This disclosure relates generally to rotary earth-boring drill bits. More particularly, this disclosure relates to a fixed cutter drill bit with features that improve drill bit hydraulics.
Rotary drill bits are typically mounted on the lower end of a drill string that is being rotated from the surface or by downhole motors. As the drill string is rotated, tension applied to the drill string is reduced to increase the weight on the bit so that the bit engages and drills a borehole into the earthen formation.
Two types of available drill bits are roller cone bits and fixed cutter bits. Roller cone bits often include a plurality of conical rollers that are rotatably mounted to the bit and imbedded with a plurality of cutting elements. Fixed cutter bits rely on a plurality of fixed blades angularly spaced about the bit and imbedded with a plurality of cutting elements. The cutting elements for either bit design are often formed from extremely hard materials such as polycrystalline diamond, cubic boron nitride, and tungsten carbide. The configuration or layout of the rollers, blades, and cutting elements vary widely between bit designs depending heavily on the formation to be drilled.
Both roller cone and fixed cutter drill bits utilize drilling fluid as a means to flush the drilled earth away from the drill bit and transport it to the surface. While the bit is rotated, drilling fluid is pumped through the drill string and directed out of the face of the drill bit through one or more nozzles. The drilling fluid acts to cool the bit and remove formation cuttings from the bit face and the bottom of the borehole. The behavior and performance of the drilling fluid as it acts on and around the drill bit is known as “bit hydraulics.”
In many fixed cutter drill bits, the nozzles are oriented such that high velocity drilling fluid is directed toward the formation at the bottom of the hole. As the drilling fluid impacts the formation and returns upward past the face of the drill bit, it cleans and cools the cutting elements of the drill bit. Because the drilling fluid first impacts the formation at the bottom of the hole, by the time it contacts the cutting elements of the drill bit the velocity of the drilling fluid is reduced from its initial velocity upon exiting the nozzles. This reduced velocity may limit the amount of cooling and cleaning that can be achieved by the drilling fluid.
Inadequate cooling of the cutting elements may lead to decreased life of the drill bit due to high temperatures supporting increased erosion and wear of the cutting elements. If formation cuttings are not cleaned from the cutting elements of a fixed cutter drill bit, formation materials may build up on the cutting elements and greatly increase drilling times.
Some types of earthen formations, sometimes referred to as plastic shales or simply plastic formations, are difficult to drill efficiently. Upon action of the cutting elements, these formations generate cuttings in the form of long ribbons of drilled material that tend to accumulate between the cutting elements of the drill bit, a phenomenon called “bit balling.” When the bit is balled, it is no longer possible for the cutting elements to engage the formation, regardless of the weight applied on the drill bit. Drilling of the borehole pauses for the drill bit to be retrieved and cleaned by means other than pumping drilling fluid through the drill string.
Thus, there is a continuing need in the art for methods and apparatus for improved fixed cutter drill bit designs that improve drill bit hydraulics.
In some aspects, a drill bit comprises a bit body having a body face. The drill bit further comprises a plurality of fixed blades extending from the bit body, each of the plurality of fixed blades having a leading face and a trailing face. The drill bit further comprises a plurality of nozzles disposed on the body face to flow drilling fluid out of the bit body. The drill bit further comprises a plurality of flow guides to direct a portion of the drilling fluid away from the bit body. Each of the plurality of flow guides extends longitudinally from the body face. Each of the plurality of flow guides extends along the leading face of one of the plurality of fixed blades. At least one of the plurality of fixed blades may have a tip profile, and at least one of the plurality of flow guides may comprise a guide edge that follows the tip profile. The body face may have a waterway profile, and at least one of the plurality of flow guides may comprise a guide edge that follows the waterway profile. At least one of the plurality of fixed blades may have a tip profile, the body face may have a waterway profile, and at least one of the plurality of flow guides may comprise a guide edge that is steeper than the tip profile and the waterway profile. The drill bit may further comprise cutting elements disposed on the leading face of one of the plurality of fixed blades; at least one of the plurality of flow guides may comprise a guide edge; the guide edge and the cutting elements may form a continuous flow channel having a flow entrance area; at least one of the plurality of nozzles may be operable to direct the drilling fluid toward the flow entrance area of the continuous flow channel. The drilling fluid may be accelerated in the continuous flow channel. At least one of the plurality of flow guides may comprise a hydrophobic material. At least one of the plurality of flow guides may comprise a front edge offset from an inside edge of at least one of the plurality of fixed blades. At least one of the plurality of nozzles may produce a flow jet, and the flow jet may be essentially parallel to the front edge. Each of the plurality of flow guides may increase hydraulic shear stress on a plurality of cutting elements disposed on each of the plurality of fixed blades. At least one of the plurality of nozzles may produce a flow jet; the flow jet may be essentially parallel to the leading face of a first one of the plurality of fixed blades; the flow jet may be closer to the leading face of the first one on the plurality of fixed blades than to the trailing face of a second one of the plurality of fixed blades.
In some aspects, a drill bit comprises a bit body, a plurality of fixed blades extending from the bit body, a plurality of cutting elements disposed on each of the plurality of fixed blades, a junk slot located in between a leading face of a first one of the plurality of fixed blades and a trailing face of a second one of the plurality of fixed blades, at least one nozzle disposed in the bit body and leading into the junk slot, and a flow guide protruding from the leading face of the first one of the plurality of fixed blades and from the bit body. The flow guide is operable to direct a fluid from the at least one nozzle in front of the plurality of cutting elements disposed on the first one of the plurality of blades. The first one of the plurality of blades may have a tip profile, and the flow guide may comprise a guide edge that follows the tip profile. The junk slot may have a waterway profile, and the flow guide may comprise a guide edge that follows the waterway profile. The first one of the plurality of blades may have a tip profile; the junk slot may have a waterway profile; the flow guide may comprise a guide edge that is steeper than the tip profile and the waterway profile.
In some aspects, a drill bit comprises a bit body, a plurality of fixed blades extending from the bit body, a plurality of cutting elements disposed on each of the plurality of fixed blades, a junk slot located in between a leading face of a first one of the plurality of fixed blades and a trailing face of a second one of the plurality of fixed blades, at least one nozzle disposed on the bit body and leading into the junk slot, a flow guide protruding from the leading face of the first one of the plurality of fixed blades and from the bit body, the flow guide having a guide edge, and a continuous flow channel formed at least partially by the guide edge and the plurality of cutting elements disposed on the first one of the plurality of fixed blades. The continuous flow channel has a flow entrance area, and the at least one nozzle directs a fluid toward the flow entrance area of the continuous flow channel. The at least one nozzle may produce a flow jet; the flow jet may be essentially parallel to the leading face of the first one on the plurality of fixed blades; the flow jet may be closer to the leading face of the first one on the plurality of fixed blades than to the trailing face of the second one of the plurality of fixed blades. The first one of the plurality of blades may have a tip profile, and the guide edge may follow the tip profile. The junk slot may have a waterway profile, and the guide edge may follow the waterway profile. The first one of the plurality of blades may have a tip profile, the junk slot may have a waterway profile; the guide edge may be steeper than the tip profile and the waterway profile.
For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein:
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.
Referring initially to
The leading face 20 of each fixed blade 14 also includes a flow guide 28. Referring now to
A nozzle 26 and a flow guide 28 may be said to be operatively associated if, in use, (1) the flow jet exiting the nozzle 26 is closer to the leading face 20 of one particular blade of the plurality of fixed blades 14 than to the leading face of any other blade of the plurality of fixed blades, and (2) the flow guide 28 protrudes from the leading face 20 of this particular blade. The nozzle 26 and the flow guide 28 shown in the partial view of
In some embodiments, the flow guide 28 may comprise a metal such as iron (Fe), nickel (Ni), cobalt (Co), copper (Cu), aluminum (Al), or titanium (Ti) and alloys thereof, a ceramic material, such as alumina, and/or a polymer, such as a thermoplastic. The flow guide 28 may optionally be coated with a hydrophobic material and/or a wear and erosion resistant material, such as polyethylene reinforced with metallic inclusions or electroless nickel-phosphorus (Ni-P) alloy with ceramic inclusions. Alternatively, the flow guide 28 may be made almost entirely of a hydrophobic material.
In some embodiments, the flow guide 28 may be integral to the fixed blade 14, for example machined out of a piece of steel used to make the drill bit 10. Alternatively, the flow guide 28 may be made separately from the drill bit 10, for example by machining or 3D printing, and then bonded to the fixed blade 14, such as by brazing or gluing. The flow guide 28 may also be secured to the fixed blade 14, such as by bolting.
Referring now to
In the example shown in
Because the flow guide 28 is disposed within a junk slot 22, the size, shape, and placement of the flow guide 28 is designed so as not to degrade the ability of the drill bit 10 to carry cuttings away from the drill bit 10 via the junk slots 22. In certain embodiments, the size, shape, and placement of the flow guide 28 may be different than the embodiment illustrated herein depending on the configuration of a particular drill bit and the environment in which it is intended to be used. In some embodiments, the flow guide 28 may span about half of the height of the fixed blades 14. In some embodiments, the thickness of the flow guide 28 may vary between 6 and 10 millimeters, that is, the flow guide 28 may protrude from the leading face 20 of one of the fixed blades by a distance that varies between 6 and 10 millimeters. In some embodiments, the flow guide 28 may protrude from the leading face 20 of one of the fixed blades by a distance that varies between 3 and 15 millimeters. In some embodiments, the flow guide 28 may protrude from the leading face 20 of one of the fixed blades by a distance that varies with the size of the junk slot 22.
A first blade of the plurality of fixed blades 114 has a shoulder 118. An outline of the shoulder shape projected in a longitudinal half plane is the profile of the shoulder tip. In the example of
The drill bit 210 has a bit body 212 from which the plurality of blades 214 extend. The bit body 212 has a face 246 which is convex. A junk slot 222 is formed in between each pair of fixed blade. An outline of the junk slot shape projected in a longitudinal half plane is the waterway profile. It is the same as an outline of the bit body shape projected in a longitudinal half plane. In the example of
In the example of
Note that the drill bit 410 includes additional nozzles that are not associated with a flow guide, and that are not positioned in the junk slots to produce a flow jet that is closer to the leading face of the first fixed blade forming the junk slot than to the trailing face of the second fixed blade forming the junk slot.
Without being limited to any theory, it is believed that the hydraulic performance of the drill bit 410 reduces balling in shale formations, and permits the effective cleaning of larger cuttings than a drill bit without flow guide. Thus, a wellbore may be drilled at a higher rate of penetration, as shown in the following examples.
A drill bit with flow guide as shown in
A drill bit with flow guide as shown in
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present disclosure.
This application claims priority to U.S. Provisional Application Ser. No. 62/036,796 filed on Aug. 13, 2014, and entitled “FIXED CUTTER DRILL BIT WITH FLOW GUIDE”. The priority application is incorporated herein by reference.