This application is a § 371 National Stage Application of PCT International Application No. PCT/EP2019/082653 filed Nov. 27, 2019 claiming priority to EP 18212827.2 filed Dec. 17, 2018.
The present disclosure relates to a percussive drill bit assembly. More particularly, the disclosure relates to the flow distribution in the down-the-hole hammer drill bit assembly.
Down-the-hole (DTH) percussive drilling involves a method combining percussions and rotations. A pressurized fluid is supplied via a drilling tube to a drill bit located at the bottom of a bore hole. This fluid acts to both drive the hammer drilling action and to flush rearwardly the broken debris resulting from the cutting action. Typically, a DTH percussive drilling assembly or a hammer drill bit assembly comprises a casing extending between a top sub and a drill bit that is releasably coupled to a drive sub. A reciprocating fluid driven impact device or piston is arranged inside the casing. At both ends of the piston are working chambers, namely a top working chamber and a bottom working chamber into which fluid is discharged according to the work cycle of the piston. Conventional DTH drilling machines also comprise a drill bit assembly made up of a shank, a bit head which further comprises buttons on the surface facing the drill hole, and flushing holes to allow broken debris to be removed immediately so that the buttons hit the fresh solid rock surface with each impact.
Presently used drill bit assemblies suffer from the drawback that there is not enough volume available in the drill bit assembly for air, especially in the assemblies having bits in which the internal bore at the center of the bit is closed at the front end of the shank and open at the rear end towards the piston. In such bits, usually the number of splines is more than the number of flushing holes, and since there is a change in the flow paths of the air when it travels from the splines to the flushing holes, some space is needed for the air to accommodate this change. When this volume for air is not provided, the efficiency of drilling gets affected.
To address this problem, it has been observed that in some drill bits, this volume is provided by the presence of a groove in the shank of the drill bit. The disadvantage of this construction is that the bit shank integrity was compromised which results in a shorter life span of the drill bit. The frequent replacement of the drill bit incurs high costs for maintenance and also results in significant down time for the drilling machine.
Another approach to address this problem has been observed in some reverse circulation (RC) hammers which comprise of a shroud-like structure or a sleeve around the drive sub to create the volume for collecting the flow from the hammer. Examples of such assemblies are described in patent documents U.S. Pat. No. 6,702,045 and EP1454031. The problem with this type of construction is that the flow is usually between the outer surface of the drive sub and the inner surface of the shroud, and the flow does not connect the flushing holes in the drill bit. Also, this kind of a solution turns out to be more expensive and complicated to construct as it involves an additional component which needs to be assembled in to the hammer. Since the DTH drilling machine is located inside the drill hole, the structure of the machine needs to be compact.
Accordingly, there exists a need for a robust, compact and structurally uncomplicated drill bit assembly which improves the flow distribution in the drill bit assembly without compromising the integrity of the drill bit.
The aim of the present disclosure is to overcome or at least reduce the above-mentioned problems.
It is an objective of the present disclosure to provide a robust and structurally uncomplicated rock drill bit assembly with good flow distribution especially through the drill bit. It is a further objective to achieve good flow distribution in the drill bit assembly by providing volume for the pressurized fluid or air which flows downstream during the drilling operation without the use of additional components. It is yet another objective to preserve the integrity of the drill bit during the drilling operations so that fewer bit replacements for the hammer are required.
The objectives are achieved by providing a rock drill bit assembly which allows for the volume or space for the upstream flow of pressurized fluid from the hammer exhaust while connecting the splines with the flushing holes.
According to the first embodiment of the present disclosure, there is provided a down-the-hole hammer assembly activated by fluid under pressure, which comprises an elongated casing having a front end or an axially forward end and a rear end or an axially rearward end, a fluid-powered piston arranged movably inside the casing, a top working chamber at an axially rearward side or top side of the piston, a bottom working chamber at an axially forward side or bottom side of the piston, a plurality of fluid passages for feeding and discharging pressurized fluid into and out of the working chambers for generating reciprocating movement for the piston, a drill bit connectable to the front end or the axially forward end of the casing and provided with an anvil facing towards the piston for receiving the impacts of the piston, and an annular drive sub surrounding at least a portion of the shank and cooperating with the drill bit to form fluid passages extending length-wise along the shank, wherein the drive sub comprises a concave arcuate groove extending circumferentially through the drive sub forming a chamber for collecting the fluid from the exhaust flow and redistributing the volume of the collected fluid to the flushing holes arranged in the drill bit. The arcuate groove is located above the feed force transmission point as the distance to the exhaust, i.e. the distance of the flushing holes to atmosphere, is greater and it will allow for the flow to be more evenly distributed among the flushing holes and less turbulent inside the flushing holes, resulting in the more predictable flushing which is easier to optimize. If the groove is positioned below the feed force transmission point a weak spot would be created that will be subject to tensile stress which leads to fatigue failures. During drilling the feed force transmission area is subject to impact and vibrations from the bit. As the piston hits to the bit striking face, the bit moves forward inside the rock, breaks the rock and then bounces back toward the hammer and is stopped by the feed force transmission area. Therefore, it is important that the groove is positioned above the feed force transmission point to avoid the formation of tensile stress. The arcuate groove has a minimum volume dimension of:
Minimum flow volume≥2×min(Flow area from hammer; Flushing holes area)
Meaning that the volume should be greater than 2 times either the flow area from hammer (the area between the splines) or the flushing holes area, depending which is the smallest.
During the drilling operation, the exhaust flow coming from the hammer is collected in a chamber formed by the arcuate concave groove in the drive sub. This volume of pressurized fluid is connected to the flushing holes arranged in the drill bit which permits even redistribution of the flow from the hammer among the flushing holes without having to create flow passages on the shank of the drill bit.
Preferably, the chamber in the drive sub creates a fluid passage between the outer surface of the drill bit and the inner surface of the drive sub for collecting the fluid from the exhaust flow. Preferably, the outer diameter of the drive sub is smaller than the outer diameter of the bit head. The drill bit and the drive sub are configured to be arranged such that the drive sub is positionable to axially overlap and to radially encompass at least a part of the shank region of the drill bit. The angle of the bottom edge of the drive sub corresponds to the angle of the bit head-shank transition area. This is advantageous because it ensures accurate positioning of the drill bit relative to the drive sub, and also provides an increased contact area between the bit and the sub which in turn reduces the surface pressure or stress on the bit thereby increasing the lifespan of the bit.
Preferably, the drive sub comprises on its top edge, a plurality of peripheral projections which create slots extending through the thickness of the wall of the drive sub. These slots allow passage of the pressurized fluid from the hammer exhaust into the drive sub. An advantage of having these slots is that the bit retaining ring does not need the traditional scallops to allow the fluid to pass, thus making the bit retaining ring stronger and allowing it to have more retention area. Another advantage of having these slots is that the pressurized fluid is more evenly distributed in the space between the splines of the bit and the splines of the drive sub providing good lubrication between the splines.
One of the advantages of this embodiment of the present disclosure is that there is no need for any additional component like a sleeve or shroud to form the chamber for accommodating volume of the pressurized fluid from the exhaust flow. This makes the construction of the apparatus substantially simplified. Another advantage of this feature is that there is no need to create flow passages on the shank. This is useful in preserving the integrity and strength of the drill bit and increasing its life-span.
Optionally, a radially inward facing part of the drive sub comprises a plurality of radially extending retaining formations and a radially outward facing part of the shank of the rock drill bit comprises a plurality of radially extending retaining formations such that the formations of the drive sub are configured to inter-engage cooperatively and releasably with the formations of the shank of the rock drill bit. Preferably, the retaining formations on both the shank of the bit and the drive sub, are in the form of axially and radially extending splines. Such an arrangement enables the transfer of torque from the drive sub to the rock drill bit. The advantage of such an arrangement is that the bit can be easily and readily removed and replaced when worn, which is especially useful when the service lifetime for the bit is different from that of the drive sub. It is an advantage to have these complimentary splines on the shank and the sub to allow easy and efficient transfer of rotational drive from the drive sub to the rock drill bit.
Preferably, the hammer described in the present disclosure is pneumatic and the fluid under pressure is air.
According to the second embodiment of the present disclosure, the drilling assembly is provided with a rock drill bit positioned at the cutting end or the axially forward end of the hammer, and comprising of a head, an elongated shank connected to the head at the front end or the axially forward end of the shank, a head-shank transition area where the head connects to the shank, an anvil at the axially rearward end of the shank for receiving the impact of the piston, a plurality of buttons provided at the front face of the head configured to engage the material to be crushed in the intended direction of drilling and a plurality of flushing passages for the fluid extending through the head and having at least one opening at the front face of the head. The rock drill bit solves the problem of increased stress on the bit head-shank transition area by the characterizing feature that the angle formed between the head and the shank at the head-shank transition area is greater than 100 degrees. The advantage of having an angle greater than 100 degrees in the bit head-shank transition area is that this kind of construction greatly reduces the stress encountered by the bit head-shank transition area during the drilling operation. Reduced stress preserves the strength of the rock drill bit ensuring that the rock drill bit has a longer than average lifespan. This reduces the maintenance cost for the drilling assembly as the rock drill bit does not have to be replaced frequently. Further, the down-time of the equipment is also reduced as now the bit is replaced fewer number of times.
Another advantage of this unique feature of the angle between the bit head and shank transition is that it forms a conical surface in the bit to transmit the feed force.
Advantageously, this conical surface guides precisely the drill bit during operation and increase the contact surface for feed force transmission thus reducing the surface pressure (stress) in the bit head-shank transition area.
Preferably, the angle between the bit head and shank in the rock drill bit should be between 100 and 160 degrees. More preferably, the angle between the bit head and shank should be between 110 and 130 degrees.
According to the third embodiment of the present disclosure, the internal bore at the center of the bit is closed at the front end or the axially forward end of the shank and open at the rear end or the axially rearward end of the shank which is towards the piston. The internal blind bore in this rock drill bit is configured to constitute a part of the bottom working chamber of the hammer. Since the center of the bit is not used for flushing as in conventional drill bits, this volume can be used as the bottom working chamber for the hammer. An advantage of this kind of construction is that it would make the hammer more compact.
Optionally, the feature of the angle between bit head and shank being greater than 100 degrees, would improve the strength of the drill bits, which is especially beneficial for bits in which the internal bore at the center is closed at the front end of the shank and open at the rear end towards the piston. These blind-bore bits encounter immense stress in the bit head-shank transition area because of the presence of flushing holes in that area which create fluid passages for the upstream flow from the hammer. Having an angle greater than 100 degrees between the bit head and the shank in such blind-bore bits substantially improves the strength of the bit.
According to the fourth embodiment of the disclosure, in the rock drill bit, the bit head-shank transition area is provided with a recess near the opening for the flushing holes, which is preferably in the form of an inward curvature or an arcuate concave groove. This structural feature provides the advantage of reduced stress in the bit head-shank transition area in the rock drill bit. Specifically, this structural feature improves the strength and lifespan of those rock drill bits in which the internal central bore is closed at the axially forward end of the shank and open at the axially rearward end of the shank which is towards the piston. Optionally, the recess can be in the shape of square, circular, elliptical, rectangular or triangular pockets.
Preferably, the bit head and the shank in the rock drill bit are constructed as a single integrated unit. However, the features explained above are also adapted to provide good drilling results if the rock drill bit constitutes of multiple components comprising the bit head and the shank assembled together.
Optionally, the rock drill bit described in the present disclosure is adapted to work with the reverse circulation percussive hammers. The reverse circulation drill bits used in this application may have flushing holes positioned between the center and the periphery of the bit head. Alternatively, the flushing holes may be positioned radially at the periphery of the bit head. The reverse circulation hammer may or may not have a shroud around the bit head. According to one of the embodiments, the reverse circulation drill bit does not have the shroud around the bit head, and the outer surface of the bit head mates with the hole wall. Advantageously, the removal of one component (the shroud) from the traditional construction makes the hammer more compact.
Some embodiments of the invention will be explained in greater detail with reference to the accompanying drawings in which:
The present disclosure will now be described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
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Complimentary splines 42 (on the drill bit 14) and 43 (on the drive sub 18) are also shown in the
The different aspects of the disclosure are also applicable to reverse circulation hammers and the bits used therein. Referring to
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Similarly,
Number | Date | Country | Kind |
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18212827 | Dec 2018 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2019/082653 | 11/27/2019 | WO |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2020/126359 | 6/25/2020 | WO | A |
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