DRILL BIT WITH CUTTER POCKETS FORMED BY PLUNGE EDM

Abstract

The disclosure provides an improved method for manufacturing a drill bit. The method includes applying a hardfacing material to the drill bit, forming a cutter pocket within the drill bit with plunge EDM, and inserting a cutting element into the cutter pocket.

Description

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a prior art drilling rig.

FIG. 2 shows a prior art steel body bit.

FIG. 3 shows a prior art plunge electrical discharge machining assembly.

FIG. 4 shows a flow chart illustrating a method of manufacturing a drill bit in accordance with an embodiment of the present disclosure.

Claims

1. A method of manufacturing a drill bit, the method comprising: applying a hardfacing to the drill bit having at least one blade;forming a cutter pocket on the at least one blade with plunge EDM; andinserting a cutting element into the cutter pocket.

2. The method of claim 1, further comprising machining the drill bit from steel.

3. The method of claim 1, wherein the hardfacing is applied to the drill bit by an automated system.

4. The method of claim 3, wherein the automated system is a CNC machine.

5. The method of claim 1, wherein the plunge EDM is controlled by an automated system.

6. The method of claim 5, wherein the automated system is a CNC machine.

7. The method of claim 1, wherein the cutting element is comprised of PDC.

8. The method of claim 1, wherein forming the cutter pocket with plunge EDM comprises at least one plunge EDM pass.

9. The method of claim 1, wherein forming the cutter pocket with plunge EDM comprises a plurality of plunge EDM passes.

10. The method of claim 1, wherein the plunge EDM comprises a plurality of electrodes.

11. The method of claim 1, wherein the forming the cutter pocket occurs after the applying the hardfacing.

12. A method of manufacturing a drill bit, the method comprising: forming a bit body having at least one blade thereon;applying a hardfacing to at least a portion of the bit body;forming a cutter pocket on the at least one blade with plunge EDM; andinserting a cutting element into the cutter pocket.

13. The method of claim 12, wherein forming the bit body comprises at least one of machining, casting, and forging.

14. The method of claim 12, wherein the hardfacing is applied to the drill bit by an automated system.

15. The method of claim 14, wherein the automated system is a CNC machine.

16. The method of claim 13, wherein the plunge EDM is controlled by an automated system.

17. The method of claim 16, wherein the automated system is a CNC machine.

18. A drill bit manufactured with the method of claim 1.