Rolling element with half lock

Abstract

A drill bit includes a bit body having one or more blades extending therefrom, a plurality of cutters secured to the one or more blades, and a rolling element assembly positioned within a cavity defined on the bit body. The rolling element assembly includes a rolling element rotatable within the cavity about a rotational axis, and a retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity. The retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a U.S. national stage patent application of International Patent Application No. PCT/US2016/037,991, filed on Jun. 17, 2016, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

In conventional wellbore drilling in the oil and gas industry, a drill bit is mounted on the end of a drill string, which may be extended by adding segments of drill pipe as the well is progressively drilled to the desired depth. At the surface of the well site, a rotary drive (referred to as a “top drive”) may be provided to rotate the entire drill string, including the drill bit at the end, to drill through the subterranean formation. Alternatively, the drill bit may be rotated using a downhole mud motor without having to rotate the drill string. When drilling, drilling fluid is pumped through the drill string and discharged from the drill bit to remove cuttings and debris. The mud motor, if present in the drill string, may be selectively powered using the circulating drilling fluid.

One common type of drill bit used to drill wellbores is a “fixed cutter” bit, wherein the cutters are secured to the bit body at fixed positions. This type of bit is sometimes referred to as a “drag bit” since the cutters in one respect drag rather than roll in contact with the formation during drilling. The bit body may be formed from a high strength material, such as tungsten carbide, steel, or a composite/matrix material. A plurality of cutters (also referred to as cutter elements, cutting elements, or inserts) are attached at selected locations about the bit body. The cutters may include a substrate or support stud made of a carbide (e.g., 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. Such cutters are commonly referred to as polycrystalline diamond compact (“PDC”) cutters.

In fixed cutter drill bits, PDC cutters are rigidly secured to the bit body, such as by being brazed within corresponding cutter pockets defined on blades that extend from the bit body. Some of the PDC cutters are strategically positioned along the leading edges of the blades to engage the formation during drilling. In use, high forces are exerted on the PDC cutters, particularly in the forward-to-rear direction. Over time, the working surface or cutting edge of each cutter that continuously contacts the formation eventually wears down and/or fails.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

FIG. 1A illustrates an isometric view of a rotary drill bit that may employ the principles of the present disclosure.

FIG. 1B illustrates an isometric view of a portion of the rotary drill bit enclosed in the indicated box of FIG. 1A.

FIG. 1C illustrates a drawing in section and in elevation with portions broken away showing the drill bit of FIG. 1.

FIG. 1D illustrates a blade profile that represents a cross-sectional view of a blade of the drill bit of FIG. 1.

FIG. 2 is an isometric view of one example of a rolling element assembly.

FIG. 3 is a side view of the rolling element assembly of FIG. 2.

FIGS. 4A and 4B are isometric an end views, respectively, of an example embodiment of the retainer of FIGS. 2 and 3.

FIGS. 5A and 5B are isometric front and back views, respectively, of another example embodiment of the retainer of FIGS. 2 and 3.

FIG. 6A is an exploded side view of the rolling element assembly of FIGS. 2 and 3.

FIGS. 6B-6D are side views of the rolling element assembly of FIGS. 2 and 3 showing progressive installation of the retainer.

FIG. 7 is an isometric view of an example cavity defined in a blade of the drill bit of FIGS. 1A-1B.

FIGS. 8A-8F are top views of example cavity designs as defined in a blade of the drill bit of FIGS. 1A-1B.

FIG. 9A is an isometric view of another example rolling element assembly.

FIG. 9B is an isometric view of the retainer of the rolling element assembly of FIG. 9A.

FIG. 10A is an isometric view of another example rolling element assembly.

FIG. 10B is an end view of the rolling element assembly of FIG. 10A.

DETAILED DESCRIPTION

The present disclosure relates to earth-penetrating drill bits and, more particularly, to rolling type depth of cut control elements that can be used in drill bits.

The embodiments of the present disclosure describe rolling element assemblies that can be secured within corresponding cavities provided on a drill bit. Each rolling element assembly includes a cylindrical rolling element strategically positioned and secured to the drill bit so that the rolling element is able to engage the formation during drilling. In response to drill bit rotation, and depending on the selected positioning (orientation) of the rolling element with respect to the body of the drill bit, the rolling element may roll against the underlying formation, cut against the formation, or may both roll against and cut the formation. The rolling elements of the presently disclosed rolling element assemblies are retained within corresponding cavities on the bit body using an arcuate retainer received within a retainer slot defined in the cavity.

The orientation of each rolling element with respect to the bit body is selected to produce a variety of different functions and/or effects. The selected orientation includes, for example, a selected side rake and/or a selected back rake. In some cases while drilling, the rolling element may be configured as a rolling cutting element that both rolls along the formation (e.g., by virtue of a selected range of side rake) and cuts the formation (e.g., by virtue of the selected back rake and/or side rake). More particularly, the rolling cutting element may be positioned to cut, dig, scrape, or otherwise remove material from the formation using a portion of the rolling element (e.g., a polycrystalline diamond table) that is positioned to engage the formation.

In some example embodiments, the rolling element assemblies described herein can be configured as rolling cutting elements. The rolling cutting elements may be configured to rotate freely about a rotational axis and, as a result, the entire outer edge of the rolling cutting element may be used as a cutting edge. Consequently, rather than only a limited portion of the cutting edge being exposed to the formation during drilling, as in the case of conventional fixed cutters, the entire outer edge of the rolling cutting element will be successively exposed to the formation as it rotates about its rotational axis during drilling. This results in a more uniform cutting edge wear, which may prolong the operational lifespan of the rolling cutting element as compared to conventional cutters.

In other example embodiments, the rolling element assemblies described herein can be configured as rolling depth of cut control (DOCC) elements that roll along the formation as the drill bit rotates. In a rolling DOCC element configuration, the orientation of the rolling element may be selected so that a full axial span of the rolling element bears against the formation. As with rolling cutting elements, rolling DOCC elements may exhibit enhanced wear resilience and allow for additional weight-on-bit without negatively affecting torque-on-bit. This may allow a well operator to minimize damage to the drill bit, thereby reducing trips and non-productive time, and decreasing the aggressiveness of the drill bit without sacrificing its efficiency. The rolling DOCC elements described herein may also reduce friction at the interface between the drill bit and the formation, and thereby allow for a steady depth of cut, which results in better tool face control.

In yet other example embodiments, the rolling element assemblies described herein may operate as a hybrid between a rolling cutting element and a rolling DOCC element. This may be accomplished by orienting the rotational axis of the rolling element on a plane that does not pass through the longitudinal axis of the drill bit nor is the plane oriented perpendicular to a plane that does pass through the longitudinal axis of the drill bit. Those skilled in the art will readily appreciate that the presently disclosed embodiments may improve upon hybrid rock bits, which use a large roller cone element as a depth of cut limiter by sacrificing diamond volume. In contrast, the presently disclosed rolling element assemblies are small in comparison and its enablement will not result in a significant loss of diamond volume on a fixed cutter drag bit.

FIG. 1A is an isometric view of an exemplary drill bit 100 that may employ the principles of the present disclosure. The drill bit 100 is depicted as a fixed cutter drill bit, and the present teachings may be applied to any fixed cutter drill bit category, including polycrystalline diamond compact (PDC) drill bits, drag bits, matrix drill bits, and/or steel body drill bits. While the drill bit 100 is depicted in FIG. 1A as a fixed cutter drill bit, however, the principles of the present disclosure are equally applicable to other types of drill bits operable to form a wellbore including, but not limited to, roller cone drill bits.

The drill bit 100 has a bit body 102 that includes radially and longitudinally extending blades 104 having leading faces 106. The bit body 102 may be made of steel or a matrix of a harder material, such as tungsten carbide. The bit body 102 rotates about a longitudinal drill bit axis 107 to drill into underlying subterranean formation under an applied weight-on-bit. Corresponding junk slots 112 are defined between circumferentially adjacent blades 104, and a plurality of nozzles or ports 114 can be arranged within the junk slots 112 for ejecting drilling fluid that cools the drill bit 100 and otherwise flushes away cuttings and debris generated while drilling.

The bit body 102 further includes a plurality of cutters 116 secured within a corresponding plurality of cutter pockets sized and shaped to receive the cutters 116. Each cutter 116 in this example comprises a fixed cutter secured within its corresponding cutter pocket via brazing, threading, shrink-fitting, press-fitting, snap rings, or any combination thereof. The fixed cutters 116 are held in the blades 104 and respective cutter pockets at predetermined angular orientations and radial locations to present the fixed cutters 116 with a desired back rake angle against the formation being penetrated. As the drill string is rotated, the fixed cutters 116 are driven through the rock by the combined forces of the weight-on-bit and the torque experienced at the drill bit 100. During drilling, the fixed cutters 116 may experience a variety of forces, such as drag forces, axial forces, reactive moment forces, or the like, due to the interaction with the underlying formation being drilled as the drill bit 100 rotates.

Each fixed cutter 116 may include a generally cylindrical substrate made of an extremely hard material, such as tungsten carbide, and a cutting face secured to the substrate. The cutting face may include one or more layers of an ultra-hard material, such as polycrystalline diamond, polycrystalline cubic boron nitride, impregnated diamond, etc., which generally forms a cutting edge and the working surface for each fixed cutter 116. The working surface is typically flat or planar, but may also exhibit a curved exposed surface that meets the side surface at a cutting edge.

Generally, each fixed cutter 116 may be manufactured using tungsten carbide as the substrate. While a cylindrical tungsten carbide “blank” can be used as the substrate, which is sufficiently long to act as a mounting stud for the cutting face, the substrate may equally comprise an intermediate layer bonded at another interface to another metallic mounting stud. To form the cutting face, the substrate may be placed adjacent 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 of the substrate. When using polycrystalline diamond as the ultra-hard material, the fixed cutter 116 may be referred to as a polycrystalline diamond compact cutter or a “PDC cutter,” and drill bits made using such PDC fixed cutters 116 are generally known as PDC bits.

As illustrated, the drill bit 100 may further include a plurality of rolling element assemblies 118, shown as rolling element assemblies 118a and 118b. The orientation of a rotational axis of each rolling element assembly 118a,b with respect to a tangent to an outer surface of the blade 104 may dictate whether the particular rolling element assembly 118a,b operates as a rolling DOCC element, a rolling cutting element, or a hybrid of both. As mentioned above, rolling DOCC elements may prove advantageous in allowing for additional weight-on-bit (WOB) to enhance directional drilling applications without over engagement of the fixed cutters 116. Effective DOCC also limits fluctuations in torque and minimizes stick-slip, which can cause damage to the fixed cutters 116.

FIG. 1B is an enlarged portion of the drill bit 100 indicated by the dashed box shown in FIG. 1A. As shown in FIG. 1B, each rolling element assembly 118a,b is located in the blade 104 and includes a rolling element 122. Exposed portions of the rolling elements 122 are illustrated in solid linetype, while portions of the rolling elements 122 that are seated within corresponding housings or pockets of the rolling element assemblies 118a,b are illustrated in dashed linetype. Each rolling element 122 has a rotational axis A, a Z-axis that is perpendicular to the blade profile 138 (FIG. 1D), and a Y-axis that is orthogonal to both the rotational and Z axes.

If, for example, the rotational axis A of the rolling element 122 is substantially parallel to a tangent to the outer surface 119 of the blade profile, the rolling element assembly 118a,b may generally operate as a rolling DOCC element. Said differently, if the rotational axis A of the rolling element 122 passes through or lies on a plane that passes through the longitudinal axis 107 (FIG. 1A) of the drill bit 100 (FIG. 1A), then the rolling element assembly 118a,b may substantially operate as a rolling DOCC element. If, however, the rotational axis A of the rolling element 122 is substantially perpendicular to the leading face 106 of the blade 104, then the rolling element assembly 118a,b may substantially operate as a rolling cutting element. Said differently, if the rotational axis A of the rolling element 122 is perpendicular to or lies on a plane that is perpendicular to a plane passing through the longitudinal axis 107 (FIG. 1A) of the drill bit 100 (FIG. 1A), then the rolling element assembly 118a,b may substantially operate as a rolling cutting element.

Accordingly, as depicted in FIG. 1B, the first rolling element assembly 118a may be positioned to operate as a rolling cutting element and the second rolling element assembly 118b may be positioned to operate as a rolling DOCC element. In embodiments where the rotational axis A of the rolling element 122 lies on a plane that does not pass through the longitudinal axis 107 (FIG. 1A) of the drill bit 100 (FIG. 1A) nor is the plane perpendicular to the longitudinal axis 107, the rolling element assembly 118a,b may then operate as a hybrid rolling DOCC and cutting element.

Traditional load-bearing type cutting elements for DOCC unfavorably affect torque-on-bit (TOB) by simply dragging, sliding, etc. along the formation, whereas a rolling DOCC element, such as the presently described rolling element assemblies 118b, may reduce the amount of torque needed to drill a formation because it rolls to reduce friction losses typical with load bearing DOCC elements. A rolling DOCC element will also have reduced wear as compared to a traditional bearing element. As will be appreciated, however, one or more of the rolling element assemblies 118b can also be used as rolling cutting elements, which may increase cutter effectiveness since it will distribute heat more evenly over the entire cutting edge and minimize the formation of localized wear flats on the rolling cutting element.

FIG. 1C is a drawing in section and in elevation with portions broken away showing the drill bit 100 drilling a wellbore through a first downhole formation 124 and into an underlying second downhole formation 126. The first downhole formation 124 may be described as softer or less hard when compared to the second downhole formation 126. Exterior portions of the drill bit 100 that contact adjacent portions of the first and/or second downhole formations 124, 126 may be described as a bit face, and are projected rotationally onto a radial plane to provide a bit face profile 128. The bit face profile 128 of the drill bit 100 may include various zones or segments and may be substantially symmetric about the longitudinal axis 107 of the drill bit 100 due to the rotational projection of the bit face profile 128, such that the zones or segments on one side of the longitudinal axis 107 may be substantially similar to the zones or segments on the opposite side of the longitudinal axis 107.

For example, the bit face profile 128 may include a first gage zone 130a located opposite a second gage zone 130b, a first shoulder zone 132a located opposite a second shoulder zone 132b, a first nose zone 134a located opposite a second nose zone 134b, and a first cone zone 136a located opposite a second cone zone 136b. The fixed cutters 116 included in each zone may be referred to as cutting elements of that zone. For example, the fixed cutters 116a included in gage zones 130a,b may be referred to as gage cutting elements, the fixed cutters 116b included in shoulder zones 132a,b may be referred to as shoulder cutting elements, the fixed cutters 116c included in nose zones 134a,b may be referred to as nose cutting elements, and the fixed cutters 116d included in cone zones 136a,b may be referred to as cone cutting elements.

Cone zones 136a,b may be generally concave and may be formed on exterior portions of each blade 104 (FIG. 1A) of the drill bit 100, adjacent to and extending out from the longitudinal axis 107. The nose zones 134a,b may be generally convex and may be formed on exterior portions of each blade 104, adjacent to and extending from each cone zone 136. Shoulder zones 132a,b may be formed on exterior portions of each blade 104 extending from respective nose zones 134a,b and may terminate proximate to a respective gage zone 130a,b. The area of the bit face profile 128 may depend on cross-sectional areas associated with zones or segments of the bit face profile 128 rather than on a total number of fixed cutters 116, a total number of blades 104, or cutting areas per fixed cutter 116.

FIG. 1D illustrates a blade profile 138 that represents a cross-sectional view of one of the blades 104 of the drill bit 100 (FIG. 1A). The blade profile 138 includes the cone zone 136, the nose zone 134, the shoulder zone 132 and the gage zone 130, as described above with respect to FIG. 1C. Each zone 130, 132, 134, 135 may be based on its respective location along the blade 104 with respect to the longitudinal axis 107 and a horizontal reference line 140 that indicates a distance from the longitudinal axis 107 in a plane perpendicular to the longitudinal axis 107. A comparison of FIGS. 1C and 1D shows that the blade profile 138 of FIG. 1D is upside down with respect to the bit face profile 128 of FIG. 1C.

The blade profile 138 includes an inner zone 142 and an outer zone 144. The inner zone 142 extends outward from the longitudinal axis 107 to a nose point 146, and the outer zone 144 extends from the nose point 146 to the end of the blade 104. The nose point 146 may be a location on the blade profile 138 within the nose zone 134 that has maximum elevation as measured by the bit longitudinal axis 107 (vertical axis) from reference line 140 (horizontal axis). A coordinate on the graph in FIG. 1D corresponding to the longitudinal axis 107 may be referred to as an axial coordinate or position. A coordinate corresponding to reference line 140 may be referred to as a radial coordinate or radial position that indicates a distance extending orthogonally from the longitudinal axis 107 in a radial plane passing through longitudinal axis 107. For example, in FIG. 1D, the longitudinal axis 107 may be placed along a Z-axis and the reference line 140 may indicate the distance (R) extending orthogonally from the longitudinal axis 107 to a point on a radial plane that may be defined as the Z-R plane.

Depending on how the rotational axis A (FIG. 1B) of each rolling element assembly 118a,b (FIG. 1B) is oriented with respect to the longitudinal axis 107, and, more particularly with respect to the Z-R plane that passes through the longitudinal axis 107, the rolling assemblies 118a,b may operate as a rolling DOCC element, a rolling cutting element, or a hybrid thereof. The rolling element assembly 118a,b will generally operate as a rolling DOCC element if the rotational axis A of the rolling element 122 lies on the Z-R plane, but will generally operate as a rolling cutting element if the rotational axis A of the rolling element 122 lies on a plane perpendicular to the Z-R plane. The rolling element assembly 118a,b may operate as a hybrid rolling DOCC element and a rolling cutting element in embodiments where the rotational axis A of the rolling element 122 lies on a plane offset from the Z-R plane, but not perpendicular thereto.

Depending on how they are oriented with respect to the longitudinal axis 107, each rolling element assembly 118a,b (FIG. 1B) may exhibit side rake or back rake during operation. Side rake can be defined as the angle between the rotational axis A (FIG. 1B) of the rolling element 122 and the Z-R plane that extends through the longitudinal axis 107. When the rotational axis A is parallel to the Z-R plane, the side rake is substantially 0°, such as in the case of the second rolling element assembly 118b of FIG. 1B. When the rotational axis A is perpendicular to the Z-R plane, however, the side rake is substantially 90°, such as in the case of the first rolling element assembly 118a of FIG. 1B. When viewed along the Z-axis from the positive Z-direction (viewing toward the negative Z-direction), a negative side rake results from counterclockwise rotation of the rolling element 122, and a positive side rake results from clockwise rotation of the rolling element 122. Said differently, when viewing from the top of the blade profile 128, a negative side rake results from counterclockwise rotation of the rolling element 122, and a positive side rake results from clockwise rotation of the rolling element 122 about the Z-axis.

Back rake can be defined as the angle subtended between the Z-axis of a given rolling element 122 and the Z-R plane. More particularly, as the Z-axis of a given rolling element 122 rotates offset backward or forward from the Z-R plane, the amount of offset rotation is equivalent to the measured back rake. If, however, the Z-axis of a given rolling element 122 lies on the Z-R plane, the back rake for that rolling element 122 will be 0°.

In some embodiments, one or more of the rolling element assemblies 118a,b may exhibit a side rake that ranges between 0° and 45° (or 0° and −45°), or alternatively a side rake that ranges between 45° and 90° (or −45° and −90°). In other embodiments, one or more of the rolling element assemblies 118a,b may exhibit a back rake that ranges between 0° and 45° (or 0° and −45°). The selected side rake will affect the amount of rolling versus the amount of sliding that a rolling element 122 included with the rolling element assembly 118a,b will undergo, whereas the selected back rake will affect how a cutting edge of the rolling element 122 engages the formation (e.g., the first and second formations 124, 126 of FIG. 1C) to cut, scrape, gouge, or otherwise remove material.

Referring again to FIG. 1A, the second rolling element assemblies 118b may be placed in the cone region of the drill bit 100 and otherwise positioned so that rolling element assemblies 118b track in the path of the adjacent fixed cutters 116; e.g., they are placed in a secondary row behind the primary row of fixed cutters 116 on the blade 104. However, since the second rolling element assemblies 118b are able to roll, they can be placed in positions other than the cone without affecting TOB.

Strategic placement of the first and second rolling element assemblies 118a,b may further allow them to be used as either primary and/or secondary rolling cutting elements as well as rolling DOCC elements, without departing from the scope of the disclosure. For instance, in some embodiments, one or more of the rolling element assemblies 118a,b may be located in a kerf forming region 120 located between adjacent fixed cutters 116. During operation, the kerf forming region 120 results in the formation of kerfs on the underlying formation being drilled. One or more of the rolling element assemblies 118a,b may be located on the bit body 102 such that they will engage and otherwise extend across one or multiple formed kerfs during drilling operations. In such an embodiment, the rolling element assemblies 118a,b may also function as prefracture elements that roll on top of or otherwise crush the kerf(s) formed on the underlying formation between adjacent fixed cutters 116. In other cases, one or more of the rolling element assemblies 118a,b may be positioned on the bit body 102 such that they will proceed between adjacent formed kerfs during drilling operations. In yet other embodiments, one or more of the rolling element assemblies 118a,b may be located at or adjacent the apex of the drill bit 100 (i.e., at or near the longitudinal axis 107). In such embodiments, the drill bit 100 may fracture the underlying formation more efficiently.

In some embodiments, as illustrated, the rolling element assemblies 118a,b may each be positioned on a respective blade 104 such that the rolling element assemblies 118a,b extend orthogonally from the outer surface 119 (FIG. 1B) of the respective blade 104. In other embodiments, however, one or more of the rolling element assemblies 118a,b may be positioned at a predetermined angular orientation (three degrees of freedom) offset from normal to the profile of the outer surface 119 of the respective blade 104. As a result, the rolling element assemblies 118a,b may exhibit an altered or desired back rake angle, side rake angle, or a combination of both. As will be appreciated, the desired back rake and side rake angles may be adjusted and otherwise optimized with respect to the primary fixed cutters 116 and/or the surface 119 (FIG. 1B) of the blade 104 on which the rolling element assemblies 118a,b are disposed.

FIG. 2 is an isometric view of one example of a rolling element assembly 200, according to one or more embodiments. The rolling element assembly 200 may be used, for example, with the drill bit 100 of FIGS. 1A-1B, in which case the rolling assembly 200 may be a substitution for either of the rolling element assemblies 118a,b or a specific example embodiment of the rolling element assemblies 118a,b. As illustrated, the rolling element assembly 200 may be positioned within a cavity 202 defined in a blade 104 of the drill bit 100. While the cavity 202 is shown as being defined in the blade 104, it will be appreciated that the principles of the present disclosure are equally applicable to the cavity 202 being defined on other locations of the drill bit 100, without departing from the scope of the disclosure.

The blade 104 is depicted in FIG. 2 in phantom to allow the component parts of the rolling element assembly 200 to be viewed. Moreover, only a portion of the blade 104 is represented in FIG. 2 and depicted in the general shape of a cube. In embodiments where the drill bit 100 is made of a matrix material, the cavity 202 may be formed by selectively placing displacement materials (i.e., consolidated sand or grapbite) at the location where the cavity 202 is to be formed. In embodiments where the drill bit 100 comprises a steel body drill bit, conventional machining techniques may be employed to machine the cavity 202 to desired dimensions at the desired location.

The rolling element assembly 200 includes a rolling element 204 that comprises a generally cylindrical or disk-shaped body having a first axial end 208a and a second axial end 208b opposite the first axial end 208a. The distance between the first and second axial ends 208a,b is referred to herein as the axial width 210 of the rolling element 204.

The rolling element 204 includes a substrate 212 and opposing diamond tables 214a and 214b arranged at the first and second axial ends 208a,b, respectively, and otherwise coupled to opposing axial ends of the substrate 212. The substrate 212 may be formed of a variety of hard or ultra-hard materials including, but not limited to, steel, steel alloys, tungsten carbide, cemented carbide, any derivatives thereof, and any combinations thereof. Suitable cemented carbides may contain varying proportions of titanium carbide (TiC), tantalum carbide (TaC), and niobium carbide (NbC). Additionally, various binding metals may be included in the substrate 212, such as cobalt, nickel, iron, metal alloys, or mixtures thereof. In the substrate 212, the metal carbide grains are supported within a metallic binder, such as cobalt. In other cases, the substrate 212 may be formed of a sintered tungsten carbide composite structure or a diamond ultra-hard material, such as polycrystalline diamond (PCD) or thermally stable polycrystalline diamond (TSP).

The diamond tables 214a,b may be made of a variety of ultra-hard materials including, but not limited to, polycrystalline diamond (PCD), thermally stable polycrystalline diamond (TSP), cubic boron nitride, impregnated diamond, nanocrystalline diamond, ultra-nanocrystalline diamond, and zirconia. Such materials are extremely wear-resistant and are suitable for use as bearing surfaces, as herein described.

The rolling element 204 may comprise and otherwise include one or more cylindrical bearing portions. More particularly, in this example, the entire rolling element 204 is cylindrical and made of hard, wear-resistant materials, and thus any portion of the rolling element 204 may be considered as a cylindrical bearing portion to the extent it slidingly engages a bearing surface of the cavity 202 or another component of the rolling element assembly 200 when rolling, such as would be expected during drilling operations. In some embodiments, for instance, one or both of the diamond tables 214a,b may be considered cylindrical bearing portions for the rolling element 204. In other embodiments, one or both of the diamond tables 214a,b may be omitted from the rolling element 204 and the substrate 212 may alternatively be considered as a cylindrical bearing portion. In yet other embodiments, the entire cylindrical or disk-shaped rolling element 204 may be considered as a cylindrical bearing portion and may be made of any of the hard or ultra-hard materials mentioned herein, without departing from the scope of the disclosure.

It should be noted that the features of the rolling element 204 are shown for illustrative purposes only and may or may not be drawn to scale. Consequently, the rolling element 204 as depicted should not be considered as limiting the scope of the present disclosure. For example, the thickness or axial extent of both the diamond tables 214a,b may or may not be the same. In at least one embodiment, one of the diamond tables 214a,b may be thicker than the other. Moreover, in some embodiments, one of the diamond tables 214a,b may be omitted from the rolling element 204 altogether. In yet other embodiments, the substrate 212 may be omitted and the rolling element 204 may instead be made entirely of the material of the diamond tables 214a,b.

The rolling element assembly 200 also includes a retainer 206 used to help secure or retain the rolling element 204 in the cavity 202 during use. More particularly, the cavity 202 provides and otherwise defines an opening 216 large enough to receive the rolling element 204. When seated within the cavity 202, an arcuate portion of the rolling element 204 extends out of cavity 202 to expose the full axial width 210 of the rolling element 204. The retainer 206 may subsequently be inserted into the cavity 202, and the cavity 202 and the retainer 206 cooperatively retain the rolling element 204 within the cavity 202. This is accomplished as portions of the cavity 202 and the retainer 206 jointly encircle more than 180° of the circumference of the rolling element 204, but less than 360°, so that the full axial width 210 of the rolling element 204 remains exposed for external contact with a formation during operation.

During drilling operations, the rolling element 204 is able to rotate within the cavity 202 about a rotational axis A of the rolling element 204. As the rolling element 204 rotates about the rotational axis A, the arcuate portion of the rolling element 204 extending out of the cavity 202 and otherwise exposed through the opening 216 engages (i.e., cut, roll against, or both) the underlying formation. This allows the full axial width 210 of the rolling element 204 across the entire outer circumferential surface to progressively be used as the rolling element 204 rotates during use.

FIG. 3 is a side view of the rolling element assembly 200 as installed within the cavity 202 defined in the blade 104. Again, the blade 104 is depicted in FIG. 3 in phantom to allow the component parts of the rolling element assembly 200 to be viewed, and only a portion of the blade 104 is represented in FIG. 2 and depicted in the general shape of a cube.

As illustrated, the cavity 202 may provide or otherwise define a retainer slot 302 configured to receive and seat the retainer 206. More specifically, the cavity 202 may provide a first arcuate portion 304a that extends from one side of the opening 216 and a second arcuate portion 304b that extends from the opposing side of the opening 216. The first arcuate portion 304a exhibits a first radius R₁ and the second arcuate portion 304b exhibits a second radius R₂ that is greater than first radius R₁, and an end wall 306 provides a transition between the first and second arcuate portions 304a,b. With a larger second radius R₂, the second arcuate portion 304b is sized to accommodate the retainer 206 within the cavity 202. Accordingly, the retainer slot 302 is defined, at least in part, by the second arcuate portion 304b and the end wall 306.

The retainer 206 provides an inner arcuate surface 308a and an outer arcuate surface 308b opposite the inner arcuate surface 308a. With the retainer 206 received within the retainer slot 302, the outer arcuate surface 308b will be disposed against or otherwise adjacent the second arcuate portion 304b and the inner arcuate surface 308a will be disposed against or otherwise adjacent the outer circumferential surface of the rolling element 204. Moreover, the retainer 206 is sized such that the curvature of the first arcuate portion 304a will transition smoothly to the curvature of the inner arcuate surface 308a to enable the rolling element 204 to bear against a continuously (uniformly) curved surface at all angular locations within the cavity 202 during operation.

The retainer 206 can be made of any of the hard or ultra-hard materials mentioned above for the substrate 212 and the diamond tables 214a,b. More specifically, the retainer 206 may be made of a material such as, but not limited to, steel, a steel alloy, tungsten carbide, a sintered tungsten carbide composite structure, cemented carbide, polycrystalline diamond (PCD), thermally stable polycrystalline diamond (TSP), cubic boron nitride, impregnated diamond, nanocrystalline diamond, ultra-nanocrystalline diamond, zirconia, any derivatives thereof, and any combinations thereof. Alternatively, or in addition thereto, the retainer 206 may be made of an engineering metal, a coated material (i.e., using processes such as chemical vapor deposition, plasma vapor deposition, etc.), or other hard or abrasion-resistant materials.

The retainer 206 may be secured within the cavity 202 (e.g., the retainer slot 302) using a variety attachment means or techniques such as, but not limited to, brazing, welding, an industrial adhesive, press-fitting, shrink-fitting, one or more mechanical fasteners (e.g., screws, bolts, snap rings, pins, a ball bearing retention mechanism, a locking wire, etc.), or any combination thereof. In at least one embodiment, as illustrated, a set screw 312 (shown in dashed lines) or the like may be used to secure the retainer 206 within the retainer slot 302. In the illustrated embodiment, the set screw 312 may be extended through a hole 314a defined in the blade 104, such as a trailing face of the blade 104, and threaded into a correspondingly aligned hole 314b defined in the retainer 206. It will be appreciated, however, that the set screw 312 may be used to secure the retainer 206 within the retainer slot 302 via alternately defined holes provided in other locations, without departing from the scope of the disclosure.

In some embodiments, the retainer 206 may define or otherwise provide an extraction feature 316 used to help extract the retainer 206 from the cavity 202 when desired. The extraction feature 316 may comprise any negative or positive alteration in the geometrical shape of the retainer 206 that provides a location where the retainer 206 may be gripped or otherwise engaged to pry (rotate) the retainer 206 out of the retainer slot 302. Negative alterations, for example, comprise material removal from the geometrical shape of the retainer 206, while positive alterations comprise material additions to the geometrical shape. In some embodiments, as illustrated, the extraction feature 316 may comprise a groove, depression, or channel (i.e., a negative alteration) defined on the outer arcuate surface 308b of the retainer 206. In other embodiments, however, the extraction feature 316 may alternatively be provided on one or both of the sidewalls of the retainer 206, without departing from the scope of the disclosure.

When it is desired to remove the retainer 206 from the cavity 202, a user may access and engage the extraction feature 316 with a rigid contrivance (e.g., a pick, a screwdriver, a rigid rod, etc.) and pry (rotate) the retainer 206 out of the retainer slot 302. In at least one embodiment, as illustrated, an access groove 318 may be defined in the upper surface of the blade 104 to provide a location where a user can access the extraction feature 316 and gain leverage over the retainer 206 to pry it out of the cavity 202. In the illustrated embodiment, where the extraction feature 316 is provided on the outer arcuate surface 308b of the retainer 206, the access groove 318 will be defined in the upper surface of the blade 104 adjacent the outer arcuate surface 308b of the retainer 206. In embodiments where the extraction feature 316 is alternatively provided on one or both of the sidewalls of the retainer 206, as mentioned above, the access groove 318 will be defined in the upper surface of the blade 104 adjacent one or both of the sidewalls of the retainer 206. In embodiments where the retainer 206 is brazed into the cavity 202, the braze may first be melted prior to extracting the retainer 206.

The rolling element assembly 200 may be arranged on the blade 104 such that the rolling element 204 will rotate about the rotational axis A in a first direction 320 during operation. As the rolling element 204 engages an underlying subterranean formation and rotates about the rotational axis A, a weight on bit (WOB) force F₁ and a friction force F₂ will act on the rolling element 204. The WOB force F₁ is the weight force applied to the rolling element 204 in the direction of advancement of the drill bit 100 (FIGS. 1A-1B). The friction force F₂ is a drag force assumed by the rolling element 204 and applied in the direction opposite rotation of the drill bit 100. Based on the respective magnitudes of the WOB force F₁ and the friction force F₂, a resultant force F_R will be assumed by the rolling element 204. The magnitude of the resultant force F_R may be determined as follows:F_R²=F₁²+F₂²  Equation (1)

And the resultant force F_R vector will be directed at an angle θ offset from the WOB force F₁. The angle θ may be determined as follows:

$\begin{array}{cc}\theta =\mathrm{arc}\tan \frac{F_2}{F_1}& \mathrm{Equation}\left(2\right)\end{array}$

If the direction of the resultant force F_R vector intersects the retainer 206 as positioned within the retainer slot 302, then the retainer 206 may not only be used to help retain the rolling element 204 in the cavity 202, but may also prove useful as a bearing element that assumes at least a portion of the resultant force F_R of the rolling element 204 during drilling operations. If, however, the direction of the resultant force F_R vector does not intersect the retainer 206, then the retainer 206 will primarily serve as a structure that helps retain the rolling element 204 in the cavity 202.

In the illustrated embodiment, an arc length L of the retainer 206 is long enough such that the resultant force F_R vector will intersect the retainer 206, which allows the retainer 206 to operate as a retaining structure and a bearing element. In other embodiments, however, and depending on known or predicted drilling parameters, the arc length L of the retainer 206 may be increased or decreased to allow the retainer 206 to operate as a retaining structure and a bearing element, or only as a retaining element. As will be appreciated, the respective arc lengths of the first and second arcuate surfaces 304a,b and the location of the end wall 306 will correspondingly be altered to accommodate the change to the arc length L. Moreover, because of the arcuate shape of the retainer 206, the maximum arc length L will be limited to the size of the opening 216.

Accordingly, the retainer 206 not only helps secure the rolling element 204 in the cavity 202, but can also serve as a bearing surface that supports and guides the rolling element 204 and may assume most (if not all) of the load exerted on the rolling element 204. In contrast, the first arcuate surface 304a may see only minimal loads under normal operation conditions. Given the design of the rolling element assembly 200, the force exerted on the retainer 206 during operation may be primarily compressive in nature. Having the retainer 206 made of a hard or ultra-hard material may help reduce the amount of friction and wear between the rolling element 204 and the retainer 206 as the rolling element 204 bears and slides against the inner arcuate surface 308a. Consequently, the hard or ultra-hard materials of the support bearing 206 may reduce or eliminate the need for lubrication between the retainer 206 and the rolling element 204. In at least one embodiment, however, the inner arcuate surface 308a may be polished so as to reduce friction between the opposing surfaces. The inner arcuate surface 308a may be polished, for example, to a surface finish of about 40 micro-inches or better.

Moreover, as the rolling element 204 rotates in the first direction 320, it inherently urges the retainer 206 to remain secured in the cavity 202. More particularly, the friction generated between the outer circumference of the rolling element 204 and the inner arcuate surface 304a of the retainer 206 will continuously provide a force that urges the retainer 206 against the end wall 306 and otherwise deeper into the cavity 202. Consequently, minimal retention means (i.e., brazing, welding, industrial adhesives, press-fitting, shrink fitting, mechanical fasteners, etc.) may be required to maintain the retainer 206 within the cavity 202.

It should be noted that, although the rolling element assembly 200 has been described as retaining one rolling element 204, embodiments of the disclosure are not limited thereto and the rolling element assembly 200 (or any of the rolling element assemblies described herein) may include and otherwise use two or more rolling elements 204, without departing from the scope of the disclosure. In such embodiments, the multiple rolling elements 204 may be retained within the cavity 202 using the retainer 206 or each rolling element 204 may be supported by individual retainers 206.

FIGS. 4A and 4B are isometric and end views, respectively, of an example embodiment of the retainer 206. As illustrated in FIG. 4A, the retainer 206 may include a generally arcuate body 402 having a first end 404a, a second end 404b, the inner arcuate surface 308a, the outer arcuate surface 308b, a first sidewall 406a, and a second sidewall 406b. The inner and outer arcuate surfaces 308a,b extend between the first and second ends 404a,b. The second end 404b may be configured to engage or come into close contact with the end wall 306 (FIG. 3) when the retainer 206 is inserted into the retainer slot 302 (FIG. 3). The first and second sidewalls 406a,b extend radially between the inner and outer arcuate surfaces 308a,b on each axial end of the retainer 206.

In some embodiments, as shown in FIG. 4B, some or all of the body 402 of the retainer 206 may exhibit a polygonally symmetric cross-sectional shape. As used herein, the term “polygonally-symmetric” refers to a cross-sectional shape that is polygonal and symmetric on both axial sides of the shape. In the illustrated, embodiment, the retainer 206 exhibits a generally dovetail cross-sectional shape. More particularly, the inner arcuate surface 308a may exhibit a first width W₁ and the outer arcuate surface 308b may exhibit a second width W₂ greater than the first width W₁. Accordingly, the sidewalls 406a,b may taper inward as extending radially from the outer arcuate surface 308b to the inner arcuate surface 308a. In embodiments where the retainer 206 is brazed into the retainer slot 302 (FIG. 3), the tapered sidewalls 406a,b may prove advantageous in helping prevent the retainer 206 from shifting out of the retainer slot 302 during the brazing process. It will be appreciated, however, that other polygonally-symmetric cross-sectional shapes may also be employed, such as a T-shaped body 402, without departing from the scope of the disclosure. Moreover, some or all of the body 402 of the retainer 206 may alternatively exhibit rounded features or polygonally asymmetric cross-sectional shape, as discussed in more detail below.

In some embodiments, the transition corners 408 between the second end 404b and the first and second sidewalls 406a,b and of the retainer 206 may be chamfered or radiused. Chamfered or radiused transition corners 408 may help with ease of installation of the retainer into the retainer slot 302 (FIG. 3). In other embodiments, however, the transition corners 408 may be angled, such as including a 90° (or substantially 90°) transition between the second end 404b and the first and second sidewalls 406a,b of the retainer 206, without departing from the scope of the disclosure.

FIGS. 5A and 5B are isometric front and back views, respectively, of another example embodiment of the retainer 206. As depicted in FIG. 5A, in some embodiments, one or more depressions 502 (four shown) may be defined in the inner arcuate surface 308a of the retainer 206. One or more of the depressions 502 may be used to retain and otherwise receive a hardfacing material 504. As will be appreciated, applying the hardfacing material 504 to the depressions 502 may prove advantageous in increasing the abrasion, erosion, and/or corrosion resistance of the inner arcuate surface 308a of the retainer 206.

The hardfacing material 504 can be applied to the depressions 502 via a variety of hardfacing techniques including, but not limited to, oxyacetylene welding (OXY), atomic hydrogen welding (ATW), welding via tungsten inert gas (TIG), gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), gas metal arc welding (GMAW—including both gas-shielded and open arc welding), oxyfuel welding (OFW), submerged arc welding (SAW), electroslag welding (ESW), plasma transferred arc welding (PTAW—also called powder plasma welding), additive/subtractive manufacturing, thermal spraying, cold polymer compounds, laser cladding, hardpaint, and any combination thereof.

One suitable hardfacing material 504 comprises sintered tungsten carbide particles in a steel alloy matrix. The tungsten carbide particles may include grains of monotungsten carbide, ditungsten carbide and/or macrocrystalline tungsten carbide. Spherical cast tungsten carbide may typically be formed with no binding material. Examples of binding materials used to form tungsten carbide particles may include, but are not limited to, cobalt, nickel, boron, molybdenum, niobium, chromium, iron and alloys of these elements. Other hard constituent materials include cast or sintered carbides consisting of chromium, molybdenum, niobium, tantalum, titanium, vanadium and alloys and mixtures thereof.

In some embodiments, one or more of the depressions 502 may alternatively be used to retain and otherwise receive a bearing element 506. The bearing element 506 may comprise, for example, a TSP or another ultra-hard material secured within a corresponding depression 502, cast into the inner arcuate surface 308a of the retainer 206, or otherwise secured thereto. Although the bearing element 506 is illustrated as having a generally circular cross-section, it will be appreciated that the bearing element 506 may alternatively exhibit any suitable shape, such as oval, polygonal, etc., without departing from the scope of the disclosure. In at least one embodiment, the entire inner arcuate surface 308a of the retainer 206 may comprise the bearing element 506 or may otherwise be coated with an ultra-hard material that acts as a bearing element or bearing surface, without departing from the scope of the disclosure.

In FIG. 5B, the extraction feature 316 is depicted in the form of a groove or channel defined on the outer arcuate surface 308b of the retainer 206. In some embodiments, as illustrated, the extraction feature 316 extends the entire distance between the opposing sidewalls 406a,b. In other embodiments, however, the extraction feature 316 may only be provided at a localized or central location on the outer arcuate surface 308b between the sidewalls 406a,b. In yet other embodiments, the extraction feature 316 may comprise two or more structures, such as two laterally offset grooves, depressions, or the like.

In some embodiments, one or more material cavities 508 (two shown) may be defined or otherwise provided on the outer arcuate surface 308b of the retainer 206. The material cavities 508 may be used to retain a locking material (e.g., braze paste, solder, etc.) used to secure the retainer 206 within the cavity 202 (FIGS. 2 and 3). As will be appreciated, the material cavities 508 may prove advantageous in helping to maintain the locking material where it is needed for properly securing the retainer within the cavity 202. More specifically, as the retainer 206 is inserted (rotated) into the retainer slot 302 (FIG. 3), a portion of a locking material applied to the outer arcuate surface 308b to secure the retainer 206 to the cavity 202 may be scraped off. The material cavities 508, however, are inset into the outer arcuate surface 308b and are, therefore, able to retain an amount of the locking material. This retained locking material may then be used during a subsequent brazing or soldering process to properly secure the retainer 206 within the cavity 202.

Exemplary assembly of the rolling element assembly 200 in a blade 104 of a drill bit 100 (FIGS. 1A-1B) will now be discussed, according to one or more embodiments. FIG. 6A is an exploded side view of the rolling element assembly 200. The opening 216 to the cavity 202 defined in the blade 104 exhibits a dimension 602 (i.e., a length or width) that is larger than the circumference C of the rolling element 204. As a result, the rolling element 204 may be able to pass through the opening 216 to be received within the cavity 202. Once the rolling element 204 is seated within the cavity 202, the retainer 206 may be inserted into the cavity 202 and, more particularity, into the retainer slot 302.

FIGS. 6B, 6C, and 6D are side views of the rolling element assembly 200 sequentially showing the retainer 206 being received within the retainer slot 302. In FIG. 6B, the second end 404b of the retainer 206 is depicted as having entered the retainer slot 302 via the opening 216.

In FIG. 6C, the retainer 206 is depicted as having advanced further into the retainer slot 302. This can be accomplished by rotating the retainer 206 about the rotational axis A and allowing the retainer 206 to slidingly engage the second arcuate portion 304b of the cavity 202.

In FIG. 6D, the retainer 206 is depicted as having advanced into the retainer slot 302 until the second end 404b has engaged or come into close contact with the end wall 306, at which point the cavity 202 and the retainer 206 cooperatively encircle more than 180° of the circumference of the rolling element 204, but less than 360° to retain the rolling element 204 within the cavity 202. In some embodiments, as illustrated, with the retainer 206 received within the retainer slot 302, the first end 404a may reside flush with the outer surface of the blade 104. In other embodiments, however, the first end 404a may be seated just below the outer surface of the blade 104. Once the retainer 206 has been extended into the retainer slot 302, as shown in FIG. 6D, the retainer 206 may be secured within the retainer slot 302 by any of the attachment means or techniques discussed herein.

FIG. 7 is an isometric view of an example cavity 202 defined in a blade 104 of the drill bit 100 of FIGS. 1A-1B. As illustrated, the cavity 702 includes the first and second arcuate portions 304a,b that help support the rolling element 204 (FIGS. 2 and 3) and the retainer 206 (FIGS. 2 and 3), respectively, and the end wall 306. The interior of the cavity 702 also provides and otherwise defines a first side surface 702a and a second side surface 702b opposite the first side surface 702a within the cavity 202. The side surfaces 702a,b may be engageable with the opposing diamond tables 214a,b (FIG. 2) of the rolling element 204 during operation. Accordingly, in at least one embodiment, the side surfaces 702a,b may be substantially parallel to the opposing diamond tables 214a,b when the rolling element 204 is installed in the cavity 202. During operation, both side surfaces 702a,b may or may not always engage or contact the opposing diamond tables 214a,b.

In some embodiments, the first and second side surfaces 702a,b may form integral parts of the blade 104 and, therefore, may be made of the same materials as the bit body 102 (FIG. 1A), e.g., a matrix composite material. In other embodiments, however, all or a portion of one or both of each side surface 702a,b may be made of tungsten carbide, steel, an engineering metal, a coated material (i.e., using processes such as chemical vapor deposition, plasma vapor deposition, etc.), or another hard or suitable abrasion resistant material.

In yet other embodiments, or in addition thereto, one or both of the side surfaces 702a,b may have a bearing element 704 positioned thereon to be engageable with an adjacent diamond table 214a,b of the rolling element 204. The bearing element 704 may comprise, for example, a TSP or another ultra-hard material cast into the particular side surface 702a,b or otherwise secured thereto. Although the bearing element 704 is illustrated as having a generally circular cross-section, it will be appreciated that the bearing element 704 may alternatively exhibit any suitable shape, such as oval, polygonal, etc., that may be engageable with the opposing diamond tables 214a,b, without departing from the scope of the disclosure. In at least one embodiment, the entire side surface 702a,b may comprise a bearing element 704 or may otherwise be coated with an ultra-hard material that acts as a bearing element or bearing surface, without departing from the scope of the disclosure.

FIGS. 8A-8F are top views of example cavities 202 defined in a blade 104 of the drill bit 100 of FIGS. 1A-1B, according to various embodiments. In each of FIGS. 8A-8F, the shape of the cavity 202 may vary at the retainer slot 302 to accommodate a particular retainer 206 (FIGS. 2 and 3). Any shape that restricts the retainer 206 from shifting from a defined radial position may be used. This may prove advantageous during assembly where exerted unintended pressure on the rolling element 204 may be avoided and a more defined cavity 202 may be result for the rolling element 204 to reside.

FIGS. 8A-8C depict generally symmetric shapes for the retainer slot 302. In FIG. 8A, the retainer slot 302 exhibits a generally dovetail shape. Accordingly, the cavity 202 of FIG. 8A may be configured to receive the retainer 206 shown in FIGS. 4A and 4B, which exhibits a dovetail cross-sectional shape. In FIG. 8B, the retainer slot 302 has squared-off ends. In FIG. 8C, the retainer slot 302 has rounded ends. It is noted that the dovetail shape of FIG. 8A and the T-shape of FIGS. 8B and 8C may be preferred in minimizing stress risers in the cavity 202.

FIGS. 8D-8F depict generally asymmetric shapes for the retainer slot 302. In FIG. 8D, for example, only one end of the retainer slot 302 has an angled feature. In FIG. 8E, only one end of the retainer slot 302 is squared off. In FIG. 8F, only one end of the retainer slot 302 is rounded.

Those skilled in the art will readily appreciate that other designs and configurations of the cavity 202 and the retainer slot 302 may be employed. For instance, a combination of rounded and polygonal features may define the retainer slot 302, without departing from the scope of the disclosure.

FIG. 9A is an isometric view of another example rolling element assembly 900, according to one or more embodiments. Similar to the rolling element assembly 200 of FIGS. 2, 3, and 6A-6D, the rolling element assembly 900 may be used with the drill bit 100 of FIGS. 1A-1B, in which case the rolling assembly 900 may be a substitution for either of the rolling element assemblies 118a,b or a specific example embodiment of the rolling element assemblies 118a,b. Moreover, the rolling element assembly 900 may also be secured within a cavity defined in a blade 104 (FIGS. 1A-1B) of the drill bit 100.

As illustrated, the rolling element assembly 900 includes a rolling element 902 and a retainer 904 used to help retain the rolling element 902 within a cavity. The rolling element 902 comprises a generally cylindrical body having a first axial end 906a and a second axial end 906b opposite the first axial end 906a. While not specifically shown, in some embodiments, diamond tables (i.e., diamond tables 214a and 214b of FIGS. 2 and 3) may be positioned at the opposing first and second axial ends 906a,b. In other embodiments, the entire cylindrical body of the rolling element 902 may be made of a monolithic hard or ultra-hard material.

Unlike the rolling element 204 of FIGS. 2 and 3, the rolling element 902 may exhibit a variable diameter between the first and second axial ends 906a,b and along the axial width 908. More specifically, the circumference of the rolling element 902 may be curved, rounded, or otherwise arcuate as extending between the opposing first and second axial ends 906a,b along the axial width 908 of the rolling element 902. Accordingly, the diameter of the rolling element 902 may be greatest at a center point between the opposing first and second axial ends 906a,b, or alternatively at another point between the opposing first and second axial ends 906a,b.

FIG. 9B is an isometric view of the retainer 904 of the rolling element assembly 900 of FIG. 9A. The retainer 904 may be similar in some respects to the retainer 206 of FIGS. 2 and 3, such as being made out of similar materials, having the inner and outer arcuate surfaces 308a,b, etc. Unlike the retainer 206, however, the inner arcuate surface 308a is curved, rounded, and otherwise exhibits a concave shape configured to receive the rolling element 902 (FIG. 9A) of the rolling element assembly 900. During drilling operations, the rolling element 902 is able to rotate about a rotational axis A (FIG. 9A) of the rolling element 902 and slidingly engage the inner arcuate surface 308a of the retainer 904.

While the rolling element 902 and the retainer 904 are depicted in FIGS. 9A and 9B as having generally curved surfaces, those skilled in the art will readily appreciate that the rolling element 902 and the retainer 904 may alternatively exhibit other mating shapes, without departing from the scope of the disclosure.

FIG. 10A is an isometric view of another example rolling element assembly 1000, according to one or more embodiments. Similar to the rolling element assembly 200 of FIGS. 2, 3, and 6A-6D, the rolling element assembly 1000 may be used with the drill bit 100 of FIGS. 1A-1B, in which case the rolling assembly 1000 may be a substitution for either of the rolling element assemblies 118a,b or a specific example embodiment of the rolling element assemblies 118a,b. Moreover, the rolling element assembly 1000 may also be secured within a cavity defined in a blade 104 (FIGS. 1A-1B) of the drill bit 100.

As illustrated, the rolling element assembly 1000 includes a rolling element 1002 and a retainer 1004 used to help retain the rolling element 1002 within a cavity. The rolling element 1002 comprises a generally cylindrical body having a first axial end 1006a and a second axial end 1006b opposite the first axial end 1006a. While not specifically shown, in some embodiments, diamond tables (i.e., diamond tables 214a and 214b of FIGS. 2 and 3) may be positioned at the opposing first and second axial ends 1006a,b. In other embodiments, the entire cylindrical body of the rolling element 1002 may be made of a monolithic hard or ultra-hard material.

Similar to the rolling element 902 of FIG. 9A, the rolling element 1002 may exhibit a variable diameter between the first and second axial ends 1006a,b along the axial width 1008 of the rolling element 1002. More specifically, the diameter of the rolling element 900 may gradually increase or decrease (linearly or non-linearly) along the axial width 1008 of the rolling element 1002. As depicted, the first axial end 1006a exhibits a first diameter 1010a and the second axial end 1006b exhibits a second diameter 1010b, where the second diameter 1010b is greater than the first diameter 1010a. Accordingly, in at least one embodiment, the rolling element 1002 may be characterized as a generally frustoconical element.

FIG. 10B is an end view of the rolling element assembly 900. The retainer 1004 may be similar in some respects to the retainer 206 of FIGS. 2 and 3, such as being made out of similar materials, having the inner and outer arcuate surfaces 308a,b, having the first and second ends 404a,b, and having the first and second sidewalls 406a,b that extend radially between the inner and outer arcuate surfaces 308a,b on each axial end of the retainer 1004. Unlike the retainer 206 of FIGS. 2 and 3, however, the body of the retainer 1004 is shaped to receive the frustoconical-shaped rolling element 1002 and, therefore, exhibits a polygonally asymmetric cross-sectional shape. More specifically, the body of the retainer 1004 exhibits a first thickness or depth 1008a at the first sidewall 406a and exhibits a second thickness or depth 1008b at the second sidewall 406b, where the first and second depths 1008a,b are different. In the illustrated, embodiment, the first depth 1008a is greater than the second depth 1008b, but the second depth 1008b could alternatively be greater than the first depth 1008a, without departing from the scope of the disclosure.

Embodiments disclosed herein include:

A. A drill bit that includes a bit body having one or more blades extending therefrom, a plurality of cutters secured to the one or more blades, and a rolling element assembly positioned within a cavity defined on the bit body, the rolling element assembly including a rolling element rotatable within the cavity about a rotational axis, and a retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity, wherein the retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed.

B. A rolling element assembly that includes a rolling element rotatable about a rotational axis when positioned within a cavity defined on a bit body of a drill bit, and a retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity, wherein the retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed.

Each of embodiments A and B may have one or more of the following additional elements in any combination: Element 1: wherein the cavity is defined on the one or more blades. Element 2: wherein the cavity comprises an opening to receive the rolling element, a first arcuate portion that extends from one side of the opening and exhibits a first radius, a second arcuate portion that extends from an opposing side of the opening and exhibits a second radius greater than first radius; and an end wall that provides a transition between the first and second arcuate portions, wherein the retainer slot is defined in part by the second arcuate portion and the end wall. Element 3: wherein the cavity provides a first side surface and a second side surface opposite the first side surface, and wherein a bearing element is positioned on one or both of the first and second side surfaces. Element 4: wherein the retainer comprises a material selected from the group consisting of steel, a steel alloy, tungsten carbide, a sintered tungsten carbide composite, cemented carbide, polycrystalline diamond, thermally stable polycrystalline diamond, cubic boron nitride, impregnated diamond, nanocrystalline diamond, ultra-nanocrystalline diamond, zirconia, any derivatives thereof, and any combination thereof. Element 5: wherein the retainer is secured within the retainer slot using at least one of brazing, welding, an industrial adhesive, press-fitting, shrink-fitting, and a mechanical fastener. Element 6: further comprising an extraction feature defined on the retainer. Element 7: further comprising an access groove defined in the bit body to access the extraction feature. Element 8: wherein the retainer comprises an arcuate body having a polygonally symmetric or polygonally asymmetric cross-sectional shape. Element 9: further comprising one or more depressions defined in an inner arcuate surface of the retainer, and a hardfacing material received within at least one of the one or more depressions. Element 10: further comprising one or more material cavities defined in an outer arcuate surface of the retainer to retain a locking material used to secure the retainer within the cavity. Element 11: wherein the rolling element assembly is oriented on the bit body to exhibit a side rake angle ranging between 0° and 45°. Element 12: wherein the rolling element assembly is oriented on the bit body to exhibit a side rake angle ranging between 45° and 90° and thereby operates as a depth of cut controller. Element 13: wherein the rolling element assembly is oriented on the bit body to exhibit a back rake angle ranging between 0° and 45°, thereby allowing the rolling element to operate as a cutter. Element 14: wherein the rotational axis of the rolling element lies on a plane that passes through a longitudinal axis of the bit body. Element 15: wherein the rotational axis of the rolling element lies on a plane that is perpendicular to a longitudinal axis of the bit body. Element 16: wherein the rolling element exhibits a variable diameter between a first axial end and a second axial end. Element 17: wherein the retainer provides an inner arcuate surface that is concave to receive the rolling element with the variable diameter.

Element 18: wherein the retainer comprises an arcuate body having a first end and a second end opposite the first end, an arcuate inner surface extending between the first and second ends, an arcuate outer surface opposite the inner arcuate surface and extending between the first and second ends, a first sidewall extending radially between the inner and outer arcuate surfaces, and a second sidewall opposite the first sidewall and extending radially between the inner and outer arcuate surfaces. Element 19: further comprising an extraction feature defined in the outer arcuate surface. Element 20: further comprising one or more depressions defined in the inner arcuate surface, and a hardfacing material received within at least one of the one or more depressions. Element 21: further comprising one or more material cavities defined in the outer arcuate surface to retain a locking material used to secure the retainer within the cavity.

By way of non-limiting example, exemplary combinations applicable to A and B include: Element 6 with Element 7; Element 16 with Element 17; and Element 18 with Element 19.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

Claims

1. A drill bit, comprising: a bit body including one or more blades extending therefrom;a plurality of cutters secured to the one or more blades;a cavity defined on the bit body, the cavity defining a first side surface, a second side surface, an opening and a retainer slot intersecting the opening; anda rolling element assembly positioned within the cavity between the first and second side surfaces, the rolling element assembly including a rolling element rotatable within the cavity about a rotational axis intersecting the first side surface and the second side surface of the cavity, and a retainer extendable within the retainer slot at least partially between the rolling element and the opening to secure the rolling element within the cavity,wherein the retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed through the opening of the cavity.

2. The drill bit of claim 1, wherein the cavity is defined on the one or more blades.

3. The drill bit of claim 1, wherein the cavity comprises: a first arcuate portion that extends from one side of the opening between the first side surface and the second side surface and exhibits a first radius;a second arcuate portion that extends from an opposing side of the opening between the first side surface and the second side surface and exhibits a second radius greater than first radius; andan end wall that provides a transition between the first and second arcuate portions, wherein the retainer slot is defined in part by the second arcuate portion and the end wall.

4. The drill bit of claim 1, wherein the retainer comprises a material selected from the group consisting of steel, a steel alloy, tungsten carbide, a sintered tungsten carbide composite, cemented carbide, polycrystalline diamond, thermally stable polycrystalline diamond, cubic boron nitride, impregnated diamond, nanocrystalline diamond, ultra-nanocrystalline diamond, zirconia, any derivatives thereof, and any combination thereof.

5. The drill bit of claim 1, wherein the retainer is secured within the retainer slot using at least one of brazing, welding, an industrial adhesive, press-fitting, shrink-fitting, and a mechanical fastener.

6. The drill bit of claim 1, further comprising an extraction feature defined on the retainer.

7. The drill bit of claim 6, further comprising an access groove defined in the bit body to access the extraction feature.

8. The drill bit of claim 1, wherein the retainer comprises an arcuate body having a polygonally symmetric or polygonally asymmetric cross-sectional shape.

9. The drill bit of claim 1, further comprising: one or more depressions defined in an inner arcuate surface of the retainer; anda hardfacing material received within at least one of the one or more depressions.

10. The drill bit of claim 1, further comprising one or more material cavities defined in an outer arcuate surface of the retainer to retain a locking material used to secure the retainer within the cavity.

11. The drill bit of claim 1, wherein the rolling element assembly is oriented on the bit body to exhibit a side rake angle ranging between 0° and 45°.

12. The drill bit of claim 1, wherein the rolling element assembly is oriented on the bit body to exhibit a side rake angle ranging between 45° and 90° and thereby operates as a depth of cut controller.

13. The drill bit of claim 1, wherein the rolling element assembly is oriented on the bit body to exhibit a back rake angle ranging between 0° and 45°, thereby allowing the rolling element to operate as a cutter.

14. The drill bit of claim 1, wherein the rotational axis of the rolling element lies on a plane that passes through a longitudinal axis of the bit body.

15. The drill bit of claim 1, wherein the rotational axis of the rolling element lies on a plane that is perpendicular to a longitudinal axis of the bit body.

16. The drill bit of claim 1, wherein the rolling element exhibits a variable diameter between a first axial end and a second axial end.

17. The drill bit of claim 16, wherein the retainer provides an inner arcuate surface that is concave to receive the rolling element with the variable diameter.

18. The drill bit of claim 1, wherein the opening is spaced from the rotational axis in a direction orthogonal to the rotational axis.

19. The drill bit of claim 1, wherein the opening defines a dimension greater than a diameter of the rolling element such that the rolling element may be received into the cavity through the opening in a radial direction, and wherein the retainer obstructs a portion of the opening when installed in the retainer slot such that only an arcuate portion of the rolling element having a length less than the diameter of the rolling element is exposed through the opening.

20. A drill bit, comprising: a bit body including one or more blades extending therefrom;a plurality of cutters secured to the one or more blades; anda rolling element assembly positioned within a cavity defined on the bit body, the rolling element assembly including a rolling element rotatable within the cavity about a rotational axis, and a retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity,wherein the retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed, wherein the cavity provides a first side surface and a second side surface opposite the first side surface, and wherein a bearing element is positioned on one or both of the first and second side surfaces.

21. A rolling element assembly, comprising: a rolling element rotatable about a rotational axis when positioned within a cavity defined on a bit body of a drill bit; anda retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity, the retainer comprising an arcuate body having: a first end and a second end opposite the first end;an arcuate inner surface extending between the first and second ends;an arcuate outer surface opposite the inner arcuate surface and extending between the first and second ends, the outer arcuate surface defining one or more material cavities therein to retain a locking material used to secure the retainer within the cavity;a first sidewall extending radially between the inner and outer arcuate surfaces; anda second sidewall opposite the first sidewall and extending radially between the inner and outer arcuate surfaces,wherein the retainer and the cavity cooperatively encircle more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed.

22. The rolling element assembly of claim 21, further comprising an extraction feature defined in the outer arcuate surface.

23. The rolling element assembly of claim 21, further comprising: one or more depressions defined in the inner arcuate surface; anda hardfacing material received within at least one of the one or more depressions.