Embodiments of the present disclosure relate generally to cutting elements that include a cutting tip of superabrasive material (e.g., polycrystalline diamond or cubic boron nitride) and a substrate base, to earth-boring tools including such cutting elements, and to methods of forming and using such cutting elements and earth-boring tools.
Earth-boring tools are commonly used for forming (e.g., drilling and reaming) bore holes or wells (hereinafter “wellbores”) in earth formations. Earth-boring tools include, for example, rotary drill bits, core bits, eccentric bits, bicenter bits, reamers, underreamers, and mills.
Different types of earth-boring rotary drill bits are known in the art including, for example, fixed-cutter bits (which are often referred to in the art as “drag” bits), rolling-cutter bits (which are often referred to in the art as “rock” bits), diamond-impregnated bits, and hybrid bits (which may include, for example, both fixed cutters and rolling cutters). The drill bit is rotated and advanced into the subterranean formation. As the drill bit rotates, the cutters or abrasive structures thereof cut, crush, shear, and/or abrade away the formation material to form the wellbore.
The 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 the formation. Often 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 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 also coupled to the drill string and disposed proximate the bottom of the wellbore. The downhole motor may comprise, for example, a hydraulic Moineau-type motor having a shaft, to which the drill bit is attached, 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 drill bit may rotate concentric with the drill string or may rotate eccentric to the drill string. For example, a device referred to as an “AKO” (Adjustable Kick Off) may be used to rotate the drill bit eccentric to the drill string.
Rolling-cutter drill bits typically include three roller cones attached on supporting bit legs that extend from a bit body, which may be formed from, for example, three bit head sections that are welded together to form the bit body. Each bit leg may depend from one bit head section. Each roller cone is configured to spin or rotate on a bearing shaft that extends from a bit leg in a radially inward and downward direction from the bit leg. The cones are typically formed from steel, but they also may be formed from a particle-matrix composite material (e.g., a cermet composite such as cemented tungsten carbide). Cutting teeth for cutting rock and other earth formations may be machined or otherwise formed in or on the outer surfaces of each cone. Alternatively, receptacles are formed in outer surfaces of each cone, and inserts fainted of hard, wear resistant material are secured within the receptacles to form the cutting elements of the cones. As the rolling-cutter drill bit is rotated within a wellbore, the roller cones roll and slide across the surface of the formation, which causes the cutting elements to crush and scrape away the underlying formation.
Fixed-cutter drill bits typically include a plurality of cutting elements that are attached to a face of bit body. The bit body may include a plurality of wings or blades, which define fluid courses between the blades. The cutting elements may be secured to the bit body within pockets formed in outer surfaces of the blades. The cutting elements are attached to the bit body in a fixed manner, such that the cutting elements do not move relative to the bit body during drilling. The bit body may be formed from steel or a particle-matrix composite material (e.g., cobalt-cemented tungsten carbide). In embodiments in which the bit body comprises a particle-matrix composite material, the bit body may be attached to a metal alloy (e.g., steel) shank having a threaded end that may be used to attach the bit body and the shank to a drill string. As the fixed-cutter drill bit is rotated within a wellbore, the cutting elements scrape across the surface of the formation and shear away the underlying formation.
Impregnated diamond rotary drill bits may be used for drilling hard or abrasive rock formations such as sandstones. Typically, an impregnated diamond drill bit has a solid head or crown that is cast in a mold. The crown is attached to a steel shank that has a threaded end that may be used to attach the crown and steel shank to a drill string. The crown may have a variety of configurations and generally includes a cutting face comprising a plurality of cutting structures, which may comprise at least one of cutting segments, posts, and blades. The posts and blades may be integrally formed with the crown in the mold, or they may be separately formed and attached to the crown. Channels separate the posts and blades to allow drilling fluid to flow over the face of the bit.
Impregnated diamond bits may be formed such that the cutting face of the drill bit (including the posts and blades) comprises a particle-matrix composite material that includes diamond particles dispersed throughout a matrix material. The matrix material itself may comprise a particle-matrix composite material, such as particles of tungsten carbide, dispersed throughout a metal matrix material, such as a copper-based alloy.
It is known in the art to apply wear-resistant materials, such as “hardfacing” materials, to the formation-engaging surfaces of rotary drill bits to minimize wear of those surfaces of the drill bits caused by abrasion. For example, abrasion occurs at the formation-engaging surfaces of an earth-boring tool when those surfaces are engaged with and sliding relative to the surfaces of a subterranean formation in the presence of the solid particulate material (e.g., formation cuttings and detritus) carried by conventional drilling fluid. For example, hardfacing may be applied to cutting teeth on the cones of roller cone bits, as well as to the gage surfaces of the cones. Hardfacing also may be applied to the exterior surfaces of the curved lower end or “shirttail” of each bit leg, and other exterior surfaces of the drill bit that are likely to engage a formation surface during drilling.
The cutting elements used in such earth-boring tools often include polycrystalline diamond cutters (often referred to as “PDCs”), which are cutting elements that include a polycrystalline diamond (PCD) material. Such polycrystalline diamond cutting elements are formed by sintering and bonding together relatively small diamond grains or crystals under conditions of high temperature and high pressure in the presence of a catalyst (such as, for example, cobalt, iron, nickel, or alloys and mixtures thereof) to form a layer of polycrystalline diamond material on a cutting element substrate. These processes are often referred to as high temperature/high pressure (“HTHP”) processes. The cutting element substrate may comprise a cermet material (i.e., a ceramic-metal composite material) such as, for example, cobalt-cemented tungsten carbide. In such instances, the cobalt (or other catalyst material) in the cutting element substrate may be drawn into the diamond grains or crystals during sintering and serve as a catalyst for forming a diamond table from the diamond grains or crystals. In other methods, powdered catalyst material may be mixed with the diamond grains or crystals prior to sintering the grains or crystals together in an HTHP process.
Upon formation of a diamond table using an HTHP process, catalyst material may remain in interstitial spaces between the grains or crystals of diamond in the resulting polycrystalline diamond table. The presence of the catalyst material in the diamond table may contribute to thermal damage in the diamond table when the cutting element is heated during use due to friction at the contact point between the cutting element and the formation. Polycrystalline diamond cutting elements in which the catalyst material remains in the diamond table are generally thermally stable up to a temperature of about 750° Celsius, although internal stress within the polycrystalline diamond table may begin to develop at temperatures exceeding about 350° Celsius. This internal stress is at least partially due to differences in the rates of thermal expansion between the diamond table and the cutting element substrate to which it is bonded. This differential in thermal expansion rates may result in relatively large compressive and tensile stresses at the interface between the diamond table and the substrate, and may cause the diamond table to delaminate from the substrate. At temperatures of about 750° Celsius and above, stresses within the diamond table may increase significantly due to differences in the coefficients of thermal expansion of the diamond material and the catalyst material within the diamond table itself. For example, cobalt thermally expands significantly faster than diamond, which may cause cracks to form and propagate within the diamond table, eventually leading to deterioration of the diamond table and ineffectiveness of the cutting element.
In order to reduce the problems associated with different rates of thermal expansion in polycrystalline diamond cutting elements, so-called “thermally stable” polycrystalline diamond (TSD) cutting elements have been developed. Such a thermally stable polycrystalline diamond cutting element may be formed by leaching the catalyst material (e.g., cobalt) out from interstitial spaces between the diamond grains in the diamond table using, for example, an acid. All of the catalyst material may be removed from the diamond table, or only a portion may be removed. Thermally stable polycrystalline diamond cutting elements in which substantially all catalyst material has been leached from the diamond table have been reported to be thermally stable up to a temperature of about 1200° Celsius. It has also been reported, however, that such fully leached diamond tables are relatively more brittle and vulnerable to shear, compressive, and tensile stresses than are non-leached diamond tables. In an effort to provide cutting elements having diamond tables that are more thermally stable relative to non-leached diamond tables, but that are also relatively less brittle and vulnerable to shear, compressive, and tensile stresses relative to fully leached diamond tables, cutting elements have been provided that include a diamond table in which only a portion of the catalyst material has been leached from the diamond table.
In some embodiments, a cutting element for an earth-boring tool of the present disclosure includes a substrate base and a cutting tip. The substrate base includes a substantially cylindrical outer side surface and a longitudinal axis substantially parallel to the substantially cylindrical outer side surface. The cutting tip includes an elongated surface defining a longitudinal end of the cutting tip, a first generally conical surface extending from proximate the substrate base to the elongated surface, and a second generally conical surface extending from proximate the substrate base to the elongated surface, the second generally conical surface opposite the first generally conical surface. The cutting tip also includes a first generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface; and a second generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface, the second generally flat surface opposite the first generally flat surface. A central axis of the cutting tip extends through the cutting tip from an interface between the substrate base and the cutting tip to a central location on the elongated surface. The longitudinal axis of the substrate base is not co-linear with the central axis of the cutting tip.
In other embodiments, the present disclosure includes a cutting element for an earth-boring tool that includes a substantially cylindrical substrate base and a cutting tip secured to the substrate base. The cutting tip includes a first generally conical surface extending from proximate the substrate base toward a longitudinal end of the cutting tip and an opposing second generally conical surface extending from proximate the substrate base toward the longitudinal end of the cutting tip. The cutting tip also includes a first flank surface extending between the first generally conical surface and the second generally conical surface and extending from proximate the substrate base toward the longitudinal end of the cutting tip and an opposing second flank surface extending between the first generally conical surface and the second generally conical surface and extending from proximate the substrate base toward the longitudinal end of the cutting tip. A surface defining the longitudinal end of the cutting tip is relatively more narrow in a central region thereof than in a radially outer region thereof.
In additional embodiments, the present disclosure includes an earth-boring tool including a body and a plurality of cutting elements attached to the body. Each of the cutting elements includes a substantially cylindrical substrate base and a cutting tip. The cutting tip of each cutting element includes a first generally conical surface extending from proximate the substrate base to a longitudinal end of the cutting tip and a second generally conical surface extending from proximate the substrate base to the longitudinal end of the cutting tip, the second generally conical surface opposite the first generally conical surface relative to a longitudinal axis of the cutting tip. Each cutting tip also includes a first flank surface extending from proximate the substrate base to the longitudinal end of the cutting tip and extending between the first generally conical surface and the second generally conical surface and a second flank surface extending from proximate the substrate base to the longitudinal end of the cutting tip and extending between the first generally conical surface and the second generally conical surface, the second flank surface opposite the first flank surface relative to a longitudinal axis of the cutting tip. At least one of the cutting elements is oriented relative to the body of the earth-boring tool such that the cutting tip of the at least one cutting element is back raked and configured to initially engage a formation to be bored by the earth-boring tool with one of the first generally conical surface and the second generally conical surface of the at least one cutting element.
The illustrations presented herein are not meant to be actual views of any particular cutting element, earth-boring tool, or portion of a cutting element or tool, but are merely idealized representations that are employed to describe embodiments of the present disclosure. Additionally, elements common between figures may retain the same numerical designation.
As used herein, the term “earth-boring tool” means and includes any tool used to remove formation material and form a bore (e.g., a wellbore) through a formation by way of the removal of the formation material. Earth-boring tools include, for example, rotary drill bits (e.g., fixed-cutter or “drag” bits and roller cone or “rock” bits), hybrid bits including both fixed cutters and roller elements, coring bits, percussion bits, bi-center bits, reamers (including expandable reamers and fixed-wing reamers), and other so-called “hole-opening” tools.
As used herein, the term “substantially” means to a degree that one skilled in the art would understand the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is “substantially” met may be at least about 90% met, at least about 95% met, or even at least about 99% met.
As used herein, any relational term, such as “first,” “second,” “over,” “under,” “on,” “underlying,” “end,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings and does not connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise.
Referring to
The cutting tip 13 may also include a first generally conical surface 16A, a second generally conical surface 16B, a longitudinal end 17, a first generally flat (i.e., planar) surface 18A, and a second generally flat (i.e., planar) surface 18B. In some embodiments, the surfaces 18A and 18B may be at least substantially flat (i.e., planar), although, in other embodiments, the surfaces 18A and 18B may be textured and/or curved, as is explained in more detail below. The first and second surfaces 18A and 18B are also somewhat more generally referred to herein as the first flank surface 18A and the second flank surface 18B, respectively. The first generally conical surface 16A may be defined by an angle ϕ1 existing between the first generally conical surface 16A and a phantom line extending from the generally cylindrical lateral side surface 15 of the cutting tip 13 (
The cutting tip 13 may have a height H (
The location of the longitudinal end 17 may be centered about and extend generally symmetrically outward from the longitudinal axis 11, as shown in
As can be seen in the cross-sectional views of
The substrate base 12 may be formed from a material that is relatively hard and resistant to wear. As one non-limiting example, the substrate base 12 may be at least substantially comprised of a cemented carbide material, such as cobalt-cemented tungsten carbide.
The substrate base 12 may include a chamfer 19 around a longitudinal end thereof opposite the cutting tip 13. The chamfer 19 may be defined by an angle γ from the lateral side surface 14 of the substrate base 12 to a phantom line generally parallel to the surface of the chamfer 19, as shown in
Although the first and second generally flat surfaces 18A and 18B are shown in
By way of another example, as shown in
Furthermore, although the cutting tip 13 has been described as comprising a substantially uniform material, the present disclosure is not so limited. For example, the cutting tip 13 may comprise a plurality of different materials, as shown in
Referring to
Referring to
The cutting tip 23 of the cutting element 20 may be formed as a relatively thin layer over the substrate base 22, as shown in the cross-sectional views of
A longitudinal end 52 of the substrate base 22 opposite the cutting tip 23 may include a first chamfer 29A and a second chamfer 29B, as shown in
Each of the cutting elements 10 and 20 may be attached to an earth-boring tool such that the respective cutting tips 13 and 23 will contact a surface of a subterranean formation within a wellbore during a drilling or reaming process.
Referring to
The shape of the cutting element 10 of the present disclosure and the orientation thereof relative to the formation 50 may provide improvements when compared to the conventional cutting elements.
As shown in
Due to the relative angle between the generally cylindrical substrate base 32 and the cutting tip 33, the interface between the substrate base 32 and the cutting tip 33 may generally be circumscribed by an oval.
In some embodiments, at least a portion of the cutting element 10, 20, 30 may be free to at least partially rotate about the axis 11, 21, 31 thereof during operation of a drill bit including the cutting element 10, 20, 30. By way of example, the cutting tip 13 of a cutting element 10E may be configured to rotate about the longitudinal axis 11 relative to the substrate base 12, as shown in
In some embodiments, the longitudinal end 17, 27 of the cutting tip 13, 23 of the present disclosure may be curved relative to a plane in which the longitudinal end 17, 27 extends. For example, as shown in
Referring to
The enhanced shape of the cutting elements 10, 20, 30 described in the present disclosure may be used to improve the behavior and durability of cutting elements when drilling in subterranean earth formations. The shape of the cutting elements 10, 20, 30 may enable the cutting elements 10, 20, 30 to fracture and damage the formation, while also providing increased efficiency in the removal of the fractured formation material from the subterranean surface of the wellbore.
During operation, the shape of the cutting elements 10, 20, 30 of the present disclosure may increase point loading and thus may create increased fracturing in earthen formations. Testing shows increased rock fracturing beyond the cut shape impression in the drilled formation. Without being bound to a particular theory, it is believed that the at least partially conical shape of the cutting elements 10, 20, 30 of the present disclosure concentrates stress in formations through which the cutting elements 10, 20, 30 drill, which propagates fracturing beyond a point of contact to a greater extent than conventional cutting elements, such as circular table PCD cutting elements. The increased rock fracturing may lead to greater drilling efficiency, particularly in hard formations. Furthermore, the cutting elements 10, 20, 30 described in the present disclosure may have increased durability due to the cutting elements 10, 20, 30 having a shape that is elongated in one plane (e.g., a plane in which the longitudinal end 17, 27 extends), as described above and shown in the figures. Such a shape may induce increased pre-fracturing of the formation along the elongated edge during operation. Such an elongated shape may increase stability by tending to guide the cutting element 10, 20, 30 in the drilling track or groove formed by the leading cutting edge of the cutting element. Furthermore, the at least partially conical shape of the cutting element 10, 20, 30 may provide depth-of-cut control due to the increasing cross-sectional area of the cutting element 10, 20, 30 in the direction extending along the longitudinal axis 11, 21, 31, 35 thereof.
In some embodiments, the cutting tip 13, 23, 33 of the present disclosure may be at least predominantly comprised of diamond with an interface geometry between the cutting tip 13, 23, 33 and the substrate base 12, 12A, 22 selected to manage residual stresses at the interface. Embodiments of the cutting element 10, 20, 30 of the present disclosure including PCD in the cutting tip 13, 23, 33 may present a continuous cutting face in operation, but with increased diamond volume. The shape of the cutting element 10, 20, 30 may provide increased point loading with the abrasion resistant material (e.g., PCD) thereof supporting the leading edge, which may improve pre-fracturing in brittle and/or hard formations. The ability to pre-fracture the formation may be particularly useful in so-called “managed pressure drilling” (MPD), “underbalanced drilling” (UBD), and/or air drilling applications. The pre-fracturing of the formation may significantly reduce cutting forces required to cut into the formation by any trailing cutting structure, such that the trailing cutting structure(s) may be relatively larger in shape for maximum formation removal.
In addition, the generally flat surfaces 18A, 18B, 28A, and 28B of the present disclosure may act as features that stabilize the cutting elements 10, 20, 30 within a groove cut in the formation. The generally flat surfaces 18A, 18B, 28A, and 28B may be significantly larger in area than the leading cutting edge. Thus, with a small forward cutting face and large blunt side faces, the cutting element 10, 20, 30 may act as a self-stabilizing cutting structure. Drilling efficiency may be improved by the cutting element 10, 20, 30 of the present disclosure at least in part because formation material that is drilled away may follow a less tortuous path than with conventional cutting elements. The generally conical shape of the cutting elements 10, 20, 30 of the present disclosure may cause the exposed surfaces of the cutting elements 10, 20, 30 to experience compression during axial plunging thereof into a formation, which may improve the durability of the cutting elements by eliminating or reducing tensile failure modes. The increased pre-fracturing and drilling efficiency may improve a rate of penetration of a drill bit including the cutting elements 10, 20, 30 of the present disclosure. Any of the cutting elements 10, 20, 30 described in the present disclosure may be used as a primary cutter or as a backup cutter.
Additional non-limiting example embodiments of the present disclosure are set forth below.
A cutting element for an earth-boring tool, comprising: a substrate base comprising a substantially cylindrical outer side surface and a longitudinal axis substantially parallel to the substantially cylindrical outer side surface; and a cutting tip comprising: an elongated surface defining a longitudinal end of the cutting tip; a first generally conical surface extending from proximate the substrate base to the elongated surface; a second generally conical surface extending from proximate the substrate base to the elongated surface, the second generally conical surface opposite the first generally conical surface; a first generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface; a second generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface, the second generally flat surface opposite the first generally flat surface; and a central axis extending through the cutting tip from an interface between the substrate base and the cutting tip to a central location on the elongated surface; wherein the longitudinal axis of the substrate base is not co-linear with the central axis of the cutting tip.
The cutting element of Embodiment 1, wherein the substrate base comprises a first material and the cutting element tip comprises a second material different than the first material.
The cutting element of Embodiment 2, wherein the first material comprises a cemented carbide material and the second material comprises an abrasion resistant material selected from the group consisting of a polycrystalline diamond material, a carbide material, a metal-matrix carbide composite material, and a cubic boron nitride material.
The cutting element of any one of Embodiments 2 and 3, wherein the second material comprises a polycrystalline diamond material and the cutting tip further comprises a third material formed over the polycrystalline diamond material.
The cutting element of any one of Embodiments 2 through 4, wherein substantially all of the cutting element from an interface between a longitudinal end of the substrate base and the longitudinal end of the cutting tip comprises the second material, the second material being a substantially uniform material.
The cutting element of any one of Embodiments 2 through 4, wherein the second material comprises a layer over the substrate base, the layer having a substantially uniform thickness.
The cutting element of Embodiment 6, wherein the substantially uniform thickness of the second material is at least about 0.15 inch (3.81 mm).
The cutting element of any one of Embodiments 1 through 7, wherein the substrate base comprises at least one chamfer around a longitudinal end thereof opposite the cutting tip.
The cutting element of Embodiment 8, wherein the at least one chamfer comprises a first chamfer extending around the substrate base between a lateral side surface of the substrate base and a second chamfer, the second chamfer extending around the substrate base between the first chamfer and the longitudinal end of the substrate base opposite the cutting tip.
A cutting element for an earth-boring tool, the cutting element comprising: a substantially cylindrical substrate base; and a cutting tip secured to the substrate base, the cutting tip comprising: a first generally conical surface extending from proximate the substrate base toward a longitudinal end of the cutting tip; an opposing second generally conical surface extending from proximate the substrate base toward the longitudinal end of the cutting tip; a first flank surface extending between the first generally conical surface and the second generally conical surface and extending from proximate the substrate base toward the longitudinal end of the cutting tip; and an opposing second flank surface extending between the first generally conical surface and the second generally conical surface and extending from proximate the substrate base toward the longitudinal end of the cutting tip; wherein a surface defining the longitudinal end of the cutting tip is relatively more narrow in a central region thereof than in a radially outer region thereof.
The cutting element of Embodiment 10, wherein the cutting tip is angled relative to the substrate base.
The cutting element of any one of Embodiments 10 and 11, wherein each of the first flank surface and the second flank surface is substantially flat.
The cutting element of any one of Embodiments 10 and 11, wherein the surface defining the longitudinal end of the cutting tip is curved relative to a plane passing longitudinally through a center of the cutting element.
The cutting element of any one of Embodiments 10 through 13, further comprising one or more valleys extending into at least one of the first flank surface and the second flank surface.
The cutting element of any one of Embodiments 10 through 14, further comprising one or more ridges extending from at least one of the first flank surface and the second flank surface.
The cutting element of any one of Embodiments 10 through 14, wherein the cutting tip is configured to rotate relative to the substrate base.
An earth-boring tool, comprising: a body; and a plurality of cutting elements attached to the body, each cutting element of the plurality of cutting elements comprising: a substantially cylindrical substrate base; and a cutting tip comprising: a first generally conical surface extending from proximate the substrate base to a longitudinal end of the cutting tip; a second generally conical surface extending from proximate the substrate base to the longitudinal end of the cutting tip, the second generally conical surface opposite the first generally conical surface relative to a longitudinal axis of the cutting tip; a first flank surface extending from proximate the substrate base to the longitudinal end of the cutting tip and extending between the first generally conical surface and the second generally conical surface; and a second flank surface extending from proximate the substrate base to the longitudinal end of the cutting tip and extending between the first generally conical surface and the second generally conical surface, the second flank surface opposite the first flank surface relative to a longitudinal axis of the cutting tip; wherein at least one cutting element of the plurality of cutting elements is oriented relative to the body such that the cutting tip of the at least one cutting element is back raked and configured to initially engage a formation to be bored by the earth-boring tool with one of the first generally conical surface and the second generally conical surface of the at least one cutting element.
The earth-boring tool of Embodiment 17, wherein the cutting tip of the at least one cutting element comprises a longitudinal axis extending centrally through the cutting tip from proximate the substrate base to the longitudinal end of the cutting tip that is not co-linear with a longitudinal axis extending centrally through the substrate base.
The earth-boring tool of any one of Embodiments 17 and 18, wherein each cutting element of the plurality of cutting elements is oriented relative to the body such that the cutting tip of each cutting element is back raked and the formation to be bored by the earth-boring tool is to be initially engaged by each cutting element with one of the first generally conical surface and the second generally conical surface of each cutting element.
The earth-boring tool of any one of Embodiments 17 through 19, wherein the cutting tip of each cutting element of the plurality of cutting elements is configured to rotate relative to the substrate base thereof.
The earth-boring tool of any one of Embodiments 17 through 20, wherein the earth-boring tool is a fixed-cutter rotary drill bit.
A method of drilling a formation using an earth-boring tool, the method comprising: positioning an earth-boring tool proximate the formation, the earth-boring tool comprising: at least one cutting element, comprising: a substrate base comprising a substantially cylindrical outer side surface; and a cutting tip attached to the substrate base, the cutting tip comprising: an elongated surface defining a longitudinal end of the cutting tip; a first generally conical surface extending from proximate the substrate base to the elongated surface; a second generally conical surface extending from proximate the substrate base to the elongated surface, the second generally conical surface opposite the first generally conical surface; a first generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface; and a second generally flat surface extending between the first generally conical surface, the second generally conical surface, and the elongated surface, the second generally flat surface opposite the first generally flat surface; and engaging the formation with the at least one cutting element, wherein one of the first generally conical surface and the second generally conical surface of the cutting tip of the at least one cutting element is positioned to initially engage the formation relative to other surfaces of the at least one cutting element.
The method of Embodiment 22, further comprising orienting the at least one cutting element such that the cutting tip of the at least one cutting element is back raked relative to the formation.
The method of Embodiment 23, wherein orienting the at least one cutting element comprises providing the at least one cutting element with the cutting tip thereof angled relative to the substrate base thereof.
A method of forming a cutting element, comprising: forming the cutting element of any one of Embodiments 1 through 16.
A method of forming an earth-boring tool comprising: forming the earth-boring tool of any one of Embodiments 17 through 21.
A method of drilling a formation using an earth-boring tool, the method comprising: drilling the formation using an earth-boring tool comprising at least one cutting element of any one of Embodiments 1 through 16.
A method of drilling a formation using an earth-boring tool, the method comprising: drilling the formation using the earth-boring tool of any one of Embodiments 17 through 21.
The earth-boring tool of any one of Embodiments 17 through 21, further comprising at least one alignment feature in or on the body with which the first flank surface and the second flank surface of the at least one cutting element of the plurality of cutting elements are aligned.
The cutting element of any one of Embodiments 1 through 16, wherein the substrate base is substantially hollow.
The cutting element of any one of Embodiments 1 through 16 and 30, further comprising another substrate base to which the substrate base is coupled.
The cutting element of Embodiment 31, wherein the another substrate base is oriented at an angle to the substrate base.
While the present disclosure has been described herein with respect to certain embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the present disclosure as contemplated by the inventor. Furthermore, many additions, deletions and modifications to the embodiments described herein may be made without departing from the scope of the invention as hereinafter claimed, including legal equivalents.
This application is a continuation of U.S. patent application Ser. No. 13/762,664, filed Feb. 8, 2013, now U.S. Pat. No. 9,316,058, issued Apr. 19, 2016, which application claims the benefit of U.S. Provisional Application Ser. No. 61/596,433, filed Feb. 8, 2012, the disclosure of each of which is hereby incorporated herein in its entirety by this reference. The subject matter of this application is related to the subject matter of U.S. Provisional Patent Application Ser. No. 61/290,401, filed Dec. 28, 2009, and to U.S. patent application Ser. No. 12/793,396 filed Jun. 3, 2010, now U.S. Pat. No. 8,505,634 issued Aug. 13, 2013. The subject matter of this application is also related to the subject matter of U.S. Provisional Patent Application Ser. No. 61/301,946, filed Feb. 5, 2010, and to U.S. patent application Ser. No. 13/022,288, filed Feb. 7, 2011, now U.S. Pat. No. 8,794,356, issued Aug. 5, 2014. The subject matter of this application is also related to the subject matter of U.S. patent application Ser. No. 13/101,840, filed May 5, 2011, now U.S. Pat. No. 8,851,207, issued Oct. 7, 2014, and to U.S. patent application Ser. No. 14/506,175, filed Oct. 3, 2014, now U.S. Pat. No. 9,200,483, issued Dec. 1, 2015. The subject matter of this application is also related to the subject matter of U.S. Provisional Patent Application Ser. No. 61/371,554, filed Aug. 6, 2010, to U.S. patent application Ser. No. 13/204,459, filed Aug. 5, 2011, now U.S. Pat. No. 9,022,149, issued May 5, 2015, and to U.S. patent application Ser. No. 14/686,093, filed Apr. 14, 2015, now U.S. Pat. No. 9,458,674, issued Oct. 4, 2016.
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Number | Date | Country | |
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20160230472 A1 | Aug 2016 | US |
Number | Date | Country | |
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61596433 | Feb 2012 | US |
Number | Date | Country | |
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Parent | 13762664 | Feb 2013 | US |
Child | 15099877 | US |