The subject matter of this application is related to the subject matter of U.S. patent application Ser. No. 14/272,360, filed on May 7, 2014 now U.S. Pat. No. 9,359,826, issued Jun. 7, 2016, in the name of Van Do et al., to the subject matter of U.S. patent application Ser. No. 14/272,369, filed on May 7, 2014 now U.S. Pat. No. 9,476,257, issued Oct. 25, 2016, in the name of Bilen et al., and to the subject matter of U.S. application Ser. No. 14/276,587, filed on May 13, 2014, in the name of Miller et al., the entire disclosure of each of which is incorporated herein by this reference.
Embodiments of the present disclosure relate to earth-boring tools carrying formation-engaging structures and, more particularly, to retention features retaining the formation-engaging structures on the earth-boring tools.
Earth-boring tools are used to form boreholes (e.g., wellbores) in subterranean formations. Such earth-boring tools include, for example, drill bits, reamers, mills, etc. For example, a fixed-cutter earth-boring rotary drill bit (often referred to as a “drag” bit) generally includes a plurality of cutting elements secured to a face of a bit body of the drill bit. The cutters are fixed in place when used to cut formation materials. A conventional fixed-cutter earth-boring rotary drill bit includes a bit body having generally radially projecting and longitudinally extending blades. During drilling operations, the drill bit is positioned at the bottom of a well borehole and rotated.
A plurality of cutting elements is positioned on each of the blades. The cutting elements commonly comprise a “table” of superabrasive material, such as mutually bound particles of polycrystalline diamond, formed on a supporting substrate of a hard material, such as cemented tungsten carbide. Such cutting elements are often referred to as “polycrystalline diamond compact” (PDC) cutting elements or cutters. The plurality of PDC cutting elements may be fixed within cutting element pockets formed in rotationally leading surfaces of each of the blades. Conventionally, a bonding material, such as a braze alloy, may be used to secure the cutting elements to the bit body.
Some earth-boring tools may also include bearing elements that may limit the depth-of-cut (DOC) of the cutting elements, protect the cutting elements from excessive contact with the formation, enhance (e.g., improve) dynamic stability of the tool, or perform other functions or combinations of functions. The bearing elements conventionally are located entirely rotationally behind associated leading cutting elements to limit DOC as the bearing elements contact and ride on an underlying earth formation, although bearing elements rotationally leading cutting elements are also known.
In one embodiment of the disclosure, an earth-boring tool comprises a blade located on a body of the earth-boring tool with a pocket formed in an exposed outer surface of the blade. The earth-boring tool includes a formation-engaging assembly affixed within the pocket. The formation-engaging assembly comprises a formation-engaging structure disposed within a holder. The holder has a distal end, a proximal end and a tapered sidewall therebetween. The tapered sidewall engages a tapered inner surface of the pocket. The tapered sidewall of the holder and the tapered inner surface of the pocket are each sized and configured to provide an interference fit between the holder and the pocket of the blade. A formation-engaging surface of the formation-engaging structure extends from the distal end of the holder.
In another embodiment of the disclosure, an earth-boring tool comprises a blade located on a body of the earth-boring tool with a pocket formed in an exposed outer surface of the blade. A formation-engaging structure is affixed within the pocket. The formation-engaging structure has a distal end, a proximal end and a tapered sidewall therebetween. The distal end of the formation-engaging structure includes a formation-engaging surface. The tapered sidewall engages a tapered inner surface of the pocket. The tapered sidewall of the formation-engaging structure and the tapered inner surface of the pocket are each sized and configured to provide an interference fit between the formation-engaging structure and the pocket of the blade.
In yet another embodiment of the disclosure, an earth-boring tool comprises a blade located on a body of the earth-boring tool with a pocket formed in an exposed outer surface of the blade. A tapped bore extends from at least one of a rotationally leading surface and a rotationally trailing surface of the blade to the pocket. The earth-boring tool includes a formation-engaging structure affixed within the pocket. The formation-engaging structure has a distal end, a proximal end and a sidewall therebetween. The distal end of the formation-engaging structure includes a formation-engaging surface. A receiving formation is formed in the sidewall of the formation-engaging structure. A threaded fastening element is threaded within the tapped bore such that a first end of the threaded fastening element engages the receiving formation of the formation-engaging structure. The threaded fastening element retains the formation-engaging structure within the pocket.
While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present invention, various features and advantages of disclosed embodiments may be more readily ascertained from the following description when read with reference to the accompanying drawings, in which:
The illustrations presented herein are not actual views of any particular material, cutting element, formation-engaging structure, or earth-boring tool, but are merely idealized representations 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 the formation by way of removing 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, etc.
The body 104 of the earth-boring tool 100 may be secured to a shank 108 having a threaded connection portion 110, which may conform to industry standards, such as those promulgated by the American Petroleum Institute (API), for attaching the earth-boring tool 100 to a drill string (not shown).
The body 104 may include internal fluid passageways that extend between fluid ports 112 at the face of the body 104 and a longitudinal bore that extends through the shank 108 and partially through the body 104. Nozzle inserts 114 may be secured within the fluid ports 112 of the internal fluid passageways. The body 104 may further include a plurality of blades 116 that are separated by fluid courses 118, which may be referred to in the art as “junk slots.” In some embodiments, the body 104 may include gage wear plugs 120, wear knots 122, or both.
Each formation-engaging structure 106 may be positioned on a blade 116 to rotationally trail at least one cutting element 102, as shown in
The formation-engaging structure holder 107 may comprise a metal alloy, such as a steel alloy, or may comprise a cemented tungsten carbide matrix material, by way of non-limiting example. The holder 107 may include a receptacle 212 for accepting at least a portion of the side surface 210 of the formation-engaging structure 106. The sidewall of the receptacle 212 may comprise a cross-sectional shape and size similar to the cross-sectional shape and size of the side surface 210 of the formation-engaging structure 106, such that the formation-engaging structure 106 fits tightly within the receptacle 212. In some embodiments, the sizes of the cross-sectional shapes of the receptacle 212 and the side surface 210 may be chosen to provide a clearance between the side surface 210 and a sidewall of the receptacle 212 to facilitate affixing the formation-engaging structure 106 within the holder 107, with, for example, a braze or adhesive.
As a non-limiting example, the formation-engaging structure 106 may be brazed within the receptacle 212 or attached within the receptacle mechanically or with an adhesive, as more fully described in U.S. patent application Ser. No. 14/272,369, filed May 7, 2014, which has been incorporated herein by reference. The receptacle 212 may extend from a distal end 218 of the holder 107 a predetermined depth into the holder 107, as also more fully described in U.S. patent application Ser. No. 14/272,369.
The formation-engaging assembly 200 may be affixed to the blade 116 within a pocket 220 formed in an exposed outer surface 222 of the blade 116. The holder 107 may have a side surface 223 extending between the distal end 218 and a proximal end 224 of the holder 107. The side surface 223 of the holder 107 may also be characterized as a sidewall. The side surface 223 of the holder 107 may comprise a cross-sectional shape and size similar to the cross-sectional shape and size of an inner surface of the pocket 220, such that the holder 107 fits tightly within the receptacle pocket 220. A portion 226 of the side surface 223 of the holder 107 may be tapered and may be sized and configured to mate with a tapered inner surface 228 of the pocket 220 in a manner providing an interference fit between the holder 107 and the pocket 220. The holder 107 may be inserted into the pocket 220 and subsequently driven into the pocket 220 by a hammer and punch, a press, such as a hydraulic press, or another suitable tool, until the holder 107 is fully disposed within the pocket 220 and retained by an interference fit between the tapered portion 226 of the side surface 223 of the holder 107 and the tapered inner surface 228 of the pocket 220. In other embodiments, the holder 107 may be shrink fitted within the pocket 220 (alternatively, or, in addition to the foregoing insertion methods). Accordingly, the radius of the tapered portion 226 of the holder 107 may be slightly larger than the radius of the tapered inner surface 228 of the pocket 220 at corresponding longitudinal positions of the tapered portion 226 of the holder 107 and the tapered inner surface 228 of the pocket 220. It is to be appreciated that the holder 107 may be affixed within the pocket 220 prior to or after the formation-engaging structure 106 is attached within the receptacle 212 of the holder 107.
As shown in
With continued reference to
Referring now to
As with the embodiment shown in
It is to be appreciated that, during an earth-boring operation, the drill string (not shown), and an earth-boring tool coupled thereto, may experience significant amounts of vibration and other disruptive phenomena, which may, in some instances, over time, cause the set screw 440 to counter-rotate within the tapped bore 444 (i.e., unscrew) from the position rigidly retaining the formation-engaging structure 406 within the pocket 420. As shown in
In other embodiments, as shown in
In additional embodiments, at shown in
For reference,
It is to be appreciated that, while the foregoing embodiments disclose retaining features for retaining the formation-engaging structures to blades of an earth-boring tool, the retaining features may also be incorporated to retain formation-engaging structures on an earth-boring tool lacking blades.
Although the foregoing description contains many specifics, these are not to be construed as limiting the scope of the present invention, but merely as providing certain exemplary embodiments. Similarly, other embodiments of the invention may be devised that do not depart from the spirit or scope of the present disclosure. For example, features described herein with reference to one embodiment also may be provided in others of the embodiments described herein. The scope of the invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions, and modifications to the disclosed embodiments, which fall within the meaning and scope of the claims, are encompassed by the present disclosure.
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