BRIEF DESCRIPTION OF THE DRAWINGS
For a thorough understanding of the present invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, wherein like reference numerals designate like or similar elements throughout the several figures of the drawings and wherein:
FIG. 1 is an isometric view of an exemplary cutter constructed in accordance with the present invention.
FIG. 2 is a top view of the cutter shown in FIG. 1.
FIG. 3 is a top view of an exemplary cutter of alternate construction in accordance with the present invention.
FIG. 4 is an illustration of an exemplary cutting arm for a downhole cutter having a plurality of prior art circular cutters secured thereupon.
FIG. 5 is an illustration of an exemplary cutting arm for a downhole cutter having secured thereupon a plurality of cutters of the type shown in FIGS. 1 and 2.
FIGS. 6 and 6A depict an exemplary mandrel cutting arm with cutters of the type shown in FIGS. 1 and 2.
FIG. 7 illustrates an exemplary downhole rotary cutting mill which incorporates cutters in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 depict an exemplary cutter 10 that is constructed in accordance with the present invention. The cutter 10 has a body 12 that is preferably formed of hardened carbide. However, the cutter 10 might also be formed of PDC, as is known in the art, or another substance suitable for use in downhole cutting. The body 12 features a cutting face 14 and a sidewall 16. Preferably, the cutter 10 features a raised chip-breaking edge 18 that is located proximate the outer circumference of the cutting face 14. When considered from the plan view offered by FIG. 2, the body 12 of the cutter 10 is generally made up of three sections: two end sections 20, 22 with end walls 23 that are semi-circular in shape, and a generally rectangular central section 24 that interconnects the two end sections 20, 22 to result in a rounded, rectangular “lozenge” shape for the cutter 10.
FIG. 2 also illustrates the currently preferred dimensions for the cutter 10. The cutter 10 has an overall length 26, as measured from the tip of one semi-circular section 20 to the tip of the other semi-circular section 22. The cutter 10 also has a width 28 that extends from one lateral side of the central section 24 to the other. The width 28 is also equal to the diameter of the semi-circular end sections 20, 22. In a currently preferred embodiment, the length 26 of the cutter 10 is approximately 1.5 times the width 28 of the cutter 10. A currently preferred width 29 for the cutter 10 is approximately ⅜″.
FIG. 3 depicts an alternative embodiment for a cutter 10′ which is constructed in accordance with the present invention. The cutter 10′ is similar to the cutter 10 described previously. However, the end sections 20′ and 22′ are arcuate, but not semi-circular. The end sections 20′ and 22′ instead, have an end wall 23′ with a larger radius of curvature and, therefore, represents an arc segment that is less than a semi-circle. In this embodiment, the length of the cutter 10′ still exceeds the width of the cutter 10′, and the preferred length-to-width ratios described above apply to this embodiment as well. It is noted that the end walls 23′ of the end sections 20′, 22′ do not require any particular radius of curvature and, therefore, may present a relatively flattened curvature, as in FIG. 3, or a more pronounced curvature. Additionally, the radius of curvature for the end walls 23, 23′ need not be a constant radius, but may otherwise be curvilinear. It is noted that the lateral sides 31 of the central section 24 are substantially straight and flat.
FIG. 4 illustrates an exemplary cutting arm, or cutting member, 30 having a raised cutting portion 32. The cutting arm 30 is of a type that is incorporated into a downhole cutter and used for rotary cutting into portions of the sidewall of a wellbore, as is known in the art. A plurality of prior art cutters 34 are affixed thereto having round-shaped cutting faces. It is noted that there is a significant amount of interstitial space 36 between the cutters 34 on the raised cutting portion 32. During downhole cutting or milling, the interstitial space 36 between the cutters 34 is highly susceptible to erosion damage. Particularly where the materials being milled or cut are highly ductile, such as those having high chrome and/or nickel content, the milled material tends to flow into the interstitial space 36 and erode away the arm 30. Also depicted in FIG. 4 is a half cutter 34a which is used to help accommodate proper spacing with the other cutters 34 upon the raised cutting portion 32. The use of half cutters 34a is problematic because there is minimal bonding area and, therefore, half cutters are very likely to break off of the cutting arm 30.
FIG. 5 depicts an exemplary cutting arm 30 having a plurality of cutters 10 of the type described previously with respect to FIGS. 1 and 2 affixed thereupon, in accordance with the present invention. The use of the rounded, rectangular cutters 10 results in less interstitial space 36 available on the raised portion 32 and as a result, less erosion of the arm 30. Additionally, the increased length 26 of the cutter 10 as compared to a cutter 34 means there is increased bond area between each cutter 10 and the arm 30 as compared to the prior art cutters 34. Cutters are typically affixed to a cutting arm by brazing and welding. The increased bond area results in cutters that are more securely affixed to the cutting arm 30. Additionally, the width 28 of the cutter 10 is the same as the width (diameter) of the conventional circular cutters 34, which allows the cutters 10 to be seated upon a cutting surface having a narrow width while providing improved bonding area and strength.
FIG. 6 depicts an exemplary arm 50 for a mandrel cutting tool. The arm 50 includes a proximal portion 52 having a pin opening 54 into which the arm 50 is pivotally attached to a cutting tool mandrel (not shown) and a distal cutting portion 56. The distal cutting portion 56, which is more clearly depicted in the close up view of FIG. 6A, includes a cutter retaining area 58 that is bounded by side surface 60 and shelf 62. Cutters 10 are accommodated inside the cutter retaining area 58 and leave very little interstitial space.
FIG. 7 illustrates an exemplary rotary cutting mill 70 of the type used in sidetracking operations to mill a lateral opening in wellbore casing. Cutting mills of this type are generally known in the art, and include the SILVERBACK™ window mill available commercially from Baker Oil Tools of Houston, Tex. The cutting mill 70 has five cutting blades, or arms, 72 that are rotated about hub 74 during operation. Each of these blades 72 has cutters 10 mounted upon them. It is pointed out that the blades 72 may include some rounded, conventional cutters 34 as well. It is noted that the cutters 10, 34 are mounted upon the cutting blades 72 in a manner such that the cutters are offset from one another in adjacent blades 72. For example, the distal tip of the edge of blade 72A has four cutters 10 that are arranged in an end-to-end manner. However, the neighboring blade 72B has the lead cutter 10A turned at a 90 degree angle to the other cutters 10, thereby causing the interstitial space 36 between the cutters 10, 10A, 34 to be staggered on adjacent blades 72. As a result of this staggering, the blades 72 will become less worn in the interstitial spaces 36.
Testing has shown that the use of cutters constructed in accordance with the present invention provide a number of advantages over conventional circular cutters. The rounded, rectangular shape of the cutters 10 allows them to be mounted upon narrow cutting surfaces, such as raised cutting portion 32. Such cutters are useful on cutting arms having narrow cutting surfaces as they provide for reduced cutting load while having sufficient bond area to remain secured during cutting. The chip breaker edge 18 serves to break up sections of earth material that may be formed during cutting.
Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof.
Patent Application
20080006446
