from a material that is thermally stable. 
         [0077]    If the at least one island  150   a  . . .  1950  is made from PCD, the at least one island  150   a  . . .  1950  made from PCD can be fully leached, partially leached, or unleached. In a construction of the cutter assembly  100  that includes fully leached PCD, the cutter assembly  100  . . .  1900  can provide thermal stability. 
         [0078]    The at least one island  150   a  . . .  1950  can be coated. The coating material can comprise a metal, a metal alloy, a compound of the metal and/or combination of series thereof. The metal may comprise tungsten, titanium, niobium, zirconium, tantalum, vanadium, chromium, or molybdenum. The coating can be applied upon at least a portion of the at least one island  150   a  . . .  1950  via a coating method that can comprise physical vapor deposition, chemical vapor deposition, sputtering, evaporation, electroless plating, electroplating, and/or combinations or series thereof. The coating layer can have a thickness of about 0.1 μm to about 100 μm. 
         [0079]    The at least one island  150   a  . . .  1950  can have a casing. In some constructions of the cutter assembly  100  . . .  1900 , the at least one island  150   a  . . .  1950  can be press fit into the casing. The casing can be a metal casing. The metal casing can provide a medium between the at least one island  160   a  . . .  1950  and the substrate  102  . . .  1902  and can help to manage the deformation and stress condition between the at least one island  150   a  . . .  1950  and the substrate  102  . . .  1902 . The casing layer can have a thickness of about 0.1 μm to about 100 μm. In another embodiment the at least one island  150  . . .  1950  can be directly fitted into the substrate  102  . . .  1902 , and thus, no casing may be needed. 
         [0080]    The at least one island  150   a  . . .  1950  can be coupled to the substrate  102  . . .  1902 . The at least one island  150   a  . . .  1950  can be coupled to the substrate  102  . . .  1902  by, for example, gluing, brazing, bonding, welding, clamping, mechanical locking, or some other suitable coupling. An embodiment can include a method for brazing an island. The method for brazing the island can comprise: brazing a coated island to a substrate, wherein the island material can comprise a cemented carbide, a polycrystalline cubic boron nitride (cBN) superabrasive, a ceramic, a metal, a metal ahoy, and/or combinations thereof; a substrate; an optional coating layer, wherein the coating layer may be in direct contact with the island or the substrate, and the coating layer may be continuous or discontinuous. The brazing step can comprise: heating at least one of the braze metal, the coating layer, and the substrate, to a temperature above a liquidus temperature sufficient to melt the braze metal; and bringing the melted braze metal into contact with both the island and the substrate and optionally the coating to form a braze metal layer. The braze metal layer can comprise silver, copper, magnesium, nickel, zinc, palladium, chromium, boron, titanium, tin, silicon, or an alloy or composite thereof. The substrate can comprise a second island, and the second island materials can comprise a cemented carbide, a polycrystalline cubic boron nitride (cBN) superabrasive, a ceramic, a metal, a metal alloy, and/or combinations thereof. In an embodiment of the method, the first and second island material may each independently comprise a single crystal diamond, a chemical vapor deposition diamond, a silicon carbide bonded diamond composite, a cobalt-polycrystalline diamond composite, a thermally-stable diamond composite, and/or combinations thereof. In an embodiment of the method, the coating metal may comprise tungsten, titanium, niobium, zirconium, tantalum, vanadium, chromium, molybdenum and/or combinations thereof. In an embodiment of the method, the coating metal may comprise at least one refractory metal and, optionally, at least one non-refractory metal. In an embodiment of the method, the refractory metal carbide may comprise at least one metal of the refractory metal or the refractory metal alloy. In an embodiment of the method, the refractory metal layer may have a thickness of about 0.1 μm to about 100 μm. In an embodiment of the method, the brazing step may comprise applying a heat source to heat at least the braze metal to the temperature of from about 500° C. to about 1000° C. In an embodiment of the method, the heat source may be at least one of a torch, a furnace, a microwave device, an arc welder, a laser, or an induction coil. In an embodiment of the method, the heat source may be an induction coil; and the temperature is maintained from about 700° C. to about 900° C. for a time period of at least about 5 seconds. In an embodiment of the method, the brazing step may be performed under ambient air pressure and in air. In another embodiment of the method, the brazaing step may be performed under flowing or stagnant inert protection gas or gas mixtures. 
         [0081]    The substrate  102  . . .  1902  can have any suitable shape. For example, in  FIGS. 1-13 ,  17 - 34 , and  38 - 52 , the substrate  102  . . .  402 ,  802  . . .  1302 , and  1502  . . .  1802  can have a generally cylindrical shape. In other constructions of the cutter assembly  100  . . .  1900 , the substrate  102  . . .  1902  can have a shape that is not generally cylindrical. For example,  FIGS. 35-37  and  53 - 55  show a substrate  1402  and  1902  that includes a concavity. 
         [0082]    The at least one island  150   a  . . .  1950  can have any suitable shape. As shown in  FIGS. 1 to 13 ,  23 - 28 , and  38 - 55 , the at least one island  150 ,  250 ,  350 ,  450 ,  1050 ,  1150 ,  1550 ,  1650 ,  1750 ,  1850 , and  1950  can have a generally cylindrical shape. As shown in  FIGS. 14-19 , the at least one island  550 ,  650 ,  750 , and  850  can have a cross-sectional shape that is not substantially circular. As shown in  FIGS. 29-37 , the at least one island  1250 ,  1350 , and  1450  can be have a ring shape or be a plurality of rings. 
         [0083]    Turning to  FIGS. 1-4 , the cutter assembly  100  can have a substrate  102  with a generally cylindrical shape. The substrate  102  can have a surface  104 . The surface  104  can be an end surface. The substrate  102  can also have a flank surface  106 . The surface  104  can be substantially perpendicular to the flank surface  106 . The flank surface  106  can meet the surface  104  so that a common boundary between the surface  104  and the flank surface  106  defines a peripheral edge  108  of the surface  104 . The surface  104  can be a substantially planar surface. The flank surface  106  can provide the substrate  102  with a generally circular cross-sectional shape. In other embodiments, the substrate  102  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0084]    The substrate  102  can include a pocket  110 . The pocket  110  can have an opening  112 . The opening  112  can be disposed on the surface  104  of the substrate  102 . The pocket  110  can extend from the opening  112  on the surface  104  to an interior of the substrate  102 . The pocket  110  can have a shape that can receive at least a portion of the at least one island  150 . 
         [0085]    Referring to  FIGS. 2   a  and  3   a , the at least one island  150   a  can have a generally cylindrical shape. The at least one island  150   a  can have an end surface  152 , a flank surface  154 , and an opposite end surface  156 . The end surface  152  can be a planar surface that can be substantially perpendicular to the flank surface  154 . The opposite end surface  156  can also be a planar surface that is substantially perpendicular to the flank surface  154 . The at least one island  150   a  can be disposed in the pocket  110  of the substrate  102 . The at least one island  150   a  can be disposed in the pocket  110  of the substrate  102  so that the end surface  152  of the at least one island  150   a  is substantially co-planar with surface  104  of the substrate  102 , the flank surface  154  extends into the interior of the substrate  102 , and the opposite end surface  156  is disposed within the interior of the substrate  102 . The end surface  152  can be a cutting surface, or the end surface  152  and the flank surface  154  together can form a cutting surface. 
         [0086]    Referring to  FIGS. 2   b  and  3   b , the at least one island  150   b  can have a generally cylindrical shape. The at least one island  150   b  can have an end surface  152 , a flank surface  154 , and an opposite end surface  156 . However, unlike the at least one island  150   a,  the at least one island  150   b  can also include an edge  158 . The edge  158  can be rounded or a chamfer. The edge  150  can relieve stress. The end surface  152  can be a planar surface that can be substantially perpendicular to the flank surface  154 . The opposite end surface  156  can also be a planar surface that is substantially perpendicular to the flank surface  154 . The at least one island  150   b  can be disposed in the pocket  110  of the substrate  102 . The at least one island  150   b  can be disposed in the pocket  110  of the substrate  102  so that the end surface  152  of the at least one island  150   a  is substantially co-planar with surface  104  of the substrate  102 , the flank surface  154  extends into the interior of the substrate  102 , and the opposite end surface  156  is disposed within the interior of the substrate  102 . Because the at least one island  150   b  can include the edge  158 , the pocket  110  can include a complementary shape that can receive the edge  158 . The end surface  152  can be a cutting surface, or the end surface  152  and the flank surface  154  together can form a cutting surface. 
         [0087]    In the construction shown in  FIGS. 1-4 , there are three islands  150  spaced equally apart from each other and equidistant from a center of the surface  104 . However, in other constructions, there may be more or less than the three islands  150  shown. Also, the exact position of each of the island  150  with respect to each other or the center of the surface  104  can be different from that shown in  FIGS. 1-4 . Also, the exact size of the islands  150  can be different. The exact number and size of islands  150  and the exact position for each of the islands  150  can depend on, for example, the application of the cutter assembly  100 . 
         [0088]    Turning to  FIGS. 5-7 , the cutter assembly  200  can have a substrate  202  with a generally cylindrical shape. The substrate  202  can have a surface  204 . The surface  204  can be an end surface. The substrate  202  can also have a flank surface  206 . The surface  204  can be substantially perpendicular to the flank surface  206 . The flank surface  206  can meet the surface  204  so that a common boundary between the surface  204  and the flank surface  206  defines a peripheral edge  208  of the surface  204 . The surface  204  can be a substantially planar surface. The flank surface  206  can provide the substrate  202  with a generally circular cross-sectional shape. In other embodiments, the substrate  202  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0089]    The substrate  202  can include a pocket  210 . The pocket  210  can have an opening  212 . The opening  212  can be disposed on the surface  204  of the substrate  202 . The pocket  210  can extend from the opening  212  on the surface  204  to an interior of the substrate  202 . The pocket  210  can have a shape that can receive at least a portion of the at least one island  250 . 
         [0090]    The at least one island  250  can have a generally cylindrical shape. The at least one island  250  can have an end surface  252 , a flank surface  254 , and an opposite end surface  256 . Unlike the at least one island  150  shown in  FIGS. 1-4 , the end surface  252  can include a dome shape. The opposite end surface  256  can be a planar surface that can be substantially perpendicular to the flank surface  254 . The at least one island  250  can be disposed in the pocket  210  of the substrate  202 . The at least one island  250  can be disposed in the pocket  210  of the substrate  202  so that the end surface  252  of the at least one island  250  protrudes away from the surface  204  of the substrate  202  and away from the interior of the substrate  202 , the flank surface  254  extends into the interior of the substrate  202 , and the opposite end surface  256  is disposed within the interior of the substrate  202 . The end surface  252  can be a cutting surface, or the end surface  252  and the flank surface  254  together can form a cutting surface. 
         [0091]    In the construction shown in  FIGS. 5-7 , there are three islands  250  spaced equally apart from each other and equidistant from a center of the surface  204 . However, in other constructions, there may be more or less than the three islands  250  shown. Also, the exact position of each of the island  250  with respect to each other or the center of the surface  204  can be different from that shown in  FIGS. 5-7 . Also, the exact size of the islands  250  can be different. The exact number and size of islands  250  and the exact position for each of the islands  250  can depend on, for example, the application of the cutter assembly  200 . 
         [0092]    Turning to  FIGS. 8-10 , the cutter assembly  300  can have a substrate  302  with a generally cylindrical shape. The substrate  302  can have a surface  304 . The surface  304  can be an end surface. The substrate  302  can also have a flank surface  306 . The surface  304  can be substantially perpendicular to the flank surface  306 . The flank surface  306  can meet the surface  304  so that a common boundary between the surface  304  and the flank surface  306  defines a peripheral edge  308  of the surface  304 . The surface  304  can be a substantially planar surface. The flank surface  306  can provide the substrate  302  with a generally circular cross-sectional shape. In other embodiments, the substrate  302  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0093]    The substrate  302  can include a pocket  310 . The pocket  310  can have an opening  312 . The opening  312  can be disposed on the surface  304  of the substrate  302 . The pocket  310  can extend from the opening  312  on the surface  304  to an interior of the substrate  302 . The pocket  310  can have a shape that can receive at least a portion of the at least one island  350 . 
         [0094]    The at least one island  350  can have a generally cylindrical shape. The at least one island  350  can have an end surface  352 , a flank surface  354 , and an opposite end surface  356 . Unlike the at least one island  150  shown in  FIGS. 1-4 , the end surface  352  can include be a planar surface that is at an angle with respect to the flank surface  354  and not generally perpendicular to the flank surface  354 . The end surface  352  can be angled such that its planar surface slopes downward toward a center of the surface  304 . The opposite end surface  356  can be a planar surface that can be substantially perpendicular to the flank surface  354 . The at least one island  350  can be disposed in the pocket  310  of the substrate  302 . The at least one island  350  can be disposed in the pocket  310  of the substrate  302  so that the end surface  352  of the at least one island  350  protrudes away from the surface  304  of the substrate  302  and away from the interior of the substrate  302 , the flank surface  354  extends into the interior of the substrate  302 , and the opposite end surface  356  is disposed within the interior of the substrate  302 . The end surface  352  can be a cutting surface, or the end surface  352  and the flank surface  354  together can form a cutting surface. 
         [0095]    In the construction shown in  FIGS. 8-10 , there are three islands  350  spaced equally apart from each other and equidistant from a center of the surface  304 . However, in other constructions, there may be more or less than the three islands  350  shown. Also, the exact position of each of the island  350  with respect to each other or the center of the surface  304  can be different from that shown in  FIGS. 8-10 . Also, the exact size of the islands  350  can be different. The exact number and size of islands  350  and the exact position for each of the islands  350  can depend on, for example, the application of the cutter assembly  300 . 
         [0096]    Turning to  FIGS. 11-13 , the cutter assembly  400  can have a substrate  402  with a generally cylindrical shape. The substrate  402  can have a surface  404 . The surface  404  can be an end surface. The substrate  402  can also have a flank surface  406 . The surface  404  can be substantially perpendicular to the flank surface  406 . The flank surface  406  can meet the surface  404  so that a common boundary between the surface  404  and the flank surface  406  defines a peripheral edge  408  of the surface  404 . The surface  404  can be a substantially planar surface. The flank surface  406  can provide the substrate  402  with a generally circular cross-sectional shape. In other embodiments, the substrate  402  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0097]    The substrate  402  can include a pocket  410 . The pocket  410  can have an opening  412 . The opening  412  can be disposed on the surface  404  of the substrate  402 . The pocket  410  can extend from the opening  412  on the surface  404  to an interior of the substrate  402 . The pocket  410  can have a shape that can receive at least a portion of the at least one island  450 . 
         [0098]    The at least one island  450  can have a generally cylindrical shape. The at least one island  450  can have an end surface  452 , a flank surface  454 , and an opposite end surface  456 . Unlike the at least one island  150  shown in  FIGS. 1-4 , the end surface  452  can include a concavity that curves toward the opposite surface  456 . The opposite end surface  456  can be a planar surface that can be substantially perpendicular to the flank surface  454 . The at least one island  450  can be disposed in the pocket  410  of the substrate  402 . The at least one island  450  can be disposed in the pocket  410  of the substrate  402  so that the end surface  452  of the at least one island  450  protrudes away from the surface  404  of the substrate  402  and towards the interior of the substrate  402 , the flank surface  454  extends into the interior of the substrate  402 , and the opposite end surface  456  is disposed within the interior of the substrate  402 . The end surface  452  can be a cutting surface, or the end surface  452  and the flank surface  454  together can form a cutting surface. 
         [0099]    In the construction shown in  FIGS. 11-13 , there are three islands  450  spaced equally apart from each other and equidistant from a center of the surface  404 . However, in other constructions, there may be more or less than the three islands  450  shown. Also, the exact position of each of the island  450  with respect to each other or the center of the surface  404  can be different from that shown in  FIGS. 11-13 . Also, the exact size of the islands  450  can be different. The exact number and size of islands  450  and the exact position for each of the islands  450  can depend on, for example, the application of the cutter assembly  400 . 
         [0100]    Turning to  FIG. 14 , the cutter assembly  500  can have a substrate  502  with a generally cylindrical shape. The substrate  502  can have a surface  504 . The surface  504  can be an end surface. The substrate  502  can also have a flank surface  506 . The surface  504  can be substantially perpendicular to the flank surface  506 . The flank surface  506  can meet the surface  504  so that a common boundary between the surface  504  and the flank surface  506  defines a peripheral edge  508  of the surface  504 . The surface  504  can be a substantially planar surface. The flank surface  506  can provide the substrate  502  with a generally circular cross-sectional shape. In other embodiments, the substrate  502  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0101]    The substrate  502  can include a pocket  510 . The pocket  510  can have an opening  512 . The opening  512  can be disposed on the surface  504  of the substrate  502 . The pocket  510  can extend from the opening  512  on the surface  504  to an interior of the substrate  502 . The pocket  510  can have a shape that can receive at least a portion of the at least one island  550 . 
         [0102]    The at least one island  550  can have a generally cylindrical shape. The at least one island  550  can have an end surface  552 , a flank surface, and an opposite end surface. Unlike the at least one island  150  shown in  FIGS. 1-4 , the at least one island  550  can have a cross-sectional shape that can be generally semi-circular. The at least one island  550  can be disposed in the pocket  510  of the substrate  502 . The at least one island  550  can be disposed in the pocket  510  of the substrate  502  so that the end surface  552  can be generally co-planar with the surface  504  of the substrate  502 , the flank surface extends into the interior of the substrate  502 , and the opposite end surface is disposed within the interior of the substrate  502 . The end surface  552  can alternatively have a convexity such that the end surface  552  can protrude from the surface  504  of the substrate  502 . In a further alternative, the end surface  552  can have a concavity such that the end surface  552  can sag from the surface  504  toward an interior of the substrate  502 . The end surface  552  can be a cutting surface, or the end surface  552  and the flank surface together can form a cutting surface. 
         [0103]    In the construction shown in  FIG. 14 , there are three islands  550  spaced equally apart from each other and equidistant from a center of the surface  504 . However, in other constructions, there may be more or less than the three islands  550  shown. Also, the exact position of each of the island  550  with respect to each other or the center of the surface  504  can be different from that shown in  FIG. 14 . Also, the exact size of the islands  550  can be different. The exact number and size of islands  550  and the exact position for each of the islands  550  can depend on, for example, the application of the cutter assembly  500 . 
         [0104]    Turning to  FIG. 15 , the cutter assembly  600  can have a substrate  602  with a generally cylindrical shape. The substrate  602  can have a surface  604 . The surface  604  can be an end surface. The substrate  602  can also have a flank surface  606 . The surface  604  can be substantially perpendicular to the flank surface  606 . The flank surface  606  can meet the surface  604  so that a common boundary between the surface  604  and the flank surface  606  defines a peripheral edge  608  of the surface  604 . The surface  604  can be a substantially planar surface. The flank surface  606  can provide the substrate  602  with a generally circular cross-sectional shape, In other embodiments, the substrate  602  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0105]    The substrate  602  can include a pocket  610 . The pocket  610  can have an opening  612 . The opening  612  can be disposed on the surface  604  of the substrate  602 . The pocket  610  can extend from the opening  612  on the surface  604  to an interior of the substrate  602 . The pocket  610  can have a shape that can receive at least a portion of the at least one island  650 . 
         [0106]    The at least one island  650  can have a generally cylindrical shape. The at least one island  650  can have an end surface  652 , a flank surface, and an opposite end surface. Unlike the at least one island  150  shown in  FIGS. 1-4 , the at least one island  650  can have a cross-sectional shape that can be generally ovalular. The at least one island  650  can be disposed in the pocket  610  of the substrate  602 . The at least one island  650  can be disposed in the pocket  610  of the substrate  602  so that the end surface  652  can be generally co-planar with the surface  604  of the substrate  602 , the flank surface extends into the interior of the substrate  602 , and the opposite end surface is disposed within the interior of the substrate  602 . The end surface  652  can alternatively have a convexity such that the end surface  652  can protrude from the surface  604  of the substrate  602 . In a further alternative, the end surface  652  can have a concavity such that the end surface  652  can sag from the surface  604  toward an interior of the substrate  602 . The end surface  652  can be a cutting surface, or the end surface  652  and the flank surface together can form a cutting surface. 
         [0107]    In the construction shown in  FIG. 15 , there are three islands  650  spaced equally apart from each other and equidistant from a center of the surface  604 . However, in other constructions, there may be more or less than the three islands  650  shown. Also, the exact position of each of the island  650  with respect to each other or the center of the surface  604  can be different from that shown in  FIG. 15 . Also, the exact size of the islands  650  can be different. The exact number and size of islands  650  and the exact position for each of the islands  650  can depend on, for example, the application of the cutter assembly  600 . 
         [0108]    Turning to  FIG. 16  the cutter assembly  700  can have a substrate  702  with a generally cylindrical shape. The substrate  702  can have a surface  704 . The surface  704  can be an end surface. The substrate  702  can also have a flank surface  706 . The surface  704  can be substantially perpendicular to the flank surface  706 . The flank surface  706  can meet the surface  704  so that a common boundary between the surface  704  and the flank surface  706  defines a peripheral edge  708  of the surface  704 . The surface  704  can be a substantially planar surface. The flank surface  706  can provide the substrate  702  with a generally circular cross-sectional shape. In other embodiments, the substrate  702  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0109]    The substrate  702  can include a pocket  710 . The pocket  710  can have an opening  712 . The opening  712  can be disposed on the surface  704  of the substrate  702 . The pocket  710  can extend from the opening  712  on the surface  704  to an interior of the substrate  702 . The pocket  710  can have a shape that can receive at least a portion of the at least one island  750 . 
         [0110]    The at least one island  750  can have a generally cylindrical shape. The at least one island  750  can have an end surface  752 , a flank surface, and an opposite end surface. Unlike the at least one island  150  shown in  FIGS. 1-4 , the at least one island  750  can have a cross-sectional shape that can be generally triangular. In other embodiments, the at least one island  750  can have a cross-sectional shape that can be similar to a polygon, and/or can have any regular or irregular shape. The at least one island  750  can be disposed in the pocket  710  of the substrate  702 . The at least one island  750  can be disposed in the pocket  710  of the substrate  702  so that the end surface  752  can be generally co-planar with the surface  704  of the substrate  702 , the flank surface extends into the interior of the substrate  702 , and the opposite end surface is disposed within the interior of the substrate  702 . The end surface  752  can alternatively have a convexity such that the end surface  752  can protrude from the surface  704  of the substrate  702 . In a further alternative, the end surface  752  can have a concavity such that the end surface  752  can sag from the surface  704  toward an interior of the substrate  702 . The end surface  752  can be a cutting surface, or the end surface  752  and the flank surface together can form a cutting surface. 
         [0111]    In the construction shown in  FIG. 16 , there are three islands  750  spaced equally apart from each other and equidistant from a center of the surface  704 . However, in other constructions, there may be more or less than the three islands  750  shown. Also, the exact position of each of the island  750  with respect to each other or the center of the surface  704  can be different from that shown in  FIG. 16 . Also, the exact size of the islands  750  can be different. The exact number and size of islands  750  and the exact position for each of the islands  750  can depend on, for example, the application of the cutter assembly  700 . 
         [0112]    Turning to  FIGS. 17-19 , the cutter assembly  800  can have a substrate  802  with a generally cylindrical shape. The substrate  802  can have a surface  804 . The surface  804  can be an end surface. The substrate  802  can also have a flank surface  806 . The flank surface  806  can meet the surface  804  so that a common boundary between the surface  804  and the flank surface  806  defines a peripheral edge  808  of the surface  804 . The flank surface  806  can provide the substrate  802  with a generally circular cross-sectional shape. In other embodiments, the substrate  802  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0113]    The substrate  802  can include a pocket  810 . The pocket  810  can have an opening  812 . The opening  812  can be disposed on the surface  804  of the substrate  802 . The pocket  810  can extend from the opening  812  on the surface  804  to an interior of the substrate  802 . The pocket  810  can have a shape that can receive at least a portion of the at least one island  850 . 
         [0114]    The at least one island  850  can have a generally cylindrical shape. The at least one island  850  can have an end surface  852 , a flank surface  854 , and an opposite end surface  856 . Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the surface  804  of the substrate  802  and the end surface  852  can together form a shape protruding away from the center of the substrate  802 . Because the end surface  852  can slope downwards, the end surface  852  can meet the opposite end surface  856 , and thus, the flank surface  854  may not extend the entire periphery of the end surface  852 . The opposite end surface  856  can be a planar surface that is substantially perpendicular to the flank surface  854 . The at least one island  850  can be disposed in the pocket  810  of the substrate  802 . The at least one island  850  can be disposed in the pocket  810  of the substrate  802  so that the end surface  852  of the at least one island  850  is substantially co-planar with surface  804  of the substrate  802 , the flank surface  854  extends into the interior of the substrate  802 , and the opposite end surface  856  is disposed within the interior of the substrate  802 . The end surface  852  can alternatively have a convexity such that the end surface  852  can protrude from the surface  804  of the substrate  802 . In a further alternative, the end surface  852  can have a concavity such that the end surface  852  can sag from the surface  804  toward an interior of the substrate  802 . The end surface  852  can be a cutting surface, or the end surface  852  and the flank surface  854  together can form a cutting surface. 
         [0115]    In the construction shown in  FIGS. 17-19 , there are three islands  850  spaced equally apart from each other and equidistant from a center of the surface  804 . However, in other constructions, there may be more or less than the three islands  850  shown. Also, the exact position of each of the island  850  with respect to each other or the center of the surface  804  can be different from that shown in  FIGS. 17-19 . Also, the exact size of the islands  850  can be different. The exact number and size of islands  850  and the exact position for each of the islands  850  can depend on, for example, the application of the cutter assembly  800 . 
         [0116]    Turning to  FIGS. 20-22 , the cutter assembly  900  can have a substrate  902  with a generally cylindrical shape. The substrate  902  can have a surface  904 . The surface  904  can be an end surface. The substrate  902  can also have a flank surface  906 . The flank surface  906  can meet the surface  904  so that a common boundary between the surface  904  and the flank surface  906  defines a peripheral edge  908  of the surface  904 . The flank surface  906  can provide the substrate  902  with a generally circular cross-sectional shape. In other embodiments, the substrate  902  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0117]    The substrate  902  can include a pocket  910 . The pocket  910  can have an opening  912 . The opening  912  can be disposed on the surface  904  of the substrate  902 . The pocket  910  can extend from the opening  912  on the surface  904  to an interior of the substrate  902 . The pocket  910  can have a shape that can receive at least a portion of the at least one island  950 . 
         [0118]    The at least one island  950  can have a generally cylindrical shape. The at least one island  950  can have an end surface  952 , a flank surface  954 , and an opposite end surface  956 . Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the surface  904  of the substrate  902  and the end surface  952  can together form a shape protruding away from the center of the substrate  902 . Also, the surface  904  and the end surface  952  protrude less from the center of the substrate  902  than the cutter assembly  800  shown in  FIGS. 17-19 . Because the end surface  952  can slope downwards, the end surface  952  can meet the opposite end surface  956 , and thus, the flank surface  954  may not extend the entire periphery of the end surface  952 . The opposite end surface  956  can be a planar surface that is substantially perpendicular to the flank surface  954 . The at least one island  950  can be disposed in the pocket  910  of the substrate  902 . The at least one island  950  can be disposed in the pocket  910  of the substrate  902  so that the end surface  952  of the at least one island  950  is substantially co-planar with surface  904  of the substrate  902 , the flank surface  954  extends into the interior of the substrate  902 , and the opposite end surface  956  is disposed within the interior of the substrate  902 . The end surface  952  can alternatively have a convexity such that the end surface  952  can protrude from the surface  904  of the substrate  902 . In a further alternative, the end surface  952  can have a concavity such that the end surface  952  can sag from the surface  904  toward an interior of the substrate  902 . The end surface  952  can be a cutting surface, or the end surface  952  and the flank surface  954  together can form a cutting surface. 
         [0119]    In the construction shown in  FIGS. 20-22 , there are three islands  950  spaced equally apart from each other and equidistant from a center of the surface  904 . However, in other constructions, there may be more or less than the three islands  950  shown. Also, the exact position of each of the island  950  with respect to each other or the center of the surface  904  can be different from that shown in  FIGS. 20-22 . Also, the exact size of the islands  950  can be different. The exact number and size of islands  950  and the exact position for each of the islands  950  can depend on, for example, the application of the cutter assembly  900 . 
         [0120]    Turning to  FIGS. 23-25 , the cutter assembly  1000  can have a substrate  1002  with a generally cylindrical shape. The substrate  1002  can have a surface  1004 . The surface  1004  can be an end surface. The substrate  1002  can also have a flank surface  1006 . The flank surface  1006  can meet the surface  1004  so that a common boundary between the surface  1004  and the flank surface  1006  defines a peripheral edge  1008  of the surface  1004 . The flank surface  1006  can provide the substrate  1002  with a generally circular cross-sectional shape. In other embodiments, the substrate  1002  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0121]    The substrate  1002  can include a pocket  1010 . The pocket  1010  can have an opening  1012 . The opening  1012  can be disposed on the surface  1004  of the substrate  1002 . The pocket  1010  can extend from the opening  1012  on the surface  1004  to an interior of the substrate  1002 . The pocket  1010  can have a shape that can receive at least a portion of the at least one island  1050 . 
         [0122]    The at least one island  1050  can have a generally cylindrical shape. The at least one island  1050  can have an end surface  1052 , a flank surface  1054 , and an opposite end surface  1056 . Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the surface  1004  of the substrate  1002  and the end surface  1052  can together form a shape protruding towards the center of the substrate  1002 . Because the end surface  1052  can slope downwards, the end surface  1052  can meet the opposite end surface  1056 , and thus, the flank surface  1054  may not extend the entire periphery of the end surface  1052 . The opposite end surface  1056  can be a planar surface that is substantially perpendicular to the flank surface  1054 . The at least one island  1050  can be disposed in the pocket  1010  of the substrate  1002 . The at least one island  1050  can be disposed in the pocket  1010  of the substrate  1002  so that the end surface  1052  of the at least one island  1050  is substantially co-planar with surface  1004  of the substrate  1002 , the flank surface  1054  extends into the interior of the substrate  1002 , and the opposite end surface  1056  is disposed within the interior of the substrate  1002 . The end surface  1052  can alternatively have a convexity such that the end surface  1052  can protrude from the surface  1004  of the substrate  1002 . In a further alternative, the end surface  1052  can have a concavity such that the end surface  1052  can sag from the surface  1004  toward an interior of the substrate  1002 . The end surface  1052  can be a cutting surface, or the end surface  1052  and the flank surface  1054  together can form a cutting surface. 
         [0123]    In the construction shown in  FIGS. 23-25 , there are three islands  1050  spaced equally apart from each other and equidistant from a center of the surface  1004 . However, in other constructions, there may be more or less than the three islands  1050  shown. Also, the exact position of each of the island  1050  with respect to each other or the center of the surface  1004  can be different from that shown in  FIGS. 23-25 . Also, the exact size of the islands  1050  can be different. The exact number and size of islands  1050  and the exact position for each of the islands  1050  can depend on, for example, the application of the cutter assembly  1000 . 
         [0124]    Turning to  FIGS. 26-28 , the cutter assembly  1100  can have a substrate  1102  with a generally cylindrical shape. The substrate  1102  can have a surface  1104 . The surface  1104  can be an end surface. The surface  1104  can be a substantially planar surface. The substrate  1102  can also have a flank surface  1106 . The surface  1104  can be substantially perpendicular to the flank surface  1106 . The flank surface  1106  can meet the surface  1104  so that a common boundary between the surface  1104  and the flank surface  1106  defines a peripheral edge  1108  of the surface  1104 . The flank surface  1106  can provide the substrate  1102  with a generally circular cross-sectional shape. In other embodiments, the substrate  1102  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0125]    The substrate  1102  can include a pocket  1110 . The pocket  1110  can have an opening  1112 . The opening  1112  can be disposed on the surface  1104  of the substrate  1102 . The pocket  1110  can extend from the opening  1112  on the surface  1104  to an opposite opening  1114  on an opposite end surface  1116  of the substrate  1102 . The pocket  1110  can have a shape that can receive at least a portion of the at least one island  1150 . 
         [0126]    The at least one island  1150  can have a generally truncated conical shape. The at least one island  1150  can have an end surface  1152 , a flank surface  1154 , and an opposite end surface  1156 . Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the end surface  1152  can be larger than opposite end surface  1156  so that the flank surface  1154  is disposed at an angle with respect to the end surface  1152 . The at least one island  1150  can be disposed in the pocket  1110  of the substrate  1102 . The at least one island  1150  can be disposed in the pocket  1110  of the substrate  1102  so that the end surface  1152  of the at least one island  1150  is substantially co-planar with surface  1104  of the substrate  1102 , the flank surface  1154  extends to the opposite end surface  1116  of the interior of the substrate  1102 , and the opposite end surface  1156  is substantially coplanar with opposite end surface  1116 . The end surface  1152  can alternatively have a convexity such that the end surface  1152  can protrude from the surface  1104  of the substrate  1102 . In a further alternative, the end surface  1152  can have a concavity such that the end surface  1152  can sag from the surface  1104  toward an interior of the substrate  1102 . The end surface  1152  can be a cutting surface, or the end surface  1152  and the flank surface  1154  together can form a cutting surface. 
         [0127]    In the construction shown in  FIGS. 26-28 , there are three islands  1150  spaced equally apart from each other and equidistant from a center of the surface  1104 . However, in other constructions, there may be more or less than the three islands  1150  shown. Also, the exact position of each of the island  1150  with respect to each other or the center of the surface  1104  can be different from that shown in  FIGS. 26-28 . Also, the exact size of the islands  1150  can be different. The exact number and size of islands  1150  and the exact position for each of the islands  1150  can depend on, for example, the application of the cutter assembly  1100 . 
         [0128]    Turning to  FIGS. 29-31 , the cutter assembly  1200  can have a substrate  1202  with a generally cylindrical shape. The substrate  1202  can have a surface  1204 . The surface  1204  can be an end surface. The surface  1204  can be a substantially planar surface. The substrate  1202  can also have a flank surface  1206 . The surface  1204  can be substantially perpendicular to the flank surface  1206 . The flank surface  1206  can provide the substrate  1202  with a generally circular cross-sectional shape. In other embodiments, the substrate  1202  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. However, the surface  1204  and the flank surface  1206  may not meet. Instead, the substrate  1202  can include a pocket  1210  so that the flank surface  1206  can extend to one side of an opening  1212  for a pocket  1210 , and the surface  1204  can form another side of the opening  1212  for the pocket  1210 . The pocket  1210  can extend from the opening  1212  towards an interior of the substrate  1202 . The pocket  1210  can have a shape that can receive at least a portion of the at least one island  1250 . 
         [0129]    The at least one island  1250  can have a generally ring-like shape. The at least one island  1250  can have an end surface  1252 , a flank surface  1254 , and an opposite end surface  1256 . The flank surface  1254  can be substantially perpendicular to the end surface  1252 , the opposite end surface  1256 , or both. Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the at least one island can include a second flank surface  1258 . The second flank surface  1258  can be substantially perpendicular to the end surface  1252 , the opposite end surface  1256 , or both. The at least one island  1250  can be disposed in the pocket  1210  of the substrate  1202 . The at least one island  1250  can be disposed in the pocket  1210  of the substrate  1202  so that the end surface  1252  of the at least one island  1250  can be substantially co-planar with surface  1204  of the substrate  1202 , the flank surface  1254  can extend between the flank surface  1206  of the substrate  1202  and the surface  1250 , the opposite end surface  1256  can be disposed in the pocket  1210 , and the second flank surface  1256  can be disposed in the pocket  1210 . The end surface  1252  can alternatively have a convexity such that the end surface  1252  can protrude from the surface  1204  of the substrate  1202 . In a further alternative, the end surface  1252  can have a concavity such that the end surface  1252  can sag from the surface  1204  toward an interior of the substrate  1202 . The end surface  1252  can be a cutting surface, or the end surface  1252  and the flank surface  1254  together can form a cutting surface. 
         [0130]    In the construction shown in  FIGS. 29-31 , there is one island  1250  disposed equidistant from a center of the surface  1204 . However, in other constructions, there may be more or less than the one island  1250  shown. Also, the exact position of the island  1250  with respect to the center of the surface  1204  can be different from that shown in  FIGS. 29-31 . Also, the exact size of the islands  1250  can be different. The exact number and size of islands  1250  and the exact position for each of the islands  1250  can depend on, for example, the application of the cutter assembly  1200 . 
         [0131]    Turning to  FIGS. 32-34 , the cutter assembly  1300  can have a substrate  1302  with a generally cylindrical shape. The substrate  1302  can have a surface  1304 . The surface  1304  can be an end surface. The surface  1304  can be a substantially planar surface. The substrate  1302  can also have a flank surface  1306 . The surface  1304  can be substantially perpendicular to the flank surface  1306 . The flank surface  1306  can meet the surface  1304  so that a common boundary between the surface  1304  and the flank surface  1306  defines a peripheral edge  1308  of the surface  1304 . The flank surface  1306  can provide the substrate  1302  with a generally circular cross-sectional shape. In other embodiments, the substrate  1302  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0132]    The substrate  1302  can include one or more pockets  1310 . The one or more pockets  1310  can each have an opening  1312 . The openings  1312  can be disposed on the surface  1304  of the substrate  1302 . The openings  1312  can be disposed such that one of the openings  1312  is surrounded by another of the openings  1312 . The one or more pockets  1310  can extend from the openings  1312  on the surface  1304  to an interior of the substrate  1302 . The one or more pockets  1310  can have a shape that can receive at least a portion of the at least one island  1350 . 
         [0133]    The at least one island  1350  can have a generally ring-like shape. The at least one island  1350  can have an end surface  1352 , a flank surface  1354 , and an opposite end surface  1356 . The flank surface  1354  can be substantially perpendicular to the end surface  1352 , the opposite end surface  1356 , or both. Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the at least one island can include a second flank surface  1358 . The second flank surface  1358  can be substantially perpendicular to the end surface  1352 , the opposite end surface  1356 , or both. The at least one island  1350  can be disposed in the one or more pockets  1310  of the substrate  1302 . The at least one island  1350  can be disposed in the one or more pockets  1310  of the substrate  1302  so that the end surface  1352  of the at least one island  1350  can be substantially co-planar with surface  1304  of the substrate  1302 , the flank surface  1354  and the second flank surface  1358  can extend into an interior of the substrate  1302 , and the opposite end surface  1356  can be disposed in the one or more pockets  1310 . The end surface  1352  can alternatively have a convexity such that the end surface  1352  can protrude from the surface  1304  of the substrate  1302 . In a further alternative, the end surface  1352  can have a concavity such that the end surface  1352  can sag from the surface  1304  toward an interior of the substrate  1302 . The end surface  1352  can be a cutting surface, or the end surface  1352  and the flank surface  1354  together can form a cutting surface. 
         [0134]    In the construction shown in  FIGS. 32-34 , there are two islands  1350  disposed concentrically with respect to a center of the surface  1304 . However, in other constructions, there may be more or less than the two islands  1350  shown. Also, the exact position of the islands  1350  with respect to the center of the surface  1304  can be different from that shown in  FIGS. 32-34 . Also, the exact size of the islands  1350  can be different. The exact number and size of islands  1350  and the exact position for each of the islands  1350  can depend on, for example, the application of the cutter assembly  1300 . 
         [0135]    Turning to  FIGS. 35-37 , the cutter assembly  1400  can have a substrate  1402  with a generally cylindrical shape. The substrate  1402  can have a surface  1404 . The surface  1404  can be an end surface. The surface  1404  can be a substantially planar surface. The substrate  1402  can also have a flank surface  1406 . The flank surface  1406  can include a concavity that curves towards an interior of the substrate  1402  or bulges away from the substrate  1402 . The flank surface  1406  can provide the substrate  1402  with a generally circular cross-sectional shape. In other embodiments, the substrate  1402  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. However, the surface  1404  and the flank surface  1406  may not meet. Instead, the substrate  1402  can include a pocket  1410  so that the flank surface  1406  can extend to one side of an opening  1412  for a pocket  1410 , and the surface  1404  can form another side of the opening  1412  for the pocket  1410 . The pocket  1410  can extend from the opening  1412  towards an interior of the substrate  1402 . The pocket  1410  can have a shape that can receive at least a portion of the at least one island  1450 . 
         [0136]    The at least one island  1450  can have a generally ring-like shape. The at least one island  1450  can have an end surface  1452 , a flank surface  1454 , and an opposite end surface  1456 . The flank surface  1454  can be substantially perpendicular to the end surface  1452 , the opposite end surface  1456 , or both. Unlike the cutter assembly  100  shown in  FIGS. 1-4 , the at least one island can include a second flank surface  1458 . The second flank surface  1458  can be substantially perpendicular to the end surface  1452 , the opposite end surface  1456 , or both. The at least one island  1450  can be disposed in the pocket  1410  of the substrate  1402 . The at least one island  1450  can be disposed in the pocket  1410  of the substrate  1402  so that the end surface  1452  of the at least one island  1450  can be substantially co-planar with surface  1404  of the substrate  1402 , the flank surface  1454  can extend between the flank surface  1406  of the substrate  1402  and the surface  1450 , the opposite end surface  1456  can be disposed in the pocket  1410 , and the second flank surface  1456  can be disposed in the pocket  1410 . The end surface  1452  can alternatively have a convexity such that the end surface  1452  can protrude from the surface  1404  of the substrate  1402 . In a further alternative, the end surface  1452  can have a concavity such that the end surface  1452  can sag from the surface  1404  toward an interior of the substrate  1402 . The end surface  1452  can be a cutting surface, or the end surface  1452  and the flank surface  1454  together can form a cuffing surface. 
         [0137]    In the construction shown in  FIGS. 35-37 , there is one island  1450  disposed equidistant from a center of the surface  1404 . However, in other constructions, there may be more or less than the one island  1450  shown. Also, the exact position of the island  1450  with respect to the center of the surface  1404  can be different from that shown in  FIGS. 35-37 . Also, the exact size of the islands  1450  can be different. The exact number and size of islands  1450  and the exact position for each of the islands  1450  can depend on, for example, the application of the cutter assembly  1400 . 
         [0138]    Turning to  FIGS. 38-40 , the cutter assembly  1500  can have a substrate  1502  with a generally cylindrical shape. The substrate  1502  can have a surface  1504 . The surface  1504  can be an end surface. The substrate  1502  can also have a flank surface  1506 . The surface  1504  can be substantially perpendicular to the flank surface  1506 . The flank surface  1506  can meet the surface  1504  so that a common boundary between the surface  1504  and the flank surface  1506  defines a peripheral edge  1508  of the surface  1504 . The surface  1504  can be a substantially planar surface. The flank surface  1506  can provide the substrate  1502  with a generally circular cross-sectional shape. In other embodiments, the substrate  1502  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0139]    The substrate  1502  can include a pocket  1510 . The pocket  1510  can have an opening  1512 . The opening  1512  can be disposed on the surface  1504 , the edge  1508 , and the flank surface  1506  of the substrate  1502 . The pocket  1510  can extend from the opening  1512  on the surface  1504 , the edge  1508 , and the flank surface  1506  to an interior of the substrate  1502 . The pocket  1510  can have a shape that can receive at least a portion of the at least one island  1550 . 
         [0140]    The at least one island  1550  can have a generally cylindrical shape. The at least one island  1550  can have an end surface  1552 , a flank surface  1554 , and an opposite end surface  1556 . The end surface  1552  can be a planar surface that can be substantially perpendicular to the flank surface  1554 . The opposite end surface  1556  can also be a planar surface that is substantially perpendicular to the flank surface  1554 . The at least one island  1550  can be disposed in the pocket  1510  of the substrate  1502 . The at least one island  1550  can be disposed in the pocket  1510  of the substrate  1502  so that the end surface  1552  of the at least one island  1550  is substantially co-planar with surface  1504  of the substrate  1502 , the flank surface  1554  extends into the interior of the substrate  1502  and protrudes beyond the flank surface  1506  of the substrate  1502 , and the opposite end surface  1556  is at least partially disposed within the interior of the substrate  1502 . The end surface  1552  can alternatively have a convexity such that the end surface  1552  can protrude from the surface  1504  of the substrate  1502 . In a further alternative, the end surface  1552  can have a concavity such that the end surface  1552  can sag from the surface  1504  toward an interior of the substrate  1502 . The end surface  1552  can be a cutting surface, or the end surface  1552  and the flank surface  1554  together can form a cutting surface. 
         [0141]    In the construction shown in  FIGS. 38-40 , there are three islands  1550  spaced equally apart from each other and equidistant from a center of the surface  1504 . However, in other constructions, there may be more or Tess than the two islands  1550  shown. Also, the exact position of the islands  1550  with respect to each other or the center of the surface  1504  can be different from that shown in  FIGS. 38-40 . Also, the exact size of the islands  1550  can be different. The exact number and size of islands  1550  and the exact position for each of the islands  1550  can depend on, for example, the application of the cutter assembly  1500 . 
         [0142]    For example, turning to  FIGS. 41-43 , there are four islands  1550  spaced equally apart from each other and equidistant from a center of the surface  1504 . 
         [0143]    Turning to  FIGS. 44-46 , the cutter assembly  1600  can have a substrate  1602  with a generally cylindrical shape. The substrate  1602  can have a surface  1604 . The surface  1604  can be an end surface. The substrate  1602  can also have a flank surface  1606 . The surface  1604  can be substantially perpendicular to the flank surface  1606 . The flank surface  1606  can meet the surface  1604  so that a common boundary between the surface  1604  and the flank surface  1606  defines a peripheral edge  1608  of the surface  1604 . The surface  1604  can be a substantially planar surface. The flank surface  1606  can provide the substrate  1602  with a generally circular cross-sectional shape. In other embodiments, the substrate  1602  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0144]    The substrate  1602  can include a pocket  1610  and portion  1614  that can extend the pocket  1610  beyond the flank surface  1606  of the substrate  1602 . The portion  1614  can be shaped to receive a portion of the at least one island  1650 . As best seen in  FIG. 46 , the portion  1614  can also be shaped to include a curve between the portion  1614  and the flank surface  1606  of the substrate  1602 , and the portion  1614  can further include another curve where the portion  1614  receives the at least one island  1650 . The pocket  1610  can have an opening  1612 . The opening  1612  can be disposed on the surface  1604 , the edge  1608 , the flank surface  1606 , and the portion  1614  of the substrate  1602 . The pocket  1610  can extend from the opening  1612  on the surface  1604 , the edge  1608 , and the flank surface  1606  to an interior of the substrate  1602 . The pocket  1610  can have a shape that can receive at least a portion of the at least one island  1650 . 
         [0145]    The at least one island  1650  can have a generally cylindrical shape. The at least one island  1650  can have an end surface  1652 , a flank surface  1654 , and an opposite end surface  1656 . The end surface  1652  can be a planar surface that can be substantially perpendicular to the flank surface  1654 . The opposite end surface  1656  can also be a planar surface that is substantially perpendicular to the flank surface  1654 . The at least one island  1650  can be disposed in the pocket  1610  of the substrate  1602 . The at least one island  1650  can be disposed in the pocket  1610  of the substrate  1602  so that the end surface  1652  of the at least one island  1650  is substantially co-planar with surface  1604  of the substrate  1602 . The at least one island  1650  can also be disposed in the pocket  1610  of the substrate  1602  so that the flank surface  1654  extends into the interior of the substrate  1602  and protrudes beyond the flank surface  1606  of the substrate  1602 . The at least one island  1650  can be further disposed in the pocket  1610  of the substrate  1602  so that the opposite end surface  1656  is at least partially disposed within the interior of the substrate  1602  and partially disposed on the portion  1614 . The end surface  1652  can alternatively have a convexity such that the end surface  1652  can protrude from the surface  1604  of the substrate  1602 . In a further alternative, the end surface  1652  can have a concavity such that the end surface  1652  can sag from the surface  1604  toward an interior of the substrate  1602 . The end surface  1652  can be a cutting surface, or the end surface  1652  and the flank surface  1654  together can form a cutting surface. 
         [0146]    In the construction shown in  FIGS. 44-46 , there are three islands  1650  spaced equally apart from each other and equidistant from a center of the surface  1604 . However, in other constructions, there may be more or less than the two islands  1650  shown. Also, the exact position of the islands  1650  with respect to each other or the center of the surface  1604  can be different from that shown in  FIGS. 44-46 . Also, the exact size of the islands  1650  can be different. The exact number and size of islands  1650  and the exact position for each of the islands  1650  can depend on, for example, the application of the cutter assembly  1600 . 
         [0147]    Turning to  FIGS. 47-49 , the cutter assembly  1700  can have a substrate  1702  with a generally cylindrical shape. The substrate  1702  can have two parts  1702   a  and  1702   b.  The substrate part  1702   a  can have a surface  1704   a  and an opposite surface  1705   a  that can be opposite to surface  1704   a.  The surface  1704   a  can be an end surface, and the surface  1705   a  can be another end surface. The substrate part  1702   a  can also have a flank surface  1706   a.  The surface  1704   a,  the surface  1705   a,  or both surfaces  1704   a  and  1705   a  can be substantially perpendicular to the flank surface  1706   a.  The flank surface  1706   a  can meet the surface  1704   a  so that a common boundary between the surface  1704   a  and the flank surface  1706   a  defines a peripheral edge  1708   a  of the surface  1704   a.  The surface  1704   a  can be a substantially planar surface. The surface  1705   a  can also be a substantially planar surface. The flank surface  1706   a  can provide the substrate part  1702   a  with a generally circular cross-sectional shape. In other embodiments, the substrate part  1702   a  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0148]    The substrate part  1702   b  can have a surface  1704   b.  The surface  1704   b  can be an end surface. The surface  1704   b  can be shaped to receive surface  1705   a  of substrate part  1702   a.  The substrate  1702   b  can also have a flank surface  1706   b.  The surface  1704   b  can be substantially perpendicular to the flank surface  1706   b.  The flank surface  1706   b  can meet the surface  1704   b  so that a common boundary between the surface  1704   b  and the flank surface  1706   b  defines a peripheral edge  1708   b  of the surface  1704   b.  The surface  1704   b  can be a substantially planar surface. The flank surface  1706   h  can provide the substrate part  1702   b  with a generally circular cross-sectional shape. In other embodiments, the substrate part  1702   b  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0149]    The substrate par  1702   a  can include a pocket  1710 . The pocket  1710  can have an opening  1712 . The opening  1712  can be disposed on the surface  1705   a  of the substrate part  1702   a.  The pocket  1710  can extend from the opening  1712  on the surface  1704  to an interior of the substrate part  1702   a.  The pocket  1710  can have a shape that can receive at least a portion of the at least one island  1750 . 
         [0150]    The at least one island  1750  can have a generally cylindrical shape. The at least one island  1750  can have an end surface  1752 , a flank surface  1754 , and an opposite end surface  1756 . The end surface  1752  can be a planar surface that can be substantially perpendicular to the flank surface  1754 . The opposite end surface  1756  can also be a planar surface that is substantially perpendicular to the flank surface  1754 . The at least one island  1750  can be disposed in the pocket  1710  of the substrate part  1702   a.  The at least one island  1750  can be disposed in the pocket  1710  of the substrate part  1702   a  so that the opposite end surface  1756  of the at least one island  1750  is substantially co-planar with surface  1705   a  of the substrate part  1702   a,  the flank surface  1754  extends into the interior of the substrate part  1702   a,  and the end surface  1752  is disposed within the interior of the substrate part  1702   a.  The end surface  1752  can be a cutting surface, or the end surface  1752  and the flank surface  1754  together can form a cutting surface. 
         [0151]    In the construction shown in  FIGS. 47-49 , there are three islands  1750  spaced equally apart from each other and equidistant from a center of the surface  1705   a  and equidistant from the surface  1704   a.  However, in other constructions, there may be more or less than the three islands  1750  shown. Also, the exact position of each of the island  1750  with respect to each other, the center of the surface  1705   a,  or the surface  1704   a  can be different from that shown in  FIGS. 47-49 . Also, the exact size of the islands  1750  can be different. The exact number and size of islands  1750  and the exact position for each of the islands  1750  can depend on, for example, the application of the cutter assembly  1700 . 
         [0152]    Turning to  FIGS. 50-52 , the cutter assembly  1800  can have a substrate  1802  with a generally cylindrical shape. The substrate  1802  can have a surface  1804 . The surface  1804  can be an end surface. The substrate  1802  can also have a flank surface  1806 . The surface  1804  can be substantially perpendicular to the flank surface  1806 . The flank surface  1806  can meet the surface  1804  so that a common boundary between the surface  1804  and the flank surface  1806  defines a peripheral edge  1808  of the surface  1804 . The surface  1804  can be a substantially planar surface. The flank surface  1806  can provide the substrate  1802  with a generally circular cross-sectional shape. In other embodiments, the substrate  1802  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0153]    The substrate  1802  can include a pocket  1810 . The pocket  1810  can have an opening  1812 . The opening  1812  can be disposed on the surface  1804  of the substrate  1802 . The pocket  1810  can extend from the opening  1812  on the surface  1804  to an interior of the substrate  1802 . The pocket  1810  can have a shape that can receive at least a portion of the at least one island  1850 . 
         [0154]    The at least one island  1850  can have a generally cylindrical shape. The at least one island  1850  can have an end surface  1852 , a flank surface  1854 , and an opposite end surface  1856 . The end surface  1852  can be a planar surface that can be substantially perpendicular to the flank surface  1854 . The opposite end surface  1856  can also be a planar surface that is substantially perpendicular to the flank surface  1854 . The at least one island  1850  can be disposed in the pocket  1810  of the substrate  1802 . The at least one island  1850  can be disposed in the pocket  1810  of the substrate  1802  so that the end surface  1852  of the at least one island  1850  is not co-planar with surface  1804  of the substrate  1802  but below the surface  1804  of the substrate. A substrate part  1858  can be disposed in the pocket  1810  on the end surface  1852  of the at least one island  1850 . The substrate part  1858  can also extend to the opening  1812  of the pocket  1810  and can be substantially co-planar with the surface  1804  of the substrate  1802 . The substrate part  1858  can be made of the same material as the substrate  1802 . Alternatively, the substrate part  1858  and the substrate  1802  can be made from different materials. The at least one island  1850  can also be disposed in the pocket  1810  of the substrate  1802  so that the flank surface  1854  extends into the interior of the substrate  1802  and the end surface  1852  is disposed within the interior of the substrate  1802 . The end surface  1852  can alternatively have a convexity such that the end surface  1852  can protrude from the surface  1804  of the substrate  1802 . In a further alternative, the end surface  1852  can have a concavity such that the end surface  1852  can sag from the surface  1804  toward an interior of the substrate  1802 . The end surface  1852  can be a cutting surface, or the end surface  1852  and the flank surface  1854  together can form a cutting surface. 
         [0155]    In the construction shown in  FIGS. 50-52 , there are three islands  1850  spaced equally apart from each other and equidistant from a center of the surface  1804 . However, in other constructions, there may be more or less than the three islands  1850  shown. Also, the exact position of each of the island  1850  with respect to each other or the center of the surface  1804  can be different from that shown in  FIGS. 50-52 . Also, the exact size of the islands  1850  can be different. The exact number and size of islands  1850  and the exact position for each of the islands  1850  can depend on, for example, the application of the cutter assembly  1800 . Also in the construction shown in  FIGS. 50-52 , there are three substrate parts  1858  of the same thickness. However, in other constructions, there may be substrate parts  1858  of different thickness and the exact position of the each of the island  1850  with respect to surface  1804  can be different from that shown in  FIGS. 50-52 . 
         [0156]    Turning to  FIGS. 53-55 , the cutter assembly  1900  can have a substrate  1902  with a generally cylindrical shape. The substrate  1902  can have a surface  1904 . The surface  1904  can be an end surface. The substrate  1902  can also have a flank surface  1906 . The surface  1904  can be substantially perpendicular to the flank surface  1906 . The flank surface  1906  can meet the surface  1904  so that a common boundary between the surface  1904  and the flank surface  1906  defines a peripheral edge  1908  of the surface  1904 . The surface  1904  can be a substantially planar surface. The flank surface  1906  can provide the substrate  1902  with a generally circular cross-sectional shape. In other embodiments, the substrate  1902  can have a cross-sectional shape that can be triangular, can be similar to a polygon, and/or can have any regular or irregular shape besides circular. 
         [0157]    The substrate  1902  can include a groove  1914 . The groove  1914  may be able to delay contact of the substrate  1902  when the at least one island  1950  is substantially worn. The groove  1914  can disposed on the flank surface  1906 . The groove  1914  can penetrate towards an interior of the substrate  1902 . The groove  1914  can be shaped like the letter “V”, an open polygonal shape, or an open semi-circle as shown in  FIGS. 53-55 . The groove  1914  can have a length that extends throughout the flank surface  1906  so that the groove  1914  extends entirely around an outer periphery of the substrate  1902 . Alternatively, the groove  1914  can extend only through a portion of the flank surface  1906  so that the groove  1914  extends only partially around an outer periphery of the substrate  1902 . The groove  1914  can extend substantially straight or meander across the flank surface  1906 . 
         [0158]    The substrate  1902  can include a pocket  1910 . The pocket  1910  can have an opening  1912 . The opening  1912  can be disposed on the surface  1904  of the substrate  1902 . The pocket  1910  can extend from the opening  1912  on the surface  1904  to an interior of the substrate  1902 . The pocket  1910  can have a shape that can receive at least a portion of the at least one island  1950 . 
         [0159]    The at least one island  1950  can have a generally cylindrical shape. The at least one island  1950  can have an end surface  1952 , a flank surface  1954 , and an opposite end surface  1956 . The end surface  1952  can be a planar surface that can be substantially perpendicular to the flank surface  1954 . The opposite end surface  1956  can also be a planar surface that is substantially perpendicular to the flank surface  1954 . The at least one island  1950  can be disposed in the pocket  1910  of the substrate  1902 . The at least one island  1950  can be disposed in the pocket  1910  of the substrate  1902  so that the end surface  1952  of the at least one island  1950  is substantially co-planar with surface  1904  of the substrate  1902 , the flank surface  1954  extends into the interior of the substrate  1902 , and the opposite end surface  1956  is disposed within the interior of the substrate  1902 . The end surface  1952  can alternatively have a convexity such that the end surface  1952  can protrude from the surface  1904  of the substrate  1902 . In a further alternative, the end surface  1952  can have a concavity such that the end surface  1952  can sag from the surface  1904  toward an interior of the substrate  1902 . The end surface  1952  can be a cutting surface, or the end surface  1952  and the flank surface  1954  together can form a cutting surface. 
         [0160]    In the construction shown in  FIGS. 53-55 , there are three islands  1950  spaced equally apart from each other and equidistant from a center of the surface  1904 . However, in other constructions, there may be more or less than the three islands  1950  shown. Also, the exact position of each of the island  1950  with respect to each other or the center of the surface  1904  can be different from that shown in  FIGS. 35-55 . Also, the exact size of the islands  1950  can be different. The exact number and size of islands  1950  and the exact position for each of the islands  1950  can depend on, for example, the application of the cutter assembly  1900 . 
         [0161]    Referring to  FIG. 56 , a method  2000  of manufacturing the cutter with at least one island is shown. The method  2000  can include providing at least one island, step  2002 ; treating the at least one island, step  2004 ; providing a substrate, step  2006 ; forming a surface circumscribed by a peripheral edge on the substrate, step  2008 ; forming at least one pocket with an opening on the surface and spaced apart from the peripheral edge such that the at least one pocket extends from the opening towards an interior of the substrate and has a shape that engages with the at least one island, step  2010 ; disposing the at least one island in the at least one pocket, step  2012 ; and coupling the at least one island to the at least one pocket, step  2014 . Alternatively, in step  2010 , the at least one pocket can be formed within the substrate. 
         [0162]    The step of providing the at least one island can further comprise forming the at least one island from a polycrystalline diamond made from at least one of a high pressure high temperature process, a chemical vapor deposition process, and a physical vapor deposition process. The step of providing the at least one island can further comprise forming the at least one island from a portion of a polycrystalline diamond. 
         [0163]    The method  2000  can further comprise coating the at least one island. The method  2000  can alternatively further comprise encasing the at least one island. The method can further comprise coupling the at least island to the at least one pocket. The at least one island can be coupled to the at least one pocket by press fit, gluing, brazing, bonding, clamping, mechanical interlocking, or welding. 
         [0164]    The step of treating the at least one island can further comprise partially leaching the at least one island. Alternatively, the step of treating the at least one island can further comprise substantially fully leaching the at least one island. 
         [0165]    The step of disposing the at least one island in the at least one pocket can further comprise disposing the at least one island such that a cutting surface of the at least one island is substantially flush with the surface of the substrate. The step of disposing the at least one island in the at least one pocket can further comprise disposing the at least one island such that a cutting surface of the at least one island protrudes outward from the surface of the substrate. The step of disposing the at least one island in the at least one pocket further comprises disposing the at least one island such that a cutting surface of the at least one island projects towards the interior of the substrate. 
         [0166]    The method  2000  can also further comprise providing a cutting surface that has a generally circular shape on the at least one island. Alternatively, the method  2000  can further comprise providing a cutting surface that has a generally ovalular shape on the at least one island. In another alternative, the method  2000  can further comprise providing a cutting surface that has a generally triangular shape. In yet another alternative, the method  2000  can further comprise providing a cutting surface that has a generally polygonal shape. 
         [0167]    The method  2000  can further comprise forming at least one other pocket on the surface symmetrically with respect to the at least one pocket; and disposing at least one other island in the at least one other pocket. Alternatively, the method  2000  can further comprise forming at least one other pocket on the surface unsymmetrically with respect to the at least one pocket and disposing at least one other island in the at least one other pocket. In another alternative, the method  2000  can further comprise forming at least one other pocket on the surface spaced apart from the at least one pocket and disposing at least one other island in the at least one other pocket. In yet another alternative, the method  2000  can further comprise forming at least one other pocket on the surface with a second opening conjoined with the opening of the at least one pocket and disposing at least one other island in the at least one other pocket. 
         [0168]    The method  2000  can further include forming a planar surface, a concave surface, a dome-shaped surface, a chiseled surface, or a wavy surface with the surface of the substrate and a cutting surface of the at least one island. 
         [0169]    The step of providing the substrate can include forming the substrate so as to provide a substrate  102  . . .  1902 , as described above and as shown in  FIGS. 1-55 . Also, the step of providing a substrate can further comprise forming the substrate from carbide, tungsten carbide composite, tungsten carbide composite held up by an eta-phase, polycrystalline cubic boron nitride, polycrystalline diamond, or a combination of two or more of the aforementioned. 
         [0170]    The step of providing the at least one pocket can be include forming the at least one pocket so as to provide at least one pocket  110  . . .  1910 , as described above and as shown in  FIGS. 1-55 . 
         [0171]    The step of providing the at least one island can be include forming the at least one island so as to provide at least one island  150  . . .  1950 , as described above and as shown in  FIGS. 1-55 . The step of providing the at least one island can further comprise forming the at least one island from polycrystalline diamond, polycrystalline diamond compact, diamond, cubic boron nitride, polycrystalline cubic boron nitride, diamond-silicon carbide composite material, polycrystalline diamond composite, chemical vapor deposition diamond, or a combination of two or more of the aforementioned. 
         [0172]    Referring to  FIG. 57 , a method  2100  of manufacturing the cutter with at least one island is shown. The method  2000  of manufacturing can include providing a PCD piece from a high pressure, high temperature (HPHT) process, step  2102 . Alternatively, the PCD can be provided from a chemical vapor deposition (CVD), a physical vapor deposition (PVD), or some other suitable process. The method can also include forming a smaller PCD part from the PCD piece, step  2104 . The method can further include fully or partially leaching the cobalt out of the PCD part, step  2106 . The PCD part can then be coated with, for example, a tungsten coating, or the PCD part can be press fitted into a casing, such as a metal casing. The PCD part with or without a coating or a casing can then be coupled to the substrate, step  2108 . The coupling can be by, for example, gluing, brazing, bonding, welding, clamping, mechanical locking, or any other suitable coupling. 
         [0173]    For the purposes of promoting an understanding of the principles of the invention, reference has been made to the embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art. The terminology used herein is for the purpose of describing the particular embodiments and is not intended to be limiting of exemplary embodiments of the invention. 
         [0174]    The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. The words “mechanism” and “element” are used broadly and are not limited to mechanical or physical embodiments, but may include software routines in conjunction with processors, etc. It will also be recognized that the terms “comprises,” “comprising,” “includes,” “including,” “has,” and “having,” as used herein, are specifically intended to be read as open-ended terms of art. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless the context clearly indicates otherwise. In addition, it should be understood that although the terms “first,” “second,” etc. may be used herein to describe various elements, these elements should not be limited by these terms, which are only used to distinguish one element from another. Furthermore, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. 
         [0175]    Numerous modifications and adaptations will be readily apparent to those of ordinary skill in this art without departing from the spirit and scope of the present invention as defined by the following claims. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the following claims, and all differences within the scope will be construed as being included in the invention. 
         [0176]    Although described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.