Patent ID: 6933049

Claim:
An abrasive tool insert, which comprises: (a) a substrate having a support face that includes: (1) an inner support table, wherein the inner support table comprises at least one of; a series of concentric grooves, a series of outwardly radiating channels, a series of intersecting channels, a series of outwardly radiating ridges, and a series of substantially parallel raised ridges that extend from said support table; (2) an outer shoulder having a width, S w , (3) a downwardly sloping interface from said support table to said shoulder which interface has a slope angle, S a ; and (b) a continuous abrasive layer integrally formed on said substrate support face, which abrasive layer includes: (1) a center having a height, D c , (2) a diameter, D d , (3) a periphery having a height, D p , in contact with said shoulder and which periphery forms a cutting edge; wherein, S w :D d ranges between about 0.01 and about 0.5; and for each S a and S w :D d ,D c :D p is selected so as to diminish residual stress in the abrasive layer.