This disclosure relates generally to cutting elements for earth-boring tools and related earth-boring tools and methods. More specifically, disclosed embodiments relate to configurations, designs, and geometries for cutting elements for earth-boring tools, which may increase cutting efficiency.
Wellbores are formed in subterranean formations for various purposes including, for example, extraction of oil and gas from the subterranean formation and extraction of geothermal heat from the subterranean formation. Wellbores may be formed in a subterranean formation using earth-boring tools, such as an earth-boring rotary drill bit. The earth-boring rotary drill bit is rotated and advanced into the subterranean formation. As the earth-boring rotary drill bit rotates, the cutting elements, cutters, or abrasive structures thereof cut, crush, shear, and/or abrade away the formation material to form the wellbore.
The earth-boring rotary drill bit is coupled, either directly or indirectly, to an end of what is referred to in the art as a “drill string,” which comprises a series of elongated tubular segments connected end-to-end that extends into the wellbore from the surface of earth above the subterranean formations being drilled. Various tools and components, including the drill bit, may be coupled together at the distal end of the drill string at the bottom of the wellbore being drilled. This assembly of tools and components is referred to in the art as a “bottom-hole assembly” (BHA).
The earth-boring rotary drill bit may be rotated within the wellbore by rotating the drill string from the surface of the formation, or the drill bit may be rotated by coupling the drill bit to a downhole motor, which is coupled to the drill string and disposed proximate the bottom of the wellbore. The downhole motor may include, for example, a hydraulic Moineau-type motor having a shaft, to which the earth-boring rotary drill bit is mounted, that may be caused to rotate by pumping fluid (e.g., drilling mud or fluid) from the surface of the formation down through the center of the drill string, through the hydraulic motor, out from nozzles in the drill bit, and back up to the surface of the formation through the annular space between the outer surface of the drill string and the exposed surface of the formation within the wellbore. The downhole motor may be operated with or without drill string rotation.
Different types of earth-boring rotary drill bits are known in the art, including fixed-cutter bits, rolling-cutter bits, and hybrid bits (which may include, for example, both fixed cutters and rolling cutters). Fixed-cutter bits, as opposed to roller cone bits, have no moving parts and are designed to be rotated about the longitudinal axis of the drill string. Most fixed-cutter bits employ Polycrystalline Diamond Compact (PDC) cutting elements. The cutting edge of a PDC cutting element drills rock formations by shearing, like the cutting action of a lathe, as opposed to roller cone bits that drill by indenting and crushing the rock. The cutting action of the cutting edge plays a major role in the amount of energy needed to drill a rock formation.
A PDC cutting element is usually composed of a thin layer, (about 3.5 mm), of polycrystalline diamond bonded to a cutting element substrate at an interface. The polycrystalline diamond material is often referred to as the “diamond table.” A PDC cutting element is generally cylindrical with a diameter from about 8 mm up to about 24 mm. However, PDC cutting elements may be available in other forms such as oval or triangle-shapes and may be larger or smaller than the sizes stated above.
A PDC cutting element may be fabricated separately from the bit body and secured within cutting element pockets formed in the outer surface of a blade of the bit body. A bonding material such as an adhesive or, more typically, a braze alloy may be used to secure the PDC cutting element within the pocket. The diamond table of a PDC cutting element is formed by sintering and bonding together relatively small diamond grains under conditions of high temperature and high pressure (HTHP) in the presence of a catalyst (such as, for example, cobalt, iron, nickel, or alloys and mixtures thereof) to form a layer or “table” of polycrystalline diamond material on the cutting element substrate.
In embodiments, cutting elements for earth-boring tools may include a substrate and a polycrystalline diamond material affixed to the substrate at an interface. The polycrystalline diamond material may have a raised cutting surface including at least two cutting edges, and first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element. The first transition surfaces may include multiple planar surfaces.
In embodiments, a method of manufacturing earth-boring tools may include forming a drill bit body and forming at least one blade extending from one end of the drill bit body. The at least one blade comprising a leading edge section. Forming at least one cutting element in each at least one blade proximate the leading edge section of the at least one blade. Forming the at least one cutting element includes forming a polycrystalline diamond material, affixing a first end of the polycrystalline diamond material at an interface to a substrate, and shaping a second end of the polycrystalline diamond material. Shaping the second end of the polycrystalline diamond material includes forming at least two cutting edges defining a raised cutting surface, and forming first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element, wherein the first transition surfaces comprise multiple planar surfaces.
In embodiments, earth-boring tools may include a bit body, a plurality of blades extending from one end of the body, each blade comprising a leading edge section, at least one cutting element disposed within each blade proximate the leading edge section of the blade. The at least one cutting element having a substrate and a polycrystalline diamond material affixed to the substrate at an interface. The polycrystalline diamond material comprising a raised cutting surface having at least two cutting edges and first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element. The first transition surfaces comprise multiple planar surfaces.
While this disclosure concludes with claims particularly pointing out and distinctly claiming specific embodiments, various features and advantages of embodiments within the scope of this disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings. In the drawings:
The illustrations presented herein are not meant to be actual views of any particular cutting element, earth-boring tool, or component thereof, but are merely idealized representations which are employed to describe embodiments of the disclosure. Thus, the drawings are not necessarily to scale.
Disclosed embodiments relate generally to geometries for cutting elements for earth-boring tools which may exhibit longer useful life, exhibit higher durability, and require lower energy input to achieve a target depth of cut and/or rate of penetration.
As used herein, the term “cutting elements” means and includes, for example, superabrasive (e.g., polycrystalline diamond compact or “PDC”) cutting elements employed as fixed cutting elements, as well as tungsten carbide inserts and superabrasive inserts employed as cutting elements mounted to a body of an earth-boring tool.
As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features, and methods usable in combination therewith should or must be excluded.
As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0 percent met, at least 95.0 percent met, at least 99.0 percent met, at least 99.9 percent met, or even 100.0 percent met.
As used herein, the term “about” used in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter, as well as variations resulting from manufacturing tolerances, etc.).
As used herein, the term “earth-boring tool” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore in a subterranean formation. For example, earth-boring tools include fixed-cutter bits, roller cone bits, percussion bits, core bits, eccentric bits, bicenter bits, reamers, mills, drag bits, hybrid bits (e.g., bits including rolling components in combination with fixed cutting elements), and other drilling bits and tools known in the art.
As used herein, 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 referred to as “superhard” materials.
As used herein, the term “polycrystalline material” means and includes any structure comprising a plurality of grains (e.g., crystals) of material that are bonded directly together by inter-granular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.
As used herein, the terms “inter-granular bond” and “interbonded” mean and include any direct atomic bond (e.g., covalent, metallic, etc.) between atoms in adjacent grains of superabrasive material.
As used herein, terms of relative positioning, such as “above,” “over,” “under,” and the like, refer to the orientation and positioning shown in the figures. During real-world formation and use, the structures depicted may take on other orientations (e.g., may be inverted vertically, rotated about any axis, etc.). Accordingly, the descriptions of relative positioning must be reinterpreted in light of such differences in orientation (e.g., resulting in the positioning structures described as being located “above” other structures underneath or to the side of such other structures as a result of reorientation).
As used herein, the term “flank angle” means and includes a smallest angle between a given transition surface and a plane at least substantially parallel to the raised cutting surface.
The table 110 of the cutting element 100 may include a raised cutting surface 108 at a farthest distance from the substrate 112 having cutting edges 106 for positioning to first engage with the earth formation and located proximate to radially outermost portions of the table 110 with respect to a longitudinal axis of the cutting element 100. The table 110 may also include a recess 102 located proximate to a geometric center of the table 110 and positioned closer to the substrate 112 than the raised cutting surface 108. The table 110 may also include transition surfaces 116 extending from portions of the raised cutting surface 108 extending between the cutting edges 106 radially outward toward a periphery of the table 110 and longitudinally from the raised cutting surface 108 toward the substrate 112. Each respective portion of the table 110 located between the cutting edges 106 may include multiple transition surfaces 116. In some embodiments, the transition surfaces 116 may be planar, may extend over at least substantially the same longitudinal distance from the raised cutting surface 108 toward the substrate 112, and may extend along a respective portion of the angular distance around the perimeter of the table 110. Such transition surfaces 116 may present an angular, faceted, series of chamfer surfaces to render the transition between the cutting edges 106 around the perimeter of the table 110, and between the raised cutting surface 108 and a side surface 118 of the cutting element 100, more gradual.
In the embodiment specifically illustrated in
Cutting element 100 may include three different flank angles (e.g., first flank angle, second flank angle, and third flank angle) for each of the transition surfaces 116 oriented at different flank angles. The flank angles are the smallest angle between a given transition surface 116 and a plane at least substantially parallel to the raised cutting surface 108 of cutting element 100. Each one of the three different flank angles differs from the other flank angles.
Similar to the cutting element 300 illustrated in
In the embodiment illustrated in
The cutting face 706 may intersect with an inner transition surface 712 transitioning from the cutting face 706 longitudinally toward a substrate to form a recess 702. The transition surface 712 may extend at an at least substantially constant angle from a planar bottom of the recess 702 to the cutting face 706 (e.g., may take the form of a chamfer), or may be curved from the planar bottom of the recess 702 to the cutting face 706 (e.g., at constant or variable radius), or may have a more complex transition geometry. In some embodiments, the inner edges of the transition surface 712 intersecting with the planar bottom surface of the recess 702 may be nonlinear. For example, the transition surface 712 may have a variable (e.g., non-constant) thickness in the regions extending between the nodes of the generally polygonal shape of the cutting surface 706, as measured in a direction perpendicular to the at least substantially linear edges of the cutting surface 706 extending between the cutting edges 708. More specifically, the inner edges 714 of the transition surfaces 712, as defined at intersections of the transition surface 712 with the planar bottom of the recess 702, may be arcuate. As a specific, nonlimiting example, the inner edges 714 of the transition surfaces 712 may be curved, may bow radially toward the geometric center of the recess 702, and may peak at least substantially at the midpoint between respective cutting edges 708, such that the thickest portion of the transition surfaces 712 may be located at least substantially at that midpoint. In other embodiments, the interior edges 714 of the inner transition surfaces 712 at the intersection with the planar bottom of the recess 702 (as illustrated in
The cutting face 706 may also intersect with an outer transition surface 704, which may extend radially outward from the cutting face 706 to the side surface 710 and longitudinally from the cutting face 706 toward the substrate. The outer transition surfaces may take any of the forms, and have any of the configurations, described previously in connection with
The recess 702 may generally be in the shape of a rectangle (e.g., a square), and the cutting surface 606 may likewise be at least substantially rectangle shaped (e.g., square shaped). In some embodiments, recess 702 may be omitted from cutting element 700 similar to cutting element 200 of
As shown in each view of
The second chamfer 920 may likewise extend around the entire circumference of the table 910, and may form a sloped or curved transition between the first chamfer 918 and a third chamfer 924 or between the first chamfer 918 and the transition surface 916 and between the first chamfer 918 and the cutting surface 908. The central view of
The right-hand view of
The geometries of the several views of
Where logically possible, the features of the cutting elements shown and described in connection with
The modified geometries of the embodiments described above are expected to mitigate thumbnail cracking and tangential overload when compared to geometries for other cutting elements known to the inventors. Furthermore, modified geometries of the embodiments described above contain critical angled faces to maintain cutting efficiency while allowing for increased durability. The modified geometries of the embodiments described above will allow for greater use in higher weight and torque drilling environments.
Additional non-limiting example embodiments of the disclosure are described below.
Embodiment 1: A cutting element comprising a substrate and a polycrystalline diamond material affixed to the substrate at an interface. The polycrystalline diamond material comprising a raised cutting surface comprising at least two cutting edges, and first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element, wherein the first transition surfaces comprise multiple planar surfaces.
Embodiment 2: The cutting element of Embodiment 1, further comprising a recess in a center of the raised cutting surface.
Embodiment 3: The cutting element of Embodiment 2, further comprising second transition surfaces between edges of the raised cutting surfaces and a bottom surface of the recess.
Embodiment 4: The cutting element of Embodiment 2 or Embodiment 3, wherein one or more edges between the raised cutting surface and the second transition surfaces are linear.
Embodiment 5: The cutting element of Embodiment 2 or Embodiment 3, wherein one or more edges between the raised cutting surface and the second transition surfaces comprise one or more arcs.
Embodiment 6: The cutting element of Embodiment 2 or Embodiment 3, wherein edges between the raised cutting surface and the second transition surfaces are chamfered.
Embodiment 7: The cutting element of Embodiment 1 through 6, wherein at least one edge of the raised cutting surface comprises a chamfered edge.
Embodiment 8: The cutting element of Embodiment 1 through 7, wherein the at least two cutting edges of the raised cutting surface are chamfered.
Embodiment 9: The cutting element of Embodiments 1 through 8, wherein edges between the longitudinal side surface of the cutting element and the first transition surfaces are chamfered.
Embodiment 10: The cutting element of Embodiments 1 through 9, wherein edges between the raised cutting surface and the first transition surfaces are chamfered.
Embodiment 11: The cutting element of Embodiments 1 through 10, wherein one or more edges between the raised cutting surface and the second transition surfaces are linear.
Embodiment 12: The cutting element of Embodiments 1 through 11, wherein one or more edges between the raised cutting surface and the first transition surfaces comprise one or more arcs.
Embodiment 13: The cutting element of Embodiments 1 through 12, wherein the raised cutting surface comprises at least three cutting edges.
Embodiment 14: The cutting element of Embodiments 1 through 13, wherein the raised cutting surface comprises at least four cutting edges.
Embodiment 15: A method of manufacturing an earth-boring tool comprising forming a drill bit body, forming at least one blade extending from one end of the drill bit body. The at least one blade comprising a leading edge section. Forming at least one cutting element in each at least one blade proximate the leading edge section of the at least one blade. Forming the at least one cutting element comprises forming a polycrystalline diamond material, affixing a first end of the polycrystalline diamond material at an interface to a substrate, and shaping a second end of the polycrystalline diamond material. Shaping the second end of the polycrystalline diamond material comprises forming at least two cutting edges defining a raised cutting surface, and forming first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element, wherein the first transition surfaces comprise multiple planar surfaces.
Embodiment 16: The method of Embodiment 15, further comprising forming a recess in a center of the raised cutting surface.
Embodiment 17: The method of Embodiment 16, further comprising forming second transition surfaces between edges of the raised cutting surface and a bottom surface of the recess.
Embodiment 18: An earth-boring tool comprising a bit body, a plurality of blades extending from one end of the body, each blade comprising a leading edge section, at least one cutting element disposed within each blade proximate the leading edge section of the blade. The at least one cutting element comprising a substrate and a polycrystalline diamond material affixed to the substrate at an interface. The polycrystalline diamond material comprising a raised cutting surface comprising at least two cutting edges and first transition surfaces between the at least two cutting edges of the raised cutting surface and a longitudinal side surface of the cutting element. The first transition surfaces comprise multiple planar surfaces.
Embodiment 19: The earth-boring tool of Embodiment 18, further comprising a recess in a center of the raised cutting surface.
Embodiment 20: The cutting element of Embodiment 19, wherein a bottom surface of the recess is positioned closer to the substrate than the raised cutting surface.
While certain illustrative embodiments have been described in connection with the figures, those of ordinary skill in the art will recognize and appreciate that the scope of this disclosure is not limited to those embodiments explicitly shown and described in this disclosure. Rather, many additions, deletions, and modifications to the embodiments described in this disclosure may be made to produce embodiments within the scope of this disclosure, such as those specifically claimed, including legal equivalents. In addition, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being within the scope of this disclosure.
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/146,531, filed Feb. 5, 2021, the disclosure of which is hereby incorporated herein in its entirety by this reference.
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