Formation degradation, such as drilling to form a well bore in the earth, pavement milling, mining, and/or excavating, may be performed using degradation assemblies. In normal use, these assemblies and auxiliary equipment are subjected to high impact, heat, abrasion, and other environmental factors that wear their mechanical components. Many efforts have been made to improve the service life of these assemblies. In some cases it is believed that the free rotation of the impact tip of the degradation assembly aides in lengthening the life of the degradation assembly by promoting even wear of the assembly.
U.S. Pat. No. 5,261,499 to Grubb, which is herein incorporated by reference for all that it contains, discloses a two-piece rotatable cutting bit which comprises a shank and a nose. The shank has an axially forwardly projecting protrusion which carries a resilient spring clip. The protrusion and spring clip are received within a recess in the nose to rotatable attach the nose to the shank.
U.S. patent application Ser. No. 12/177,556 to Hall, et al., which is herein incorporated by reference for all that it contains discloses, a degradation assembly comprises a shank with a forward end and a rearward end, the rearward end being adapted for attachment to a driving mechanism, with a shield rotatably attached to the forward end of the shank. The shield comprises an underside adapted for rotatable attachment to the shank and an impact tip disposed on an end opposing the underside. A seal is disposed intermediate the shield and the shank.
In one aspect of the present invention, a tool assembly comprises a rotary portion and a stationary portion. The rotary portion comprises a bolster bonded to a diamond, symmetric, substantially conically shaped tip. The stationary portion comprises a block mounted to a driving mechanism. A compressible element is disposed intermediate and in mechanical contact with both the rotary and stationary portions. The compressible element is compressed sufficiently to restrict free rotation during a degradation operation. In some embodiments, the compressible element is compressed sufficiently enough to prevent free rotation. The tool assembly may be a degradation assembly.
In some embodiments, the compressible element comprises an o-ring under 20%-40% compression. The o-ring may also comprise a hardness of 70-90 durometers. The compression element may also act as a seal that retains lubricant within the assembly. The compression element may comprise any of the following: at least one rubber ball, a compression spring, a set screw, a non-round spring clip, a spring clip with at least one flat surface, a press fit pin, or any combination thereof. A first rubber compressible element may be disposed on the stationary portion and be in contact with a second rubber compressible element disposed on the rotary portion.
In some embodiments, the rotary portion of the assembly may comprise a puller attachment and/or a wrench flat. The rotary portion may also comprise a shield, such that a recess of the shield is rotatably connected to a first end of the stationary portion. The bolster may also wrap around a portion of the stationary portion.
In some embodiments, the compressible element may comprise a metallic material. The compressible element may be part of a metal seal, which is tight enough to prevent restrict or prevent free rotation.
In another aspect of the present invention the assembly may comprise a holder. The holder may be part of either the stationary or the rotary portion of the assembly. The holder may comprise at least on longitudinal slot.
In one aspect of the present invention, a degradation assembly comprises a bolster intermediate a shank and a symmetric, substantially conical shaped tip. The tip comprises a substrate bonded to a diamond material. The diamond comprises an apex coaxial with the tip, and the diamond being over 0.100 inches thick along the central axis of the tip. The shank is inserted into a holder attached to a driving mechanism. The assembly comprises a mechanical indexing arrangement, wherein the tip comprises a definite number of azimuthal positions determined by the mechanical indexing arrangement, each position orienting a different azimuth of the tip such that the different azimuth impacts first during an operation.
In some embodiments, the shank comprises substantially symmetric longitudinal flat surfaces. The shank may axially comprise a hexagonal shape, a star shape, or any other axially symmetric shapes. The shank may comprise and o-ring, a catch, a spring clip, or any combination thereof. The tip may be rotationally isolated from the shank.
In some embodiments, the bolster may comprise a puller attachment. The bolster may also be in communication with the driving mechanism through a press fit pin.
In some embodiments, the assembly may comprise a holder. The holder may be indexible, and the holder may comprise a substantially axially symmetric geometry. The holder may be in communication with the shank through a thread form. The holder may also comprise a spring loaded catch or a racketed cam.
In another aspect of the present invention, a method of utilizing a degradation assembly comprises, providing an degradation assembly comprising a bolster intermediate a shank and a tip, the tip comprising a substrate bonded to a diamond material comprising a symmetric, substantially conical shape, the diamond comprising an apex coaxial with the tip, and the diamond being over 0.100 inches thick along the central axis of the tip. Then an operator actuates the driving mechanism for a first period of time. Next, an operator rotates the degradation assembly along its central axis to another indexed azimuth. An operator then actuates the driving mechanism for a second period of time.
a is a cross-sectional and exploded diagram of an embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a perspective view of an embodiment of a snap ring.
b is a top view of an embodiment of a snap ring.
c is a perspective view of another embodiment of a snap ring.
d is a top view of another embodiment of a snap ring.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a perspective view of a diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a perspective view of a diagram of another embodiment of a degradation assembly.
a is a cross-sectional diagram of another embodiment of a degradation assembly.
b is a cross-sectional diagram of another embodiment of a degradation assembly.
a is a cross sectional exploded diagram of an embodiment of a degradation assembly 101. In this embodiment the degradation assembly 101 comprises a rotary portion 200 in the form of a shield 201 and a stationary portion 203 in the form of a shank 204. A conical diamond tip 206 may be bonded to the shield 201. A compression element 208 in the form of an o-ring 205 may be adapted to be disposed intermediate the shield 201 and the shank 204. A spring clip 202 may also be adapted to be disposed intermediate the shield 201 and the shank 204. The o-ring may function as a grease barrier by maintaining grease intermediate the shield 201 and the shank 204.
The embodiment depicted in
The rotary portion 200 comprises a tip 206 comprising a cemented metal carbide substrate 260 and a volume of sintered polycrystalline diamond 261 forming a substantially conical geometry with a rounded apex. The diamond 261 is preferably 0.100 to 0.250 inches thick from the apex to the interface between the substrate 260 and diamond 261 through its central axis. The substrate 260 comprises a relatively short thickness, preferably less than the mentioned thickness of the diamond 261. A short substrate 260 as identified may reduce the potential bending moments experienced by the substrate 260 during operation and therefore reduce the stress on the interface 262 between the substrate 260 and diamond 261 as well as the braze joint 263 bonding the substrate 260 to the rotary portion 200 of the assembly. Preferably, the substrate 260 is brazed to cemented metal bolster 301 affixed to the shield 201. The shank 204, bolster 301, and substrate 260 are preferably share a common central axis.
The bolster 301 is preferably wider at its base than the largest diameter of the substrate 260. However, preferably at their braze joint 263, the surface of the substrate 260 is slightly larger than the surface of the bolster. This may allow the substrate 260 to overhang slightly. The overhang may be small enough that it is not visible after brazing because braze material may extrude out filling the gap formed by the overhang. While an overhang as small as described may seem insignificant, improvement in field performance is contributed, in part, to it and is believed to further reduce stresses at the braze joint 263.
Preferably, the bolster 301 tapers from the interface with the substrate 260 to a second interface with a steel portion of the shield 201. At this interface, the braze joint 263 is relieved at the center with a small cavity 265 formed in the bolster 301. Also the thickness of the braze increases closer to the periphery of the braze joint, which is believed to help absorb impact loads during operation. Also, the steel curves around the corners of the bolster 301 at the second interface 264 to reduce stress risers.
The bolster's 301 shape tapers from the first interface 263 to the second interface 264 with a slightly convex form. The largest cross sectional thickness of the bolster 301 is critical because this thickness must be large enough to protect the steel beneath it as well as spread the formation fragment apart for effective cutting.
The described bolster 301 and tip 206 combination have proven very successful in the field. Many of the features described herein are critical for a long lasting degradation assembly 101. In the prior art, the weakest part of the degradation assembly 101 is generally the impact tip 206, which fail first. The prior art attempts to improve the life of these weaker tips by rotating the tips 206 through a bearing usually located between the inner surface of a holder bore and the outer surface of a shank 204. This rotation allows different azimuths of the tip 206 to engage the formation at each impact, effectively distributing wear and impact damage around the entire circumference of the tip 206. In the present invention, however, the combination of the tip 206 and bolster 301 is currently the most durable portion of the degradation assembly 101. In fact, it is so durable, that at present the applicants have not been able to create a bearing capable of outlasting this combination. In most cases, the bearing will fail before the tip 206 or bolster 301 receives enough wear or damage sufficient to replace them. At present, the tip 206 and bolster 301 combination is outlasting many of the commercially sold milling teeth by at least a factor of ten.
The advantage of the rotary portion 200 with a bolster 301 and tip 206 that is substantially prevented from rotating during operation as described is an extended life of the overall degradation assembly 101. Rotating the rotary portion manually at predetermined times, or as desired, allows the wear to be distributed around the tip 206 and bolster 301 as well.
The assemblies' longer life benefits operators by reducing down time to replace worn assemblies and reducing replace part inventories.
a is a cross sectional diagram depicting o-ring 205 disposed within a recess formed in the shank 204. The o-ring may still be under enough compression to substantially prevent the rotary portion's rotation.
a discloses an additional compressive element 306, which may also be an annular elastic element. The additional compressive element may be disposed substantially within the stationary portion 203 adjacent the first compressive element, which is within the rotary portion. It is believed that the interaction between these two elements 208 may generate sufficient friction to prevent free rotation.
b discloses a degradation assembly 101 with a rotary portion 200 comprising an integral shank 302. The stationary portion 203 comprises a holder 303 with a bore adapted to rotational support the integral shank. A compressible element 208 in the form of at least one rubber ball 304 is disposed intermediate the shank 302 and the holder 303. The compressible element may be a elastic ball, wedge, strip, block, square, blob, or combinations thereof. The assembly may also comprise an o-ring 205 disposed intermediate the shank 302 and the holder 303. The o-ring may function as a sealing element to retain lubricant within the assembly. It is believed that the at least one rubber ball 304 may substantially prevent the rotation. The assembly 101 may also comprises a puller attachment 305 disposed on the bolster 301. The puller attachment may be used to remove the rotary portion 200 of the assembly from the holder 303.
a discloses a compression spring 401 is disposed within the holder 303 such that a portion of the spring 401 engages the integral shank 302. It is believed that the compression spring 401 may put enough pressure on the shank 302 to prevent free rotation of the rotary portion 200.
b discloses a press fit pin 402 as a compressible element 208. It is believed that the press fit pin 402 is adjusted to put enough pressure on the shank 302 of the rotary portion 200 to prevent free rotation.
a discloses a set screw 403 adapted to energize a compressible element 208.
b discloses an outer edge of the rotary portion with an integral shank than wraps around a portion of the holder 303. A compressible element 208 in the form of a compressed o-ring 205 is disposed there between. The assembly may also comprise a snap ring 202 disposed intermediate the shank 302 and the holder 303. The snap ring 202 may prevent the rotary portion 200 from separating from the stationary portion 203.
a-8d disclose different embodiment of snap rings 202 that may be used as compressible elements 208 to prevent free rotation of an assembly 101 while still allowing for manual rotation.
c and 8d disclose a snap ring 202 with at least a flat side 701. The flat side 701 may also prevent free rotation by collapsing on both the shank and holder.
a and 9b disclose rotationally indexible degradation assemblies 101. The assembly comprises a holder 303 with a bore 802. The shank 302 comprises longitudinal surfaces 801 complementary to those formed in the bore.
b discloses a shank 302 and bore 802 of the holder 303 forming a star shape. This shape would allow for multiple azimuthal positions of the conical diamond tip 206.
a and 10b disclose a rotationally indexible degradation assembly 101. A bolster 301 is intermediate a conical diamond tip 206 and a shank 302. An o-ring 205 may be disposed around the shank 302. The assembly may be disposed within a holder 303. The side of the bolster 301 opposite the conical diamond tip 206 may comprise circumferentially equally spaced holes 901. These holes 901 may be adapted to receive interlocking elements 902. The holder 303 may comprise corresponding holes 901 adapted to receive interlocking elements 902. This embodiment may be used in degradation operations until the conical diamond tip 206 begins to show uneven wear at which time the rotary assembly may be detached from the holder 303 by pulling the holder 303 and the bolster 301 away from each other causing the press fit pins 902 to come out of their holes 901. The bolster may then be rotated until another set of holes 901 align, the interlocking elements 902 are reinserted, and then the bolster 301 may be pressed onto the holder 303. In some embodiments, the interlocking elements are integral to with the stationary or rotary portions of the assembly.
a and 11b discloses a racketed cam system 1001 with a set of indexible teeth 1002 disposed around the shank 302. The holder 303 may comprise a tab 1003 adapted to interface with the indexible teeth 1002 on the shank 302. The tab 1003 and the teeth 1002 may interact in such a way that the tab only allows for the teeth 1003 to rotate in a single direction. The tab 1003 may also interfere with the single direction of rotation enough as to prevent free rotation of the assembly 101 while in use.
a discloses a rotary portion that comprises the conical diamond tip 206 and a shield 201. The stationary portion of the assembly may comprise the shank 302. The shank 302 may comprises equally circumferentially spaced flat surfaces 1102 adapted to receive a set screw 1101. As a conical diamond tip 206 begins to wear the set screw 1102 may be loosened, the shield 201 rotated, and the screw 1102 reset.
b discloses an indexible holder 1201 that comprises axial flats. In this embodiment, the holder comprises a hexagonal shape. When the assembly 101 begins to show uneven wear the holder 1201 may be removed from a block, rotated, and then reinserted.
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
This application is a continuation of U.S. patent application Ser. No. 12/428,531, filed Apr. 23, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 12/177,556, filed Jul. 22, 2008, now U.S. Pat. No. 7,635,168 which is a continuation-in-part of U.S. patent Ser. No. 12/135,595, filed Jun. 9, 2008, now U.S. Pat. No. 7,946,656 which is a continuation-in-part of U.S. patent Ser. No. 12/112,743, filed Apr. 30, 2008, now U.S. Pat. No. 8,029,068 which is a continuation-in-part of U.S. patent application Ser. No. 12/051,738, filed Mar. 19, 2008, now U.S. Pat. No. 7,669,674 which is a continuation-in-part of U.S. patent application Ser. No. 12/051,689, filed Mar. 19, 2008, now U.S. Pat. No. 7,963,617 which is a continuation of U.S. patent application Ser. No. 12/051,586, filed Mar. 19, 2008, now U.S. Pat. No. 8,007,050 which is a continuation-in-part of U.S. patent application Ser. No. 12/021,051, filed Mar. 19, 2008, now U.S. Pat. No. 8,123,302 which is a continuation-in-part of U.S. patent application Ser. No. 12/021,019, filed Jan. 28, 2008, which was a continuation-in-part of U.S. patent application Ser. No. 11/971,965, filed Jan. 10, 2008, now U.S. Pat. No. 7,648,210 which is a continuation of U.S. patent application Ser. No. 11/947,644, filed Nov. 29, 2007, now U.S. Pat. No. 8,007,051 which was a continuation-in-part of U.S. patent application Ser. No. 11/844,586, filed Aug. 24, 2007, now U.S. Pat. No. 7,600,823. U.S. patent application Ser. No. 11/844,586 is a continuation-in-part of U.S. patent application Ser. No. 11/829,761, filed Jul. 27, 2007, now U.S. Pat. No. 7,722,127. U.S. patent application Ser. No. 11/829,761 is a continuation-in-part of U.S. patent application Ser. No. 11/773,271, filed Jul. 3, 2007, now U.S. Pat. No. 7,997,661. U.S. patent application Ser. No. 11/773,271 is a continuation-in-part of U.S. patent application Ser. No. 11/766,903, filed Jun. 22, 2007. U.S. patent application Ser. No. 11/766,903 is a continuation of U.S. patent application Ser. No. 11/766,865, filed Jun. 22, 2007, now abandoned. U.S. patent application Ser. No. 11/766,865 is a continuation-in-part of U.S. patent application Ser. No. 11/742,304, filed Apr. 30, 2007, now U.S. Pat. No. 7,475,948. U.S. patent application Ser. No. 11/742,304 is a continuation of U.S. patent application Ser. No. 11/742,261, filed Apr. 30, 2007, now U.S. Pat. No. 7,469,971. U.S. patent application Ser. No. 11/742,261 is a continuation-in-part of U.S. patent application Ser. No. 11/464,008, filed Aug. 11, 2006, now U.S. Pat. No. 7,338,135. U.S. patent application Ser. No. 11/464,008 is a continuation-in-part of U.S. patent application Ser. No. 11/463,998, filed Aug. 11, 2006, now U.S. Pat. No. 7,384,105. U.S. patent application Ser. No. 11/463,998 is a continuation-in-part of U.S. patent application Ser. No. 11/463,990, filed Aug. 11, 2006, now U.S. Pat. No. 7,320,505. U.S. patent application Ser. No. 11/463,990 is a continuation-in-part of U.S. patent application Ser. No. 11/463,975, filed Aug. 11, 2006, now U.S. Pat. No. 7,445,294. U.S. patent application Ser. No. 11/463,975 is a continuation-in-part of U.S. patent application Ser. No. 11/463,962, filed Aug. 11, 2006, now U.S. Pat. No. 7,413,256. The present application is also a continuation-in-part of U.S. patent application Ser. No. 11/695,672, filed Apr. 3, 2007, now U.S. Pat. No. 7,396,086. U.S. patent application Ser. No. 11/695,672 is a continuation-in-part of U.S. patent application Ser. No. 11/686,831, filed Mar. 15, 2007, now U.S. Pat. No. 7,568,770. All of these applications are herein incorporated by reference for all that they contain.
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Number | Date | Country | |
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20110266861 A1 | Nov 2011 | US |
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