Patent ID: 8795460

Claim:
A method of making a construction for an indexable cutter insert, the method including providing an insert base having proximate and distal major ends connected by peripheral sides, the proximate end of the insert base being configured to have at least two corners defined by junctions of the peripheral sides; providing a precursor body comprising a grade of PCBN material that is capable of being cut by means of electro-discharge machining, and having a first thickness between a pair of opposite major end surfaces; cutting the precursor body into 2 to 10 sub-structures, each having a volume of substantially 50 percent down to 10 percent, respectively, of the volume of the precursor body, the sub-structures comprising the grade of PCBN material, having a second thickness between a pair of opposite major sub-structure surfaces, the second thickness being less than the first thickness; in which the major sub-structure surfaces are cut to correspond to a major surface of the precursor body, the major sub-structure surfaces being substantially parallel to or inclined at an angle of at most 45 degrees to at least one of the major surfaces of the precursor body; cutting at least one of the sub-structures to provide a wafer comprising the grade of PCBN material, the wafer being unsupported by a cemented carbide substrate, having a mean thickness of at most 2 mm, and the wafer being configured to have at least two corners corresponding to the two corners of the proximate end of the insert base; the method including bonding the wafer to the proximate end of the insert base using a bond material, the corners of the wafer being disposed adjacent the corresponding corners of the proximate end to provide the construction.