Patent Grant
10246943
The present disclosure is directed to directional drilling and, in particular, to drill bits for directional drilling, which have improved wear characteristics.
Directional drilling (e.g., horizontal directional drilling) involves drilling or boring through the earth, for example, to form a well or to run utilities through the ground. A directional drilling system typically includes a directional drilling machine (e.g., rig, drill, boring machine, etc.), multiple segments of drill pipe (e.g., step, rod, etc.), and a drill bit (e.g., cutting head or bit, drill bit). A proximal end of the drill pipe is coupled to and rotated by the directional drilling machine, while a distal end of the drill pipe is coupled to and rotates the drill bit. The drill bit can thereby drill a hole through the earth, which is increased in length as additional segments of drill pipe are added.
One type of drill bit is commonly referred to as a duckbill, which includes a base and a head. The base is configured to couple to the drill pipe. For example, the base is a generally planar segment having a predetermined hole pattern that corresponds to a bolt or hole pattern on the drill pipe. The predetermined pattern may, for example, be associated with a particular manufacturer of the directional drilling machine and/or drill pipe. The head is configured to direct the drill bit in a desired direction, while also engaging and drilling through the earth material. More particularly, the head extends from the base in a direction that is not parallel with the axis of the drill pipe (e.g., the head is portion of surface). This non-parallel angle allows the drill bit to be driven forward when not rotated, so as to steer the drill bit in the direction of the taper. The peripheral edges of the drill bit engage and move the earth material for drilling therethrough, but are subject to wear at varying rates depending on the earth material being drilled through.
Disclosed herein is a drill bit for directional drilling. The drill bit includes a main body and a wear component. The main body is unitary and formed of a first material. The main body includes opposed outer surfaces and a periphery extending between the opposed surfaces. The wear component is unitary and is formed of a second material that is harder than the first material. The wear component comprises a retention portion and a wear portion. The retention portion is positioned within the first material of the main body. The retention portion includes opposed retention surfaces that, moving in a direction inward from the periphery, taper apart from each other toward the opposed outer surfaces of the main body. The wear portion extends outward from the retention portion relative to the periphery of the main body. The wear portion is substantially planar and is configured to form an outer wear edge.
The wear edge may be coextensive with the periphery of the main body or may protrude from the periphery of the main body. The retention portion may also include a plurality of retention segments that are spaced apart from each other, each of which includes the opposed retention surfaces. The wear component may further comprise a sacrificial portion that extends outward from the wear portion relative to the periphery of the main body. The sacrificial portion is coupled to the wear portion with a weakened portion therebetween. The sacrificial portion is configured to be removed from the wear component at the weakened portion to form the wear edge.
These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims and the accompanying figures.
The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
As shown schematically in
As shown in
With reference to
The head 130 is configured to engage the earth material to both guide the drill bit 100 in a desired direction and to move or drill the earth material. The head 130 forms another generally planar segment having planar, opposed surfaces 132 with an outer periphery 134 (e.g., peripheral surface or edge, or wear edge) that extends between the opposed surfaces 132. The periphery 134 of the head 130 is continuous with the periphery 126 of the base 120, such that the main body 110 may be considered to have one periphery. The head 130 extends forward from the base 120 at a non-parallel angle relative thereto. For example, one or both of the opposed surfaces 132 of the head 130 may extend at an angle of approximately 5-20 degrees relative to the opposed surfaces 122 of the base 120. The head 130 also extends or tapers at a non-parallel angle relative to an axis of rotation of the drill tube, which allows the drill bit 100 to engage the earth material and be moved in a direction of the taper relative to the axis of the drill tube. The head 130 also includes one or more wear components 240, 340, which are embedded in the head 130 at various locations around the periphery of the head 130. For example, the wear components 240 may be positioned toward a proximal end of the head 130 in a region adjacent the base 120, while the wear component 340 may be position toward or at a distal end of the head 130 away from the base 120.
The main body 110 of the drill bit 100 is a unitary body, which is formed during a casting process. For example, the main body 110 may be a cast material, such as chromium-molybdenum alloy steel, iron, etc.
As referenced above, each of the wear components 140, 240, 340 is embedded in the main body 110 of the drill bit 100. More particularly, each of the different types of wear components 140, 240, 340 are cast-in-place components, meaning that the material forming the main body 110 solidifies around a portion of the wear components 140, 240, 340 for retention in the main body 110.
With reference to
The retention segments 152 are configured be positioned (e.g., embedded) within the cast material of the main body 110 of the drill bit 100, so as to couple and retain the wear component 140 to the main body 110 of the drill bit 100. As shown in
Instead or additionally, as shown in
In the example shown, the retention portion 150 may three retention segments 152, including two outer retention segments 152 and one middle retention segment. The outermost opposed edges 152b of the two outer retention segments flare or taper outwardly relative to each other. Inner opposed edges 152b of the two outer retention segments 152, as well both opposed edges 152b of the inner retention segment 152, may extend at a generally perpendicular angle relative to the edge 162 of the wear portion 160.
According to other embodiments, it is contemplated that the opposed surfaces 152a and opposed edges 152b of the retention segments 152 may widen in other manners (e.g., in a curved manner and/or at different angles). Furthermore, while the retention portion 150 is depicted as including three retention segments 152, the wear component 140 may be configured with fewer (e.g., one or two) or more (e.g., four or more retention) retention segments 152.
The wear portion 160 extends outward from the retention segments 152 relative to the base 120 of the drill bit 100. The wear portion 160 forms an outer edge 162 (e.g., outer or wear edge or surface) that protrudes outward from the periphery 126 of the base 120 (as shown) or is coextensive (e.g., flush) therewith. For example, the outer edge 162 of the wear portion 160 may extend generally parallel with the periphery 126 of the base 120. In use, the outer edge of the wear portion 160 engages the earth material for drilling or boring therethrough.
The wear portion 160 is substantially planar having opposed surfaces 164 (e.g., upper and lower surfaces) which are substantially planar and parallel with each other. The opposed surfaces 164 may, for example, protrude outwardly from the periphery 126 of the base 120 and be substantially parallel with one of the opposed surfaces 122 of the base 120, or be at an inclined angle relative thereto (see, e.g., wear component 140 in the drill bit 300 shown in
The wear portion 160 has a thickness that is less than that of the main body 110 of the drill bit 100. For example, the wear portion 160 may have a thickness of between approximately ⅛ and ¼ inch, while the main body 110 may have a thickness of between approximately ½ and 1 inch (e.g., approximately ¾ inch). The wear portion 160 also has a thickness that is less than that of the retention portion 150 at its thickest point at the peak of its tapered profile. According to other exemplary embodiments, the wear portion 160 may have a thickness that is approximately equal to that of the main body 110, such as approximately 75% or more (e.g., 90% or more) of the thickness of the main body 110. The wear portion 160 may also be thicker than the retention portion 150 at its peak thickness, for example, by forming a concave region between the retention portion 150 and the wear portion 160, thereby allowing the retention portion 150 to still taper toward the opposed surfaces 122 of the base 120 of the main body 110.
The wear portion 160 may be partially surrounded by the cast material of the base 120 of the main body 110 of the drill bit 100 and protrude outwardly therefrom. The wear portion 160 may also be coupled to and extend between multiple retention segments 152 at spaced apart locations generally along the outer periphery 126 of the base 120 of the drill bit 100. According to other embodiments, the wear portion 160 may have other shapes (e.g., curved) and/or be nonplanar (e.g., having a trapezoidal or curved cross-sectional profile in an inward/outward direction).
The sacrificial portion 170 is coupled to and extends outward from the wear portion 160 relative to the base 120 of the main body 110 of the drill bit 100. The sacrificial portion 170 is configured to be received in and supported by the mold during the casting process, so as to properly position and orient the wear component 140 relative to the main body 110 of the drill bit 100. The sacrificial portion 170 may, for example, be substantially rectilinear and planar and extend for a distance substantially equal to that of the wear portion 160 along the periphery 126 of the base 120. The sacrificial portion 170 may also include protrusions 172 that extend away from a planar face thereof. The protrusions 172 are positioning features that properly locate, orient, and retain the wear component 140 to the mold during the casting process.
The sacrificial portion 170 is configured to be detached from the wear portion 160 after the casting process (see
The wear component 140, including the retention portion 150, the wear portion 160, and the sacrificial portion 170, is a unitary component that is harder and/or exhibits other improved wear characteristics as compared to the cast material forming the body 110 of the drill bit 100. For example, the wear component 140 may be formed (e.g., cast, forged, machined, and/or hardened) from a steel alloy (e.g., 15-3 chrome iron alloy) or other suitable material.
As shown in
As with the retention portion 150, the retention portion 250 tapers or flares moving inward form the periphery 134 toward the opposed surfaces 132 of the head 130 and/or parallel with the opposed surfaces 132 (e.g., in a direction following the periphery 134). As with the wear portion 160, the wear portion 260 may be substantially planar and extends outward from the retention portion 250 to form a wear edge 262 beyond or coextensive with the periphery 134. As with the sacrificial portion 170, the sacrificial portion 270 extends outward form the wear portion 260 and is configured to detach therefrom at a weakened portion 272 to form the wear edge 262. The wear component 240 may, but for locating features of the sacrificial portion 270, have a substantially constant cross-section over a majority of the length thereof in a plane that is generally perpendicular to an upper surface and an inner and/or outer edge of the wear component 240. The wear components 240 may, for example, be coupled to the head 130 of the drill bit 100 proximate the periphery 134 thereof.
As with the wear component 140, the wear component 240, including its retention portion 250, wear portion 260, and sacrificial portion 270, is a unitary component that is harder and/or exhibits other improved wear characteristics as compared to the cast material forming the body 110 of the drill bit 100. For example, the wear component 240 may be formed (e.g., cast, forged, machined, hardened) from a steel alloy (e.g., containing chromium and/or molybdenum) or other suitable material. For further details of the wear component 240, including alternative configurations for various features or aspects thereof, refer to the discussion of the wear component 140 above.
As shown in
The retention portion 350 includes one or more retention segments 352, which are flared moving inward from the periphery 134 of the head 130 in a direction toward the opposed surfaces 132 of the head 130. While the wear portion 360 protrudes outwardly to form teeth 364a, as discussed below, the retention segments 352 each extend straight at a non-parallel angle relative to each other. The retention segments 352 may also protrude outwardly from the periphery 134 of the head 130 of the main body 110. As outer edges of the retention segments 352 are not surrounded by the cast material of the head 130, the angled relationship between the segments 352 aids in preventing side-to-side movement of the wear component 330 relative to the main body 110 of the drill bit 100.
The wear portion 360 extends outward from the retention portion 350. The wear portion 360 is substantially planar and includes opposed planar surfaces 362. An outer edge 364 of the wear portion 360 has a convoluted profile that forms a series of teeth 364a (e.g., jagged elements). The teeth 364a protrude outwardly from the retention portion 350 to form a distal end of the drill bit 100. The periphery 134 at a distal end of the head 130 may also have a convoluted profile that is complementary in shape to the teeth 364a of the wear component 350. In
During the casting process, the teeth 364a and/or retention segments 352 that protrude outwardly from the periphery 134 of the head 130 are engaged and supported by the mold.
As with the wear component 140, the wear component 340, including its retention portion 350 and wear portion 360, is a unitary component that is harder and/or exhibits other improved wear characteristics as compared to the cast material forming the body 110 of the drill bit 100. For example, the wear component 340 may be formed (e.g., cast, forged, machined, hardened) from a steel alloy (e.g., containing chromium and/or molybdenum) or other suitable material.
While the drill bit 100 has been described and depicted as having two wear components 140, four wear components 240, and one wear component 340, it should be understood that other drill bits may have more or fewer of any one of these wear components or modifications thereof, which are positioned at different locations of the main body 110 and/or in different orientations relative thereto.
For example, as shown in
Various methods are provided for manufacturing the drill bits 100, 200, 300 described above. While the method may vary depending on which of the wear components 140, 240, 340 are selected and their orientation relative to the main body 110 of the drill bits, each method generally involves the steps described herein and illustrated in
In a first step S402 a mold is provided. The mold generally includes two halves (e.g., a cope and a drag), which cooperative define a void in a shape of the main body 110 of the drill bit 100. The mold may additionally include locating features (e.g., recesses) that correspond to the protrusions 172 of the wear components 140, 240, 340
In a second step S404, one or more of the wear components 140, 240, and/or 340 are inserted into the mold. As noted described above, the wear components 140, 240, 340 may be made from one of several manufacturing processes (e.g., casting, forging, machining, etc.) and of a material that is harder than the cast material forming the main body 110 of the drill bit 100, 200, or 300. When the wear components 140, 240, and/or 340 are inserted into the mold, the sacrificial portions 170 and/or 270 of the wear components 140 and/or 240, and/or the wear portion 360 of the wear component 340 are arranged between the upper and lower halves of the mold. Further, any protrusions 172 thereof are inserted into the corresponding locating feature, or are pressed into the material of the mold (e.g., sand) to be retained therein. The wear components 140, 240, and/or 340 are thereby held in proper position and orientation relative to the void of the mold. That is, the retention portions 150, 250, 350, which include the retention segments 152, 252, and/or 352 that are flared in the manners described above, extend into and are suspended within the void defined by the upper and lower halves of the mold.
In a third step S406, the cast material (e.g., chromium-molybdenum alloy steel, iron, etc.) is inserted in molten form into the mold in a manner that causes the molten material to flow around the retention portions 150, 250, and/or 350 of the wear components 140, 240, and/or 340, respectively.
In a fourth step S408, the cast material solidifies around the retention portions 150, 250, and/or 350 of the wear components 140, 240, and/or 340.
In fifth step S410, the drill bit 100, 200, or 300 is removed from the mold, or the mold material is removed from the drill bit 100.
In a sixth step S412, the sacrificial portion 170 and/or 270 are removed from each the wear components 140 and/or 240, respectively, and discarded. By removing the sacrificial portion 170 and/or 270, the wear edges 162 and/or 262 are formed on the wear portions 160 and/or 260, respectively, of the wear components 140 and/or 240.
While the present disclosure has been described in connection with certain embodiments, it is to be understood that the present disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
This application claims the benefit of U.S. Provisional Patent Application No. 62/346,875 filed Jun. 7, 2016, and hereby incorporates by reference the provisional application in its entirety.
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