Patent Application
20160010397
Embodiments of the present disclosure relate generally to cutting elements for earth-boring tools. More specifically, disclosed embodiments relate to polycrystalline superabrasive materials for use in cutting elements for earth-boring tools, which polycrystalline superabrasive materials may have catalyst materials removed from one or more selected regions thereof.
Earth-boring tools for forming wellbores in subterranean earth formations may include cutting elements secured to a body. For example, fixed-cutter, earth-boring rotary drill bits (also referred to as “drag bits”) include cutting elements that are fixedly attached to a body of the drill bit. Roller-cone earth-boring rotary drill bits include cones that are mounted on bearing pins extending from legs of a body such that each cone is capable of rotating about the bearing pin on which it is mounted. Cutting elements may be mounted to each cone of the drill bit.
The cutting elements used in such earth-boring tools are often polycrystalline diamond compact (often referred to as “PDC”) cutting elements, also termed “cutters.” PDC cutting elements include a polycrystalline diamond (PCD) material, which may be characterized as a superabrasive or superhard material. Such polycrystalline diamond materials are formed by sintering and bonding together small diamond grains (e.g., diamond crystals), termed “grit,” under conditions of high temperature and high pressure in the presence of a catalyst material to form polycrystalline diamond. The polycrystalline diamond is frequently in the shape of a disc, also called a “diamond table.” The processes used to from polycrystalline diamond are often referred to as high temperature/high pressure (“HTHP”) processes.
PDC cutting elements frequently include a substrate to which the polycrystalline diamond is secured. The cutting element substrate may be formed of a ceramic-metallic composite material (i.e., a cermet), such as cobalt-cemented tungsten carbide. In some instances, the polycrystalline diamond table may be formed on the substrate, for example, during the HTHP sintering process. In such instances, cobalt or other metal solvent catalyst material in the cutting element substrate (e.g., a metal matrix of the ceramic-metallic composite material) may be swept among the diamond grains during sintering and serve as a catalyst for forming a diamond table from the diamond grains. Powdered catalyst material may also be mixed with the diamond grains prior to sintering the grains together in an HTHP process. In other methods, however, the diamond table may be formed separately from the cutting element substrate and subsequently attached thereto.
To reduce problems associated with differences in thermal expansion and chemical breakdown of the diamond crystals in PDC cutting elements, “thermally stable” polycrystalline diamond compacts (which are also known as thermally stable products or “TSPs”) have been developed. Such a thermally stable polycrystalline diamond compact may be formed by removing catalyst material out from interstitial spaces among the interbonded grains in the diamond table (e.g., by leaching catalyst material from the diamond table using an acid). Diamond tables that have been at least substantially fully leached are relatively more brittle and vulnerable to shear, compressive, and tensile stresses than are unleached diamond tables. In addition, it may be difficult to secure a completely leached diamond table to a supporting substrate. To provide cutting elements having diamond tables that are more thermally stable relative to unleached diamond tables, but that are also relatively less brittle and vulnerable to shear, compressive, and tensile stresses than fully leached diamond tables, cutting elements have been provided that include a diamond table in which the catalyst material has been leached from only a portion or portions of the diamond table. For example, it is known to leach catalyst material from the cutting face, from the side of the diamond table, or both, to a desired depth within the diamond table, but without leaching all of the catalyst material out from the diamond table.
In some embodiments, an earth-boring tool includes a bit body and a cutting element secured to the bit body. The cutting element exhibits a contact back rake angle with respect to a surface of a formation to be cut by the bit body and comprises a polycrystalline superabrasive material. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a continuous boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary is nonlinear in a cross-sectional plane that includes a centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the earth-boring tool. Each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element greater than the contact back rake angle of the cutting element.
In certain embodiments, an earth-boring tool includes a bit body and a cutting element secured to the bit body. The cutting element exhibits a contact back rake angle with respect to a surface of a formation to be cut by the bit body and comprises a polycrystalline superabrasive material. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary comprises a first area and a second area. The first area includes a portion of the boundary within a first radial distance of a centerline of the cutting element in a cross-sectional plane that includes the centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the earth-boring tool. The second area includes a portion of the boundary between the first radial distance from the centerline of the cutting element and a second radial distance from the centerline of the cutting element in the cross-sectional plane. The second radial distance corresponds to an exterior surface of the cutting element, and the first radial distance is at least 50% of the second radial distance. Each line tangent to the boundary in the cross-sectional plane in the second area forms an angle with a centerline of the cutting element greater than the contact back rake angle of the cutting element.
In other embodiments, a cutting element for an earth-boring tool includes a substrate and a polycrystalline superabrasive material secured to the substrate. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary is nonlinear in a cross-sectional plane that includes a centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the cutting element. Each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of greater than 20°.
A method of forming a wellbore may include contacting an earth-boring tool with a surface of a subterranean formation. The earth-boring tool comprises a bit body and at least one cutting element secured to the bit body. The at least one cutting element comprises a polycrystalline superabrasive material comprising a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material and a second volume at least substantially free of catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material. A surface of the second volume is exposed at least partially around the cutting element. The method further comprises removing at least a portion of the polycrystalline superabrasive material from the second volume through contact with the surface of the subterranean formation and removing a portion of the first volume adjacent to and in contact with the second volume without rendering a portion of the second volume radially discontinuous with a remainder of the second volume.
Other methods of forming a wellbore may include contacting an earth-boring tool with a surface of a subterranean formation. The earth-boring tool comprises a bit body and a cutting element secured to the bit body. The cutting element comprises a polycrystalline superabrasive material comprising a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material and a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material. A surface of the second volume is exposed at least partially around the cutting element. The method further comprises removing a portion of the second volume and removing a portion of the first volume without exposing the first volume through an aperture formed in the second volume.
While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:
The illustrations presented in this disclosure are not meant to be actual views of any particular earth-boring tool, cutting element, polycrystalline superabrasive material, or component thereof, but are merely idealized representations employed to describe illustrative embodiments. Thus, the drawings are not necessarily to scale. Additionally, elements common between figures may retain the same numerical designation.
Disclosed embodiments relate generally to cutting elements having polycrystalline superabrasive materials that have catalyst materials removed from selected volumes of the polycrystalline superabrasive materials. More specifically, catalyst materials are selectively removed, for example and without limitation by acid leaching, such that during wear of the cutting element, polycrystalline superabrasive material wears without exposing catalyst-containing polycrystalline material through an aperture formed in the catalyst-free polycrystalline material. That is, a wear scar formed does not expose a radially discontinuous portion of the catalyst-containing polycrystalline material. Examples of embodiments of geometries are shown in the FIGS. and described in more detail below. Such cutting elements may exhibit improved resistance to spalling of the polycrystalline material, as well as more favorable wear properties than superabrasive cutting elements having conventional leach profiles.
The ter ms “earth-boring tool” and “earth-boring drill bit,” as used in this disclosure, mean and include any type of bit or tool used for drilling during the formation or enlargement of a wellbore in a subterranean formation and include, for example, fixed-cutter bits, roller-cone bits, percussion bits, core bits, eccentric bits, bicenter bits, reamers, mills, drag bits, hybrid bits, and other drilling bits and tools known in the art.
As used in this disclosure, the term “superabrasive material” means and includes any material having a Knoop hardness value of about 3,000 Kgf/mm2 (29,420 MPa) or more. Superabrasive materials include, for example, diamond and cubic boron nitride. Superabrasive materials may also be characterized as “superhard” materials.
As used in this disclosure, the term “polycrystalline material” means and includes any material including grains (i.e., crystals) of material that are bonded directly together by intergranular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.
As used in this disclosure, the terms “intergranular bond” and “interbonded” mean and include any direct atomic bond (e.g., covalent, ionic, metallic, etc.) between atoms in adjacent grains of superabrasive material.
The term “sintering” as used in this disclosure means temperature-driven mass transport, which may include densification and/or coalescing of a particulate component, and typically involves removal of at least a portion of the pores between the starting particles (accompanied by shrinkage) combined with coalescence and bonding between adjacent particles.
As used herein, the terms “catalyst” and “catalyst material” refer to any material capable of catalyzing the formation of intergranular diamond-to-diamond bonds in a diamond grit or powder during an HTHP process in the manufacture of polycrystalline material (e.g., diamond). By way of example, catalyst materials include elements from Groups 8, 9, and 10 of the Periodic Table of the Elements, such as cobalt, iron, nickel, and alloys and mixtures thereof, even when alloyed or mixed with other, noncatalyzing materials.
As used in this disclosure, the term “tungsten carbide” means any material composition that contains chemical compounds of tungsten and carbon, such as WC, W2C, and combinations of WC and W2C. Tungsten carbide includes, for example, cast tungsten carbide, sintered tungsten carbide, and macrocrystalline tungsten carbide.
As used in this disclosure, the terms “at least substantially free of catalyst material,” “free of catalyst material,” and “catalyst-free” mean that catalyst material has been removed to commercial purity. For example, a volume of material may be at least substantially free of catalyst material even though residual catalyst material may adhere to other materials (e.g., to surfaces of interbonded grains of a superabrasive polycrystalline material) in the volume and isolated volumes of catalyst material may remain in interstitial spaces that are inaccessible by leaching (e.g., because they are closed off by interbonded grains of a superabrasive polycrystalline material and not connected to an otherwise continuous, open network of interstitial spaces among the interbonded grains).
As used herein, the term “contact back rake angle” means an angle of a major, planar portion of a cutting face of a cutting element with respect to a line perpendicular to an anticipated point of contact with a surface of a formation to be engaged by the cutting face of the cutting element. If a cutting element is devoid of a planar portion, the back rake angle means the angle of a plane perpendicular to a centerline of a cutting with respect to a line perpendicular to a surface of a formation engaged by the cutting face of the cutting element. If a cutting element is configured to have a minor planar portion come in contact with the surface of the formation, the back rake angle means the angle of the minor planar portion with respect to a line perpendicular to a surface of a formation engaged by the cutting face of the cutting element.
As used herein, the term “critical failure” means an accumulated chipping, spallation, or material removal of the diamond working surface that exceeds 20% of the radial distance towards the centroid of the cutter as measured from the outer diametrical cutting edge. For example,
The second volume 116 may have approximately the same thickness across the cutting element 110. For example, the second volume 116 may have a thickness t1, measured near a centerline 130 of the cutting element 110, from about 25 μm to about 750 μm, such as from about 100 μm to about 500 μm. The thickness t1 may be, for example, from about 1% to about 60% of the thickness of the polycrystalline table 113. In some embodiments, the second volume 116 may have a different thickness t2 at the edge of the cutting element 110 than the thickness t1 within the body of the cutting element 110. For example, the second volume 116 may have a thickness t2 at the edge of the cutting element from about 200 μm to about 1,000 μm, such as from about 300 μm to about 500 μm. The thickness t2 may be, for example, from about 2% to about 80% of the thickness of the polycrystalline table 113.
The boundary 118 between the first volume 114 and the second volume 116 may generally have a roughness at least partially defined by the microstructure of the polycrystalline table 113. Fine-grained and uniformed materials may exhibit a smoother or more uniform boundary, and coarse-grained materials may exhibit a rougher boundary. Some irregularity of the boundary 118 may also be attributable to different particle sizes in various regions of the polycrystalline table 113.
The boundary 118 may be shaped such that a portion thereof forms a substantially frustoconical shape (i.e., the shape a portion of cone whose tip has been truncated by a plane parallel to the base of the cone). As shown in
The boundary 118 shown in
The boundary 118 shown in
In some embodiments, the second volume 116 may include an annular volume adjacent to and extending along a peripheral surface of the cutting element 110 from a working surface of the cutting element 110 (e.g., the chamfer 120 and/or the cutting face 122) to the boundary 118. Such an annular volume may be referred to in the art as an “annulus leach.” As discussed above, a portion of the boundary 118 in the second area 128 defines a plurality of planes tangent to the boundary 118, wherein each tangent plane forms an angle with the centerline 130 of the cutting element greater than the contact back rake angle 136 of the cutting element 110. In the first area 126, the boundary 118 may have any selected shape. For example, the boundary 118 may have an undulating shape in the first area 126, such as described in U.S. patent application Ser. No. 14/248,068, filed Apr. 8, 2014, and titled “Cutting Elements including Undulating Boundaries Between Catalyst-Containing and Catalyst-Free Regions of Polycrystalline Superabrasive Materials and Related Earth-Boring Tools and Methods,” which is incorporated herein in its entirety by this reference. Without being bound to any particular theory, the angle of the tangent planes near the cutting edge may have a relatively greater influence on the durability of the cutting element 110 than the angle of the tangent planes near the center of the cutting element 110 due to the way materials are exposed by a wear scar 124, as shown in
In some embodiments, the boundary 118 between the first volume 114 and the second volume 116 of the polycrystalline table 113 defines a plurality of tangent planes (e.g., planes containing lines 138 and 140) that each form angles 142, 144 with the centerline of the cutting element of greater than 20°, greater than 30°, or even greater than 45°.
An earth-boring tool may be formed by securing a polycrystalline cutting element formed as described herein to a bit body. As a non-limiting example,
Cutting elements 110 and earth-boring rotary drill bits 200 as described herein may be used for forming a wellbore by contacting the earth-boring rotary drill bit 200 and its cutting elements 110 with a surface 132 of a subterranean formation 134 (see
In the cutting element 170 shown in
In the cutting element 180 shown in
Any of the cutting elements 150, 160, 170, 180 may be used with the earth-boring tool 200 or any other earth-boring tool, instead of or in addition to the cutting element 110. Furthermore, various other geometries may be selected for cutting elements and boundaries 118 based on the embodiments and principles disclosed herein.
To form the cutting elements 110, 150, 160, 170, 180 disclosed herein, portions of the polycrystalline table 113 and the substrate 112 may be masked, and the cutting element 10 may be at least partially placed in a corrosive material, such as an acid. For example, portions of the polycrystalline table 113 may be protected from the corrosive material by a seal or o-ring before the cutting elements 110, 150, 160, 170, 180 are exposed to the corrosive material.
Catalyst material may be selectively removed from certain portions of the polycrystalline table 113 to define the boundary 118 by, for example, targeted laser, ion, or focused particle beam removal of the catalyst material to differing depths or by selective masking and leaching of different portions of the polycrystalline table 113. In embodiments that include leaching, masking material may be selectively added or removed during the leaching process to facilitate formation of a boundary 118 having a selected shape. In some embodiments, the boundary 118 may be formed by a processes for selectively removing catalyst material to different depths within a polycrystalline superabrasive material as disclosed in U.S. patent application Ser. No. 13/947,723, filed Jul. 22, 2013, titled “Thermally Stable Polycrystalline Compacts for Reduced Spalling Earth-Boring Tools Including Such Compacts, and Related Methods,” the disclosure of which is incorporated herein in its entirety by this reference.
A cutting element was formed having polycrystalline diamond over a substrate, the polycrystalline diamond having a leach profile substantially as shown in
A cutting element was formed having polycrystalline diamond over a substrate, the polycrystalline diamond having a leach profile substantially as shown in
Additional non limiting example embodiments of the disclosure are described below.
An earth-boring tool, comprising a bit body and a cutting element secured to the bit body. The cutting element exhibits a contact back rake angle with respect to a surface of a formation to be cut by the bit body and comprises a polycrystalline superabrasive material. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a continuous boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary is nonlinear in a cross-sectional plane that includes a centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the earth-boring tool. Each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element greater than the contact back rake angle of the cutting element.
The earth-boring tool of Embodiment 1, wherein at least a portion of the boundary forms a frustoconical shape.
The earth-boring tool of Embodiment 2, wherein the frustoconical shape has an axis of revolution substantially coincidental with the centerline of the cutting element.
The earth-boring tool of Embodiment 1, wherein at least a portion of the boundary forms a paraboloid of revolution.
The earth-boring tool of Embodiment 4, wherein the paraboloid of revolution has an axis of revolution substantially coincidental with the centerline of the cutting element.
The earth-boring tool of any of Embodiments 1 through 5, wherein each tangent line in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the second volume.
The earth-boring tool of any of Embodiments 1 through 5, wherein each tangent line in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the first volume.
The earth-boring tool of any of Embodiments 1 through 7, wherein each tangent line in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 20°.
The earth-boring tool of Embodiment 8, wherein each tangent line in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 30°.
The earth-boring tool of Embodiment 9, wherein each tangent line in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 45°.
The earth-boring tool of any of Embodiments 1 through 10, wherein the second volume includes an annular volume adjacent to and extending along a peripheral surface of the cutting element from a working surface of the cutting element to the boundary between the first volume and the second volume.
An earth-boring tool, comprising a bit body and a cutting element secured to the bit body. The cutting element exhibits a contact back rake angle with respect to a surface of a formation to be cut by the bit body and comprises a polycrystalline superabrasive material. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary comprises a first area and a second area. The first area includes a portion of the boundary within a first radial distance of a centerline of the cutting element in a cross-sectional plane that includes the centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the earth-boring tool. The second area includes a portion of the boundary between the first radial distance from the centerline of the cutting element and a second radial distance from the centerline of the cutting element in the cross-sectional plane. The second radial distance corresponds to an exterior surface of the cutting element, and the first radial distance is at least 50% of the second radial distance. Each line tangent the boundary in the cross-sectional plane in the second area forms an angle with the centerline of the cutting element greater than the contact back rake angle of the cutting element.
The earth-boring tool of Embodiment 12, wherein the portion of the boundary in the first area forms a frustoconical shape.
The earth-boring tool of Embodiment 13, wherein the frustoconical shape has an axis of revolution substantially coincidental with the centerline of the cutting element.
The earth-boring tool of Embodiment 12, wherein the portion of the boundary in the first area forms a paraboloid of revolution.
The earth-boring tool of Embodiment 15, wherein the paraboloid of revolution has an axis of revolution substantially coincidental with the centerline of the cutting element.
The earth-boring tool any of Embodiments 12 through 16, wherein each line tangent the boundary in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the second volume.
The earth-boring tool of any of Embodiments 12 through 16, wherein each line tangent the boundary in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the first volume.
The earth-boring tool of any of Embodiments 12 through 18, wherein each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 20°.
The earth-boring tool of Embodiment 19, wherein each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 30°.
The earth-boring tool of Embodiment 20, wherein each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 45°.
A cutting element for an earth-boring tool, comprising a substrate and a polycrystalline superabrasive material secured to the substrate. The polycrystalline superabrasive material comprises a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material, a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material, and a boundary between the first volume and the second volume of the polycrystalline superabrasive material. The boundary is nonlinear in a cross-sectional plane that includes a centerline of the cutting element and an anticipated point of contact of the cutting element with the surface of the formation to be cut by the cutting element. Each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of greater than 20°.
The cutting element of Embodiment 22, wherein at least a portion of the boundary forms a frustoconical shape.
The cutting element of Embodiment 23, wherein the frustoconical shape has an axis of revolution substantially coincidental with the centerline of the cutting element.
The cutting element of Embodiment 22, wherein at least a portion of the boundary forms a paraboloid of revolution.
The cutting element of Embodiment 25, wherein the paraboloid of revolution has an axis of revolution substantially coincidental with the centerline of the cutting element.
The cutting element of any of Embodiments 22 through 26, wherein each line tangent the boundary in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the second volume.
The cutting element of any of Embodiments 22 through 26, wherein each line tangent the boundary in the cross-sectional plane intersects the centerline on a side of the boundary adjacent the first volume.
The cutting element of any of Embodiments 22 through 28, wherein each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 30°.
The cutting element tool of Embodiment 29, wherein each line tangent the boundary in the cross-sectional plane forms an angle with the centerline of the cutting element of greater than 45°.
A method of forming a wellbore comprising contacting an earth-boring tool with a surface of a subterranean formation. The earth-boring tool comprises a bit body and at least one cutting element secured to the bit body. The at least one cutting element comprises a polycrystalline superabrasive material comprising a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material and a second volume at least substantially free of catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material. A surface of the second volume is exposed at least partially around the cutting element. The method further comprises removing at least a portion of the polycrystalline superabrasive material from the second volume through contact with the surface of the subterranean formation and removing a portion of the first volume adjacent to and in contact with the second volume without rendering a portion of the second volume radially discontinuous with a remainder of the second volume.
A method of forming a wellbore comprising contacting an earth-boring tool with a surface of a subterranean formation. The earth-boring tool comprises a bit body and a cutting element secured to the bit body. The cutting element comprises a polycrystalline superabrasive material comprising a first volume including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material and a second volume at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material. A surface of the second volume is exposed at least partially around the cutting element. The method further comprises removing a portion of the second volume and removing a portion of the first volume without exposing the first volume through an aperture formed in the second volume.
The earth-boring tool, cutting element, or method of any of Embodiments 1 through 32, wherein the polycrystalline superabrasive material comprises diamond.
The earth-boring tool, cutting element, or method of any of Embodiments 1 through 32, wherein the polycrystalline superabrasive material comprises cubic boron nitride.
The earth-boring tool, cutting element, or method of any of Embodiments 1 through 34, wherein the cutting element further comprises a substrate.
While the present invention has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the invention as claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the invention as contemplated by the inventors. Further, embodiments of the disclosure have utility with different and various types and configurations of tools.
