Patent Grant
9016409
1. Technical Field
Embodiments disclosed herein relate generally to cutting elements for drilling earth formations. More specifically, embodiments disclosed herein relate generally to rotary drill bits having rotatable cutting elements installed thereon.
2. Background Art
Drill bits used to drill wellbores through earth formations generally are made within one of two broad categories of bit structures. Drill bits in the first category are generally known as “roller cone” bits, which include a bit body having one or more roller cones rotatably mounted to the bit body. The bit body is typically formed from steel or another high strength material. The roller cones are also typically formed from steel or other high strength material and include a plurality of cutting elements disposed at selected positions about the cones. The cutting elements may be formed from the same base material as is the cone. These bits are typically referred to as “milled tooth” bits. Other roller cone bits include “insert” cutting elements that are press (interference) fit into holes formed and/or machined into the roller cones. The inserts may be formed from, for example, tungsten carbide, natural or synthetic diamond, boron nitride, or any one or combination of hard or superhard materials.
Drill bits of the second category are typically referred to as “fixed cutter” or “drag” bits. This category of bits has no moving elements but rather have a bit body formed from steel or another high strength material and cutters (sometimes referred to as cutter elements, cutting elements or inserts) attached at selected positions to the bit body. For example, the cutters may be formed having a substrate or support stud made of carbide, for example tungsten carbide, and an ultra hard cutting surface layer or “table” made of a polycrystalline diamond material or a polycrystalline boron nitride material deposited onto or otherwise bonded to the substrate at an interface surface.
An example of a prior art drag bit having a plurality of cutters with ultra hard working surfaces is shown in
Nozzles 23 are typically formed in the drill bit body 12 and positioned in the gaps 16 so that fluid can be pumped to discharge drilling fluid in selected directions and at selected rates of flow between the cutting blades 14 for lubricating and cooling the drill bit 10, the blades 14, and the cutters 18. The drilling fluid also cleans and removes the cuttings as the drill bit rotates and penetrates the geological formation. The gaps 16, which may be referred to as “fluid courses,” are positioned to provide additional flow channels for drilling fluid and to provide a passage for formation cuttings to travel past the drill bit 10 toward the surface of a wellbore (not shown).
The drill bit 10 includes a shank 24 and a crown 26. Shank 24 is typically formed of steel or a matrix material and includes a threaded pin 28 for attachment to a drill string. Crown 26 has a cutting face 30 and outer side surface 32. The particular materials used to form drill bit bodies are selected to provide adequate toughness, while providing good resistance to abrasive and erosive wear. For example, in the case where an ultra hard cutter is to be used, the bit body 12 may be made from powdered tungsten carbide (WC) infiltrated with a binder alloy within a suitable mold form. In one manufacturing process the crown 26 includes a plurality of holes or pockets 34 that are sized and shaped to receive a corresponding plurality of cutters 18.
The combined plurality of surfaces 20 of the cutters 18 effectively forms the cutting face of the drill bit 10. Once the crown 26 is formed, the cutters 18 are positioned in the pockets 34 and affixed by any suitable method, such as brazing, adhesive, mechanical means such as interference fit, or the like. The design depicted provides the pockets 34 inclined with respect to the surface of the crown 26. The pockets 34 are inclined such that cutters 18 are oriented with the working face 20 at a desired rake angle in the direction of rotation of the bit 10, so as to enhance cutting. It should be understood that in an alternative construction (not shown), the cutters may each be substantially perpendicular to the surface of the crown, while an ultra hard surface is affixed to a substrate at an angle on a cutter body or a stud so that a desired rake angle is achieved at the working surface.
A typical cutter 18 is shown in
Generally speaking, the process for making a cutter 18 employs a body of tungsten carbide as the substrate 38. The carbide body is placed adjacent to a layer of ultra hard material particles such as diamond or cubic boron nitride particles and the combination is subjected to high temperature at a pressure where the ultra hard material particles are thermodynamically stable. This results in recrystallization and formation of a polycrystalline ultra hard material layer, such as a polycrystalline diamond or polycrystalline cubic boron nitride layer, directly onto the upper surface 54 of the cemented tungsten carbide substrate 38.
One type of ultra hard working surface 20 for fixed cutter drill bits is formed as described above with polycrystalline diamond on the substrate of tungsten carbide, typically known as a polycrystalline diamond compact (PDC), PDC cutters, PDC cutting elements, or PDC inserts. Drill bits made using such PDC cutters 18 are known generally as PDC bits. While the cutter or cutter insert 18 is typically formed using a cylindrical tungsten carbide “blank” or substrate 38 which is sufficiently long to act as a mounting stud 40, the substrate 38 may also be an intermediate layer bonded at another interface to another metallic mounting stud 40.
The ultra hard working surface 20 is formed of the polycrystalline diamond material, in the form of a cutting layer 44 (sometimes referred to as a “table”) bonded to the substrate 38 at an interface 46. The top of the ultra hard layer 44 provides a working surface 20 and the bottom of the ultra hard layer cutting layer 44 is affixed to the tungsten carbide substrate 38 at the interface 46. The substrate 38 or stud 40 is brazed or otherwise bonded in a selected position on the crown of the drill bit body 12 (
Bits 10 using conventional PDC cutters 18 are sometimes unable to sustain a sufficiently low wear rate at the cutter temperatures generally encountered while drilling in abrasive and hard rock. These temperatures may affect the life of the bit 10, especially when the temperatures reach 700-750° C., resulting in structural failure of the ultra hard layer 44 or PDC cutting layer. A PDC cutting layer includes individual diamond “crystals” that are interconnected. The individual diamond crystals thus form a lattice structure. A metal catalyst, such as cobalt may be used to promote recrystallization of the diamond particles and formation of the lattice structure. Thus, cobalt particles are typically found within the interstitial spaces in the diamond lattice structure. Cobalt has a significantly different coefficient of thermal expansion as compared to diamond. Therefore, upon heating of a diamond table, the cobalt and the diamond lattice will expand at different rates, causing cracks to form in the lattice structure and resulting in deterioration of the diamond table.
It has been found by applicants that many cutters 18 develop cracking, spalling, chipping and partial fracturing of the ultra hard material cutting layer 44 at a region of cutting layer subjected to the highest loading during drilling. This region is referred to herein as the “critical region” 56. The critical region 56 encompasses the portion of the ultra hard material layer 44 that makes contact with the earth formations during drilling. The critical region 56 is subjected to high magnitude stresses from dynamic normal loading, and shear loadings imposed on the ultra hard material layer 44 during drilling. Because the cutters are typically inserted into a drag bit at a rake angle, the critical region includes a portion of the ultra hard material layer near and including a portion of the layer's circumferential edge 22 that makes contact with the earth formations during drilling.
The high magnitude stresses at the critical region 56 alone or in combination with other factors, such as residual thermal stresses, can result in the initiation and growth of cracks 58 across the ultra hard layer 44 of the cutter 18. Cracks of sufficient length may cause the separation of a sufficiently large piece of ultra hard material, rendering the cutter 18 ineffective or resulting in the failure of the cutter 18. When this happens, drilling operations may have to be ceased to allow for recovery of the drag bit and replacement of the ineffective or failed cutter. The high stresses, particularly shear stresses, may also result in delamination of the ultra hard layer 44 at the interface 46.
In some drag bits, PDC cutters 18 are fixed onto the surface of the bit 10 such that a common cutting surface contacts the formation during drilling. Over time and/or when drilling certain hard but not necessarily highly abrasive rock formations, the edge 22 of the working surface 20 that constantly contacts the formation begins to wear down, forming a local wear flat, or an area worn disproportionately to the remainder of the cutting element. Local wear flats may result in longer drilling times due to a reduced ability of the drill bit to effectively penetrate the work material and a loss of rate of penetration caused by dulling of edge of the cutting element. That is, the worn PDC cutter acts as a friction bearing surface that generates heat, which accelerates the wear of the PDC cutter and slows the penetration rate of the drill. Such flat surfaces effectively stop or severely reduce the rate of formation cutting because the conventional PDC cutters are not able to adequately engage and efficiently remove the formation material from the area of contact. Additionally, the cutters are typically under constant thermal and mechanical load. As a result, heat builds up along the cutting surface, and results in cutting element fracture. When a cutting element breaks, the drilling operation may sustain a loss of rate of penetration, and additional damage to other cutting elements, should the broken cutting element contact a second cutting element.
Additionally, another factor in determining the longevity of PDC cutters is the generation of heat at the cutter contact point, specifically at the exposed part of the PDC layer caused by friction between the PCD and the work material. This heat causes thermal damage to the PCD in the form of cracks which lead to spalling of the polycrystalline diamond layer, delamination between the polycrystalline diamond and substrate, and back conversion of the diamond to graphite causing rapid abrasive wear. The thermal operating range of conventional PDC cutters is typically 750° C. or less.
In U.S. Pat. No. 4,553,615, a rotatable cutting element for a drag bit was disclosed with an objective of increasing the lifespan of the cutting elements and allowing for increased wear and cuttings removal. The rotatable cutting elements disclosed in the '615 patent include a thin layer of an agglomerate of diamond particles on a carbide backing layer having a carbide spindle, which may be journalled in a bore in a bit, optionally through an annular bush. With significant increases in loads and rates of penetration, the cutting element of the '615 patent is likely to fail by one of several failure modes. Firstly, thin layer of diamond is prone to chipping and fast wearing. Secondly, geometry of the cutting element would likely be unable to withstand heavy loads, resulting in fracture of the element along the carbide spindle. Thirdly, the retention of the rotatable portion is weak and may cause the rotatable portion to fall out during drilling. Fourthly, the prior art does not disclose optimization of the location of rotatable cutting elements on a bit body.
Accordingly, there exists a continuing need for cutting elements that may stay cool and avoid the generation of local wear flats, and the incorporation of those cutting elements on a drill bit or other cutting tool.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In one aspect, embodiments disclosed herein relate to a cutting tool that includes a tool body having a plurality of blades extending radially therefrom; and a plurality of rotatable cutting elements mounted on at least one of the plurality of blades, wherein the plurality of rotatable cutting elements are mounted on the at least one blade in a forward spiral configuration, and wherein each of the plurality of rotatable cutting elements has a negative side rake angle.
In another aspect, embodiments disclosed herein relate to a cutting tool that includes a tool body having a plurality of blades extending radially therefrom; and a plurality of rotatable cutting elements mounted on at least one of the plurality of blades, wherein the plurality of rotatable cutting elements are mounted on the at least one blade in a reverse spiral configuration, and wherein each of the plurality of rotatable cutting elements has a positive side rake angle.
In yet another aspect, embodiments disclosed herein relate to a cutting tool cutting tool that includes a tool body having a plurality of blades extending radially therefrom; and a plurality of rotatable cutting elements mounted on at least one of the plurality of blades, wherein the plurality of rotatable cutting elements are mounted on the at least one blade in a nose and/or shoulder region of the cutting tool at a side rake angle ranging from about 10 to about 30 degrees or −10 to about −30 degrees.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
In one aspect, embodiments disclosed herein relate to bit design using rotatable cutting structures. Specifically, embodiments disclosed herein relate to improving the life of a drill bit by positioning rotatable cutting elements in particular arrangements on the drill bit.
Generally, rotatable cutting elements (also referred to as rolling cutters) described herein allow at least one surface or portion of the cutting element to rotate as the cutting elements contact a formation. As the cutting element contacts the formation, the cutting action may allow portion of the cutting element to rotate around a cutting element axis extending through the cutting element. Rotation of a portion of the cutting structure may allow for a cutting surface to cut the formation using the entire outer edge of the cutting surface, rather than the same section of the outer edge, as observed in a conventional cutting element. The following discussion describes various embodiments for a rotatable cutting element; however, the present disclosure is not so limited. One skilled in the art would appreciate that any cutting element capable of rotating may be used with the drill bit or other cutting tool of the present disclosure.
The rotation of the inner rotatable cutting element may be controlled by the side cutting force and the frictional force between the bearing surfaces. If the side cutting force generates a torque which can overcome the torque from the frictional force, the rotatable portion will have rotating motion. The side cutting force may be affected by cutter side rake, back rake and geometry, including the working surface patterns disclosed herein. Additionally, the side cutting force may be affected by the surface finishing of the surfaces of the cutting element components, the frictional properties of the formation, as well as drilling parameters, such as depth of cut. The frictional force at the bearing surfaces may affected, for example, by surface finishing, mud intrusion, etc. The design of the rotatable cutters disclosed herein may be selected to ensure that the side cutting force overcomes the frictional force to allow for rotation of the rotatable portion. Various design considerations of the present disclosure are described below, as well as exemplary embodiments of rolling cutters.
Placement of Rolling Cutters
According to embodiments of the present disclosure, a bit design consideration may include placement of rolling cutters on a drill bit. Placement design of rolling cutters on a drill bit may involve, first, predicting where conventional cutter (fixed cutter) wear occurs most frequently or quickly on a drill bit. For example, fixed cutter wear may be predicted using engineering and design software, such as I-DEAS, “Integrated Design and Engineering Analysis Software”, or CAD software. Such engineering and design software may also be used to optimize bit stabilization dynamics using various placements of rolling cutters. Fixed cutter wear may also be predicted by observing and/or measuring wear flat sizes on dull drill bits. In particular, as a drill bit having conventional, fixed cutters contacts and cuts an earthen formation, the cutting surface and cutting edge of a fixed cutter may wear and form a wear flat. An example of a wear flat 2305 progression in a fixed cutter 2300 is shown in
Once fixed cutter wear is predicted, criteria for the placement of rolling cutters may be set according to where the fixed cutter wear occurs. For example, according to embodiments of the present disclosure, rolling cutter placement design may include replacing fixed cutters having the most amount of wear with rolling cutters. In one embodiment, rolling cutter placement design may include replacing half of the total number of fixed cutters experiencing the largest amount of wear with rolling cutters. Further, in other embodiments, rolling cutter placement design may include replacing fixed cutters with rolling cutters on only certain blades of a drill bit.
According to embodiments of the present disclosure, rolling cutter placement design criteria may be set so that rolling cutters and fixed cutters on a drill bit have a plural set configuration. Drill bits having a plural set configuration have more than one cutting element at at least one radial position with respect to the bit axis. Expressed alternatively, at least one cutting element includes a “back up” cutting element disposed at about the same radial position with respect to the bit axis. For example, referring to
Further, a bit may have a single set configuration of cutting elements, wherein each cutting element in a single set configuration is at a unique radial position of the bit. In embodiments having a single set configuration, a plurality of rolling cutters may be placed at various unique radial positions with respect to the bit axis. For example, a plurality of rolling cutters may have a forward spiral or a reverse spiral single set configuration, wherein the rolling cutters are placed in Further, a bit may have a single set configuration of cutting elements, wherein each cutting element in a single set configuration is at a unique radial position of the bit. In embodiments having a single set configuration, a plurality of rolling cutters may be placed at various unique radial positions with respect to the bit axis. For example, a plurality of rolling cutters may have a forward spiral or a reverse spiral single set configuration, wherein the rolling cutters are placed in areas experiencing wear. As used herein, a forward spiral layout refers to a cutter placement where cutters having incrementally increasing radial distances from the bit centerline are placed in a clockwise distribution, as illustrated in
Additionally, leading and trailing cutting elements may be placed on a single blade. However, as used herein, the term “backup cutting element” is used to describe a cutting element that trails any other cutting element on the same blade when the bit is rotated in the cutting direction. Further, as used herein, the term “primary cutting element” is used to describe a cutting element provided on the leading edge of a blade. In other words, when a bit is rotated about its central longitudinal axis in the cutting direction, a “primary cutting element” does not trail any other cutting elements on the same blade. Suitably, each primary cutting elements and optional backup cutting element may have any suitable size and geometry. Primary cutting elements and backup cutting elements may have any suitable location and orientation and may be rolling cutters or fixed cutters. In an example embodiment, backup cutting elements may be located at the same radial position as the primary cutting element it trails, or backup cutting elements may be offset from the primary cutting element it trails, or combinations thereof may be used.
In particular, each blade on a bit face (e.g., primary blades and secondary blades) provides a cutter-supporting surface to which cutting elements are mounted. Primary cutting elements may be disposed on the cutter-supporting surface of the blades and one or more of the primary blades may also have backup cutting elements disposed on the cutter-supporting surface of the bit. In an exemplary embodiment, backup cutting elements may be provided on the cutter-supporting surface of one or more of the bit primary blades in the cone region. In a different example embodiment, backup cutting elements may be provided on the cutter-supporting surface of any one or more secondary blades in the shoulder and/or gage region. In another example embodiment, backup cutting elements may be provided on the cutter-supporting surface of any one or more primary blades in the gage region. In yet another example embodiment, the primary and/or secondary blades may have at least two rows of backup cutting elements disposed on the cutter-supporting surfaces.
Primary cutting elements may be placed adjacent one another generally in a first row extending radially along each primary blade of a bit and along each secondary blade of a bit. Further, backup cutting elements may be placed adjacent one another generally in a second row extending radially along each primary blade in the shoulder region. Suitably, the backup cutting elements form a second row that may extend along each primary blade in the shoulder region, cone region and/or gage region. Backup cutting elements may be placed behind the primary cutting elements on the same primary blade, wherein backup cutting elements trail the primary cutting elements on the same primary blades.
In general, primary cutting elements as well as backup cutting elements need not be positioned in rows, but may be mounted in other suitable arrangements provided each cutting element is either in a leading position (e.g., primary cutting element) or a trailing position (e.g., backup cutting element). Examples of suitable arrangements may include without limitation, rows, arrays or organized patterns, randomly, sinusoidal pattern, or combinations thereof. Further, in other embodiments, additional rows of cutting elements may be provided on a primary blade, secondary blade, or combinations thereof.
In some embodiments of the present disclosure, rolling cutter placement design criteria may be set so that rolling cutters are positioned in the areas of the bit experiencing the greatest wear. For example, rolling cutters may be placed in the shoulder region of a drill bit. Referring to
Further, in a particular embodiment, a bit may have cutting elements placed in a single set configuration with rolling cutters placed in areas of the bit experiencing the greatest wear. In another embodiment, a bit may have cutting elements placed in a plural set configuration, wherein at least one rolling cutter is placed in areas of the bit experiencing the greatest wear.
Position of Rolling Cutters
Bit design considerations of the present disclosure may further include positioning of rolling cutters on a drill bit. Position design of rolling cutters on a drill bit may include adjusting the back rake (i.e., vertical orientation) and the side rake (i.e., a lateral orientation) of the cutting element, or adjusting the extension height of the cutting element, for example.
Referring to
In some embodiments, each rolling cutter placed in the nose and/or shoulder region of the bit may have a side rake ranging from 10 to 30 degrees or −10 to 30 degrees. In other embodiments, each rolling cutter placed in the nose and/or shoulder region of the bit may have a side rake ranging from 20 to 30 degrees or −20 to −30 degrees. In some embodiments, rolling cutters radially outside the shoulder, i.e., in the gage region, may range from 5 to 35 degrees or −5 to −35 degrees. In more particular embodiments, rolling cutters in the gage region may be >5 degrees, >10 degrees, >15 degrees, >20 degrees, >25 degrees, >30 degrees, and/or <10 degrees, <15 degrees, <20 degrees, <25, <30 degrees, <35 degrees, with any of such angles being positive or negative, and any upper limit being used with any lower limit. Further, in some embodiments, cutters may be placed in the cone region of the bit may have a side rake of less than 20 degrees or ranging from 10 to 15 degrees in more particular embodiments. In various embodiments, cutters in the cone region may be either fixedly attached or may be rolling, but may have such side rake range if fixed or rolling. It is specifically understood that any of the side rake angles for any region may be used in singly or in combination with any of the other ranges for other regions.
In another embodiment, a cutter may have a back rake ranging from about 5 to 35 degrees. In a particular embodiment, the back rake angle of a rolling cutter may be >5 degrees, >10 degrees, >15 degrees, >20 degrees, >25 degrees, >30 degrees, and/or <10 degrees, <15 degrees, <20 degrees, <25, <30 degrees, <35 degrees, with any upper limit being used with any lower limit. Such back rake angles may be used in for rolling cutters in any of the cone, nose, shoulder or gage region of the bit, but in particular embodiments, a back rake of between 10 and 35 degrees (or 15 to 35 degrees or 20 to 30 degrees in more particular embodiments) may be particularly suitable for cutters in the nose and/or shoulder region of the bit. A cutter may be positioned on a blade with a selected back rake to assist in removing drill cuttings and increasing rate of penetration. A cutter disposed on a drill bit with side rake may be forced forward in a radial and tangential direction when the bit rotates. In some embodiments, because the radial direction may assist the movement of a rotatable cutting element, such rotation may allow greater drill cuttings removal and provide an improved rate of penetration. One of ordinary skill in the art may realize that any back rake and side rake combination may be used with the cutting elements of the present disclosure to enhance rotatability and/or improve drilling efficiency.
As a rolling cutter contacts an earth formation, the rotating motion of the cutting element may be continuous or discontinuous. For example, when the cutting element is mounted with a determined side rake and back rake, the cutting force may be generally pointed in one direction. Providing a directional cutting force may allow the cutting element to have a continuous rotating motion, further enhancing drilling efficiency.
In accordance with the present disclosure, a plurality of rotatable cutting elements are disposed on a bit body utilizing two or more side rake angles, for example three or more side rake angles. In one or more embodiments, the two or more side rake angles may vary by at least 1 degree, for example at least 2 degrees (i.e., the difference between the greatest side rake and the least side rake) or at least 5 degrees. In one or more embodiments, the side rake angles of radially adjacent rotatable cutting elements may vary in the range of from 1 to 45 degrees, for example from 1 to 15 degrees, from 1 to 10 degrees, or from 1 to 5 degrees. In one or more embodiments, the side rake angles of radially adjacent rotatable cutting elements may vary by at least 2 degrees, for example at least 3. In one or more embodiments, the side rake angles of the radially adjacent rotatable cutting elements may vary in the range of from 2 to 10 degrees or from 2 to 5 degrees.
In another embodiment, as shown in
In yet another embodiment, as shown in
Bits having a plurality of rolling cutters of the present disclosure may include at least two rolling cutters, for example at least three, at least 4, at least 6, at least 9, or at least 12 rolling cutters, with any remaining cutting elements being conventional fixed cutting elements. In one or more embodiments, two or more primary blades may contain one or more rolling cutters, for example each primary blade may contain one or more rolling cutters. In one or more additional embodiments, one or more secondary blades may also contain one or more rolling cutters, for example each secondary blade may contain one or more rolling cutters. In one or more embodiments, all cutting elements may be rotatable.
In other exemplary embodiments, different types of rolling cutters may be used to provide increased design freedom. For example, rolling cutters that do not have an outer shell may take up less space on a downhole cutting tool, and therefore, more of the rolling cutters without a shell may be placed on the cutting tool, which may provide an increased diamond cutting density. Further, using rolling cutters without an outer shell may provide more space on the cutting tool for higher side rake angles. For example, rolling cutters without an outer shell may be positioned on a cutting tool, wherein the rolling cutters each have a side rake angle ranging between 0 and 40 degrees.
In one or more embodiments, one or more first rolling cutters may be mounted on one or more primary blades at a first side rake angle and one or more second rolling cutters may be mounted on one or more secondary blades at a second side rake angle which second side rake angle differs from the first side rake angle by at least 2 degrees. In one or more embodiments, a third rolling cutter may be mounted on another of the primary blades having a different side rake angle from the one or more first rolling cutters. In one or more embodiment, a fourth rolling cutter may be mounted on another of the secondary blades having a different side rake angle from the one or more second rolling cutters. In one or more embodiments, the first, second, third, and fourth rolling cutters may be the same rolling cutters with different side rake angles and optionally different back rake angles. Alternatively, one r more of the first, second, third and fourth rolling cutters may use two or more different rolling cutter devices.
In alternate embodiments, cutting elements may be disposed in cutting tools that do not incorporate back rake and/or side rake. When the cutting element is disposed on a drill bit with substantially zero degrees of side rake and/or back rake, the cutting force may be random instead of pointing in one general direction. The random forces may cause the cutting element to have a discontinuous rotating motion. Generally, such a discontinuous motion may not provide the most efficient drilling condition, however, in certain embodiments, it may be beneficial to allow substantially the entire cutting surface of the insert to contact the formation in a relatively even manner. In such an embodiment, alternative inner rotatable cutting element and/or cutting surface designs may be used to further exploit the benefits of rotatable cutting elements.
According to some embodiments, the extension height of cutting element cutting faces (i.e., the upper surface of the cutting table of the cutting element) may vary. In an example embodiment, cutting faces of primary cutting elements may have a greater extension height than the cutting faces of backup cutting elements (i.e., “on-profile” primary cutting elements engage a greater depth of the formation than the backup cutting elements; and the backup cutting elements are “off-profile”). As used herein, the term “off-profile” may be used to refer to a structure extending from the cutter-supporting surface (e.g., the cutting element, depth-of-cut limiter, etc.) that has an extension height less than the extension height of one or more other cutting elements that define the outermost cutting profile of a given blade. As used herein, the term “extension height” is used to describe the distance a cutting face extends from the cutter-supporting surface of the blade to which it is attached. In some example embodiments, one or more backup cutting faces may have the same or a greater extension height than one or more primary cutting faces. Such variables may impact the properties of the BHA, in particular the drill bit, which can affect the arrangement or positioning of the different types of cutting elements. For example, “on-profile” cutting elements may experience a greater amount of wear and load than “off-profile” cutting elements. Also, primary cutting elements may experience a greater amount of wear and load than backup cutting elements.
Exemplary Embodiments of Rolling Cutters
Rolling cutters of the present disclosure may include various types and sizes of rolling cutters. For example, rolling cutters may be formed in sizes including, but not limited to, 9 mm, 13 mm, 16 mm, and 19 mm. Further, rolling cutters may include those held within an outer support element, held by a retention mechanism or blocker, or a combination of the two. Examples of rolling cutters that may be used in the present disclosure may be found at least in U.S. Publication No. 2007/0278017 and U.S. Provisional Application No. 61/351,035, which are hereby incorporated by reference. Exemplary embodiments of rolling cutters are also described below; however, the types of rotatable cutting elements that may be used with the present disclosure are not necessarily limited to those described below.
Referring to
In various embodiments, the cutting face of the inner rotatable cutting element may include an ultra hard layer that may be comprised of a polycrystalline diamond table, a thermally stable diamond layer (i.e., having a thermal stability greater than that of conventional polycrystalline diamond, 750° C.), or other ultra hard layer such as a cubic boron nitride layer.
As known in the art, thermally stable diamond may be formed in various manners. A typical polycrystalline diamond layer includes individual diamond “crystals” that are interconnected. The individual diamond crystals thus form a lattice structure. A metal catalyst, such as cobalt, may be used to promote recrystallization of the diamond particles and formation of the lattice structure. Thus, cobalt particles are typically found within the interstitial spaces in the diamond lattice structure. Cobalt has a significantly different coefficient of thermal expansion as compared to diamond. Therefore, upon heating of a diamond table, the cobalt and the diamond lattice will expand at different rates, causing cracks to form in the lattice structure and resulting in deterioration of the diamond table.
To obviate this problem, strong acids may be used to “leach” the cobalt from a polycrystalline diamond lattice structure (either a thin volume or entire tablet) to at least reduce the damage experienced from heating diamond-cobalt composite at different rates upon heating. Examples of “leaching” processes can be found, for example, in U.S. Pat. Nos. 4,288,248 and 4,104,344. Briefly, a strong acid, typically hydrofluoric acid or combinations of several strong acids may be used to treat the diamond table, removing at least a portion of the co-catalyst from the PDC composite. Suitable acids include nitric acid, hydrofluoric acid, hydrochloric acid, sulfuric acid, phosphoric acid, or perchloric acid, or combinations of these acids. In addition, caustics, such as sodium hydroxide and potassium hydroxide, have been used to the carbide industry to digest metallic elements from carbide composites. In addition, other acidic and basic leaching agents may be used as desired. Those having ordinary skill in the art will appreciate that the molarity of the leaching agent may be adjusted depending on the time desired to leach, concerns about hazards, etc.
By leaching out the cobalt, thermally stable polycrystalline (TSP) diamond may be formed. In certain embodiments, only a select portion of a diamond composite is leached, in order to gain thermal stability without losing impact resistance. As used herein, the term TSP includes both of the above (i.e., partially and completely leached) compounds. Interstitial volumes remaining after leaching may be reduced by either furthering consolidation or by filling the volume with a secondary material, such by processes known in the art and described in U.S. Pat. No. 5,127,923, which is herein incorporated by reference in its entirety.
Alternatively, TSP may be formed by forming the diamond layer in a press using a binder other than cobalt, one such as silicon, which has a coefficient of thermal expansion more similar to that of diamond than cobalt has. During the manufacturing process, a large portion, 80 to 100 volume percent, of the silicon reacts with the diamond lattice to form silicon carbide which also has a thermal expansion similar to diamond. Upon heating, any remaining silicon, silicon carbide, and the diamond lattice will expand at more similar rates as compared to rates of expansion for cobalt and diamond, resulting in a more thermally stable layer. PDC cutters having a TSP cutting layer have relatively low wear rates, even as cutter temperatures reach 1200° C. However, one of ordinary skill in the art would recognize that a thermally stable diamond layer may be formed by other methods known in the art, including, for example, by altering processing conditions in the formation of the diamond layer.
The substrate on which the cutting face is disposed may be formed of a variety of hard or ultra hard particles. In one embodiment, the substrate may be formed from a suitable material such as tungsten carbide, tantalum carbide, or titanium carbide. Additionally, various binding metals may be included in the substrate, such as cobalt, nickel, iron, metal alloys, or mixtures thereof. In the substrate, the metal carbide grains are supported within the metallic binder, such as cobalt. Additionally, the substrate may be formed of a sintered tungsten carbide composite structure. It is well known that various metal carbide compositions and binders may be used, in addition to tungsten carbide and cobalt. Thus, references to the use of tungsten carbide and cobalt are for illustrative purposes only, and no limitation on the type substrate or binder used is intended. In another embodiment, the substrate may also be formed from a diamond ultra hard material such as polycrystalline diamond and thermally stable diamond. While the illustrated embodiments show the cutting face and substrate as two distinct pieces, one of skill in the art should appreciate that it is within the scope of the present disclosure the cutting face and substrate are integral, identical compositions. In such an embodiment, it may be preferable to have a single diamond composite forming the cutting face and substrate or distinct layers.
The outer support element may be formed from a variety of materials. In one embodiment, the outer support element may be formed of a suitable material such as tungsten carbide, tantalum carbide, or titanium carbide. Additionally, various binding metals may be included in the outer support element, such as cobalt, nickel, iron, metal alloys, or mixtures thereof, such that the metal carbide grains are supported within the metallic binder. In a particular embodiment, the outer support element is a cemented tungsten carbide with a cobalt content ranging from 6 to 13 percent.
In other embodiments, the outer support element may be formed of alloy steels, nickel-based alloys, and cobalt-based alloys. One of ordinary skill in the art would also recognize that cutting element components may be coated with a hardfacing material for increased erosion protection. Such coatings may be applied by various techniques known in the art such as, for example, detonation gun (d-gun) and spray-and-fuse techniques.
Referring again to
In a particular embodiment, the cutting face of the inner rotatable cutting element has a thickness of at least 0.050 inches. However, one of ordinary skill in the art would recognize that depending on the geometry and size of the cutting structure, other thicknesses may be appropriate.
In another embodiment, the inner rotatable cutting element may have a non-planar interface between the substrate and the cutting face. A non-planar interface between the substrate and cutting face increases the surface area of a substrate, thus may improve the bonding of the cutting face to the substrate. In addition, the non-planar interfaces may increase the resistance to shear stress that often results in delamination of the diamond tables, for example.
One example of a non-planar interface between a carbide substrate and a diamond layer is described, for example, in U.S. Pat. No. 5,662,720, wherein an “egg-carton” shape is formed into the substrate by a suitable cutting, etching, or molding process. Other non-planar interfaces may also be used including, for example, the interface described in U.S. Pat. No. 5,494,477. According to one embodiment of the present disclosure, a cutting face is deposited onto the substrate having a non-planar surface.
An inner rotatable cutting element may be retained in the outer support element by a variety of mechanisms, including for example, ball bearings, pins, and mechanical interlocking. In various embodiments, a single retention system may be used, while, alternatively, in other embodiments, multiple retention systems may be used.
Referring again to
Balls 230 may be made any material (e.g., steel or carbides) capable of withstanding compressive forces acting thereupon while cutting element 200 engages the formation. In a particular embodiment the balls may be formed of tungsten carbide or silicon carbide. If tungsten carbide balls are used, it may be preferable to use a cemented tungsten carbide composition varying from that of the outer support element and/or substrate. Balls 230 may be of any size and of which may be variable to change the rotational speed of inner rotatable cutting element 210. In certain embodiments, the rotatable speed of dynamic portion 210 may be between one and five rotations per minute so that the surface of cutting face 212 may remain sharp without compromising the integrity of cutting element 200.
Referring to
In various embodiments including, for example, those shown in
In one embodiment, the bearing surfaces of the cutting elements disclosed herein may be enhanced to promote rotation of the inner rotatable cutting element in the outer support element. Bearing surface enhancements may be incorporated on a portion of either or both of the inner rotatable cutting element bearing surface and outer support element bearing surface. In a particular embodiment, at least a portion of one of the bearing surfaces may include a diamond bearing surface. According to the present disclosed, a diamond bearing surface may include discrete segments of diamond in some embodiments and a continuous segment in other embodiments. Bearing surfaces that may be used in the cutting elements disclosed herein may include diamond bearing surfaces, such as those disclosed in U.S. Pat. Nos. 4,756,631 and 4,738,322, assigned to the present assignee and incorporated herein by reference in its entirety.
In some embodiments, diamond-on-diamond bearing surfaces may be provided. This may be achieved by using diamond enhanced bearing surfaces on both the inner rotatable cutting element and outer support element, or alternatively, the substrate may be formed of diamond and diamond enhanced bearing surfaces may be provided on the outer support element. In other embodiments, diamond-on-carbide bearing surfaces may be used, where diamond bearing surfaces may be included on one of the substrate or the outer support element, where carbide comprises the other component.
To further enhance rotation of the inner rotatable cutting element, the bottom mating surfaces of the inner rotatable cutting element and outer support element may be varied. For example, ball bearings may be provided between the two components or, alternatively, one of the surfaces may contain and/or be formed of diamond.
In another embodiment, at least a portion of at least one of the bearing surfaces may be surface treated for optimizing the rotation of the inner rotatable cutting element in the inner support element. Surface treatments suitable for the cutting elements of the present disclosure include addition of a lubricant, applied coatings and surface finishing, for example. In a particular embodiment, a bearing surface may undergo surface finishing such that the surface has a mean roughness of less than about 125 μ-inch Ra, and less than about 32 μ-inch Ra in another embodiment. In another particular embodiment, a bearing surface may be coated with a lubricious material to facilitate rotation of the inner rotatable cutting element and/or to reduce friction and galling between the inner rotatable cutting element and the outer support element. In a particular embodiment, a bearing surface may be coated with a carbide, nitride, and/or oxide of various metals that may be applied by PVD, CVD or any other deposition techniques known in the art that facilitate bonding to the substrate or base material. In another embodiment, a floating bearing may be included between the bearing surfaces to facilitate rotation. Incorporation of a friction reducing material, such as a grease or lubricant, may allow the surfaces of the inner rotatable cutting element and the outer support element to rotate and contract one another, but result in only minimal heat generation therefrom.
In another embodiment, surface alterations may be included on the working surfaces of the cutting face, the substrate, and/or an inner hole of the inner rotatable cutting element. Surface alterations may be included in the cutting elements of the present disclosure to enhance rotation through hydraulic interactions or physical interactions with the formation. In various embodiments, surface alterations may be etched or machined into the various components, or alternatively formed during sintering or formation of the component, and in some particular embodiments, may have a depth ranging from 0.001 to 0.050 inches. One of ordinary skill in the art would recognize the surface alterations may take any geometric or non-geometric shape on any portion of the inner rotatable cutting element and may be formed in a symmetric or asymmetric manner. Further, depending on the size of the cutting elements, it may be preferable to vary the depth of the surface alterations.
While the above embodiments describe surface alterations formed, for example, by etching or machining, it is also within the scope of the present disclosure that the cutting element includes a non-planar cutting face that may be achieved through protrusions from the face. Non-planar cutting faces may also be achieved through the use of shaped cutting faces in the inner rotatable cutting element. For example, shaped cutting faces suitable for use in the cutting elements of the present disclosure may include domed or rounded tops and saddle shapes.
Further, the types of bearing surfaces between the inner rotatable cutting element and outer support elements present in a particular cutting element may vary. Among the types of bearing surfaces that may be present in the cutting elements of the present disclosure include conical bearing surfaces, radial bearing surfaces, and axial bearing surfaces.
In one embodiment, the inner rotatable cutting element may of a generally frusto-conical shape within an outer support element having a substantially mating shape, such that the inner rotatable cutting element and outer support element have conical bearing surfaces therebetween. Referring to
Referring to
As shown in the various illustrated above, the inner rotatable cutting element and outer support cutting element may take the form of a variety of shapes/geometries. Depending on the shapes of the components, different bearings surfaces, or combinations thereof may exist between the inner rotatable cutting element and outer support element. However, one of ordinary skill in the art would recognize that permutations in the shapes may exist and any particular geometric forms should not be considered a limitation on the scope of the cutting elements disclosed herein.
Further, one of ordinary skill in the art would also appreciate that any of the design modifications as described above, including, for example, side rake, back rake, variations in geometry, surface alteration/etching, seals, bearings, material compositions, etc, may be included in various combinations not limited to those described above in the cutting elements of the present disclosure.
The cutting elements of the present disclosure may be incorporated in various types of downhole cutting tools, including for example, as cutters in fixed cutter bits or as inserts in roller cone bits, reamers, hole benders, or any other tool that may be used to drill earthen formations. Cutting tools having the cutting elements of the present disclosure may include a single rotatable cutting element with the remaining cutting elements being conventional cutting elements, all cutting elements being rotatable, or any combination therebetween of rotatable and conventional cutting elements.
Referring now to
The cutting elements of the present disclosure may be attached to or mounted on a drill bit by a variety of mechanisms, including but not limited to conventional attachment or brazing techniques in a cutter pocket. One alternative mounting technique that may be suitable for the cutting elements of the present disclosure is shown in
Referring to
The rolling cutter 2230 may also have a side surface 2235 formed around the circumference and extending the entire length of the rolling cutter 2230. Thus, in embodiments having a cutting face made from a material that is different from the substrate, the side surface may include both substrate material and the cutting face material. Further, as shown in
Further, the rolling cutter may be modified to have diamond material (e.g., polycrystalline diamond) at the cutting face and/or the cutting edge. A rolling cutter 2230 having a cutting edge 2233 of polycrystalline diamond 2234, as shown in
Referring to
In addition to grooves, the cutting face 2232 of a rolling cutter 2230 may have a concave or convex portion. The terms “concave portion” and “convex portion” refer to a portion of a cutting face that has a concave or convex shape and is configured to correspond with an adjacent blocker. Although a concave portion may have a shape similar to or the same as the shape of a groove 2236, a concave/convex portion differs in function and typically in size and location from grooves. In particular, a concave/convex portion may be formed to fit with the retention end of a corresponding blocker and may be generally located in the radial center of a cutting face. Grooves may be formed around or near the edges of a cutting face to enhance rotation of the rolling cutter and are generally smaller than a concave/convex portion.
An example of a rolling cutter having both grooves and a concave portion is shown in
As referred to herein, a blocker is a component separate from a bit that is attached to the bit, adjacent to the cutting face of a rolling cutter. A blocker includes an attachment end, which acts as an attachment between the blocker and the bit, and a retention end, which is located adjacent to the cutting face of a rolling cutter. A blocker may be formed from various materials and have various shapes and sizes to prevent the rolling cutter from coming out of a cutter pocket formed in the bit.
Advantageously, embodiments disclosed herein may provide for at least one of the following. Cutting elements that include a rotatable cutting portion may avoid the high temperatures generated by typical fixed cutters. Because the cutting surface of prior art cutting elements is constantly contacting formation, heat may build-up that may cause failure of the cutting element due to fracture. Embodiments in accordance with the present invention may avoid this heat build-up as the edge contacting the formation changes. The lower temperatures at the edge of the cutting elements may decrease fracture potential, thereby extending the functional life of the cutting element. By decreasing the thermal and mechanical load experienced by the cutting surface of the cutting element, cutting element life may be increase, thereby allowing more efficient drilling.
Further, rotation of a rotatable portion of the cutting element may allow a cutting surface to cut formation using the entire outer edge of the cutting surface, rather than the same section of the outer edge, as provided by the prior art. The entire edge of the cutting element may contact the formation, generating more uniform cutting element edge wear, thereby preventing for formation of a local wear flat area. Because the edge wear is more uniform, the cutting element may not wear as quickly, thereby having a longer downhole life, and thus increasing the overall efficiency of the drilling operation.
Additionally, because the edge of the cutting element contacting the formation changes as the rotatable cutting portion of the cutting element rotates, the cutting edge may remain sharp. The sharp cutting edge may increase the rate of penetration while drilling formation, thereby increasing the efficiency of the drilling operation. Further, as the rotatable portion of the cutting element rotates, a hydraulic force may be applied to the cutting surface to cool and clean the surface of the cutting element.
Some embodiments may protect the cutting surface of a cutting element from side impact forces, thereby preventing premature cutting element fracture and subsequent failure. Still other embodiments may use a diamond table cutting surface as a bearing surface to reduce friction and provide extended wear life. As wear life of the cutting element embodiments increase, the potential of cutting element failure decreases. As such, a longer effective cutting element life may provide a higher rate of penetration, and ultimately result in a more efficient drilling operation.
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
This application is a continuation-in-part of U.S. patent application Ser. No. 13/111,453, filed on May 19, 2011, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/346,260, filed May 19, 2010, both of which are herein incorporated by reference in their entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20120132471 A1 | May 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61346260 | May 2010 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13111453 | May 2011 | US |
| Child | 13303837 | US |
