This disclosure relates generally to earth-boring tools, cutting elements for earth-boring tools, and methods for forming a cutting element and affixing the cutting element to an earth-boring tool. More specifically, disclosed embodiments relate to methods of forming an instrumented cutting element and affixing the instrumented cutting element to an earth-boring tool that may reduce reliance on complex, time-consuming, and expensive manufacturing techniques and may better protect sensitive equipment during manufacturing.
When forming or enlarging a borehole in an earth formation, operators of earth-boring tools may utilize information collected from the downhole environment to better manually or automatically control the earth-boring tools. For example, sensors may be deployed at various locations on or within earth-boring tools to detect various environmental conditions within a borehole or operating conditions of the earth-boring tool itself proximate to the sensors. More specifically, sensors, such as temperature sensors, may be deployed in or around cutting elements of earth-boring tools to measure environmental conditions proximate to the point of contact between the cutting elements and the earth material and/or operating conditions of the cutting elements.
In some embodiments, methods of forming instrumented cutting elements and affixing the instrumented cutting elements to earth-boring tools may involve forming a first hole over a first distance partially through a cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face. The first hole may include a first maximum diameter. A second hole may be formed over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face. The second hole may include a second, larger maximum diameter, and the second hole may be in fluid communication with the first hole. An extension comprising a passageway extending through the extension may be placed at least partially into the second hole, such that the passageway may be in fluid communication with the first hole. The cutting element may be affixed in a pocket extending into a body of an earth-boring tool. A thermocouple may be inserted through the passageway and into the first hole after affixing the cutting element in the pocket.
In additional embodiments, earth-boring tools may include a cutting element brazed within a pocket extending into a body of the earth-boring tool. The cutting element may include a first hole extending over a first distance partially through the cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face, the first hole including a first maximum diameter. A second hole may extend over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face. The second hole may include a second, larger maximum diameter, and the second hole may be in fluid communication with the first hole. An extension may be located at least partially within the second hole, the extension including a passageway extending through the extension and in fluid communication with the first hole. A thermocouple may extend through the passageway and into the first hole. Braze material may affix the cutting element within the pocket and be exposed to a portion of the first hole located proximate to the back side of the cutting element.
In further embodiments, forming earth-boring tools including one or more instrumented cutting elements may involve brazing a cutting element in a pocket extending into a body of an earth-boring tool. A portion of a first hole located proximate to a back side of the cutting element opposite the cutting face may be exposed to flow of a braze material. The first hole may extend over a first distance partially through the cutting element from the back side toward the cutting face, the first hole including a first maximum diameter. Flow of the braze material into a second hole and into a remainder of the first hole may be inhibited utilizing an extension located at least partially within the second hole. The second hole may extend over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, and the second hole may include a second, larger maximum diameter. The second hole may be in fluid communication with the first hole located the portion of the first hole, and the extension may include a passageway extending through the extension and in fluid communication with the remainder of the first hole. A thermocouple may be inserted through the passageway defined by the extension and into the remainder of the first hole.
In other embodiments, methods of making earth-boring tools including one or more instrumented cutting elements may involve placing a cutting element partially within a pocket extending into a body of an earth-boring tool. The cutting element may include a first hole extending over a first distance partially through the cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face, the first hole including a first maximum diameter. A second hole may extend over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, the second hole including a second, larger maximum diameter, the second hole in fluid communication with the first hole. An extension including a passageway extending through the extension may be located at least partially within the second hole, the passageway in fluid communication with the first hole. The cutting element may be affixed in the pocket, and a thermocouple may be inserted through the passageway and into the first hole after affixing the cutting element in the pocket.
While this disclosure concludes with claims particularly pointing out and distinctly claiming specific embodiments, various features and advantages of embodiments within the scope of this disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings, in which:
The illustrations presented in this disclosure are not meant to be actual views of any particular earth-boring tool, cutting element, intermediate product in a process of forming a cutting element and/or earth-boring tool, or component thereof, but are merely idealized representations employed to describe illustrative embodiments. Thus, the drawings are not necessarily to scale.
Disclosed embodiments relate generally to methods of forming an instrumented cutting element and affixing the instrumented cutting element to an earth-boring tool that may reduce reliance on complex, time-consuming, and expensive manufacturing techniques and may better protect sensitive equipment during manufacturing.
As used herein, the terms “substantially” and “about” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially or about a specified value may be at least about 90% the specified value, at least about 95% the specified value, at least about 99% the specified value, or even at least about 99.9% the specified value.
As used herein, the terms “earth-boring tool” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore in a subterranean formation. For example, earth-boring tools include fixed-cutter bits, roller cone bits, percussion bits, core bits, eccentric bits, bicenter bits, reamers, mills, drag bits, hybrid bits (e.g., bits including rolling components in combination with fixed cutting elements), and other drilling bits and tools known in the art.
As used herein, the term “superabrasive material” means and includes any material having a Knoop hardness value of about 3,000 Kgf/mm2 (29,420 MPa) or more. Superabrasive materials include, for example, diamond and cubic boron nitride. Superabrasive materials may also be characterized as “superhard” materials.
As used herein, the term “polycrystalline material” means and includes any structure comprising a plurality of grains (i.e., crystals) of material that are bonded directly together by inter-granular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.
As used herein, the terms “inter-granular bond” and “interbonded” mean and include any direct atomic bond (e.g., covalent, metallic, etc.) between atoms in adjacent grains of superabrasive material.
As used herein, terms of relative positioning, such as “above,” “over,” “under,” and the like, refer to the orientation and positioning shown in the figures. During real-world formation and use, the structures depicted may take on other orientations (e.g., may be inverted vertically, rotated about any axis, etc.). Accordingly, the descriptions of relative positioning must be reinterpreted in light of such differences in orientation (e.g., resulting in the positioning structures described as being located “above” other structures underneath or to the side of such other structures as a result of reorientation).
As a result, a terminus 114 of the first hole 104 may be located proximate to the cutting face 108, proximate to a cutting edge 116 located at an intersection between the cutting face 108 and a side surface 118 of the cutting element 100, between the cutting face 108 and a chamfer, or between the chamfer and the side surface 118, or proximate to the cutting face 108 and the cutting edge 116.
The first distance 110 over which the first hole 104 may extend, as measured in a direction perpendicular to the longitudinal axis 112, may depend on an angle 120 at which the first hole 104 is oriented relative to the longitudinal axis 112. For example, the angle 120 between the longitudinal axis 112 and a geometrically central axis of the first hole 104, as measured counterclockwise from the longitudinal axis 112 when the cutting face 108 is oriented upward, may be between about 0° and about 60°. More specifically, the angle 120 between the longitudinal axis 112 and the first hole 104 may be, for example, between about 0° and about 50°. As a specific, nonlimiting example, the angle 120 between the longitudinal axis 112 and the first hole 104 may be between about 0° and about 45° (e.g., about 15°, about 20°, about 25°, about 30°). Orienting the first hole 104 at a given angle 120 may enable a sensor 102 located within the first hole 104 to measure a characteristic proximate a desired location on the cutting element 100, such as, for example, proximate to the cutting edge 116 at a specified angular position or proximate to the cutting face 108 at a specified angular and radial position.
The first hole 104 may have a first maximum diameter 124 (i.e., a maximum distance between walls defining the first hole 104 on opposite sides thereof as measured through a geometrically central axis of the first hole 104) large enough to accommodate a sensor 102 at least partially therein and small enough to maintain sufficient structural integrity in the cutting element 100 for downhole use. The first maximum diameter 124 may be, for example, between about 0.01 inch and about 0.05 inch. More specifically, the first maximum diameter 124 may be, for example, between about 0.015 inch and about 0.045 inch. As a specific, nonlimiting example, the first maximum diameter 124 may be between about 0.02 inch and about 0.04 inch (e.g., about 0.025 inch, about 0.03 inch, about 0.035 inch).
The first hole 104 may be at least substantially straight along at least a majority of a length of the first hole 104. For example, a geometrically central axis of the first hole 104 may be an at least substantially straight line from the back side 106 to proximate the cutting face 108. As another example, the first hole 104 may lack sharp bends and/or corners within the first hole 104 itself as the first hole 104 extends to form a channel for receiving a sensor 102 at least partially within the first hole 104 from proximate to the cutting face 108 toward the back side 106.
The cutting element 100 may include a second hole 126 extending from the back side 106 of the cutting element 100 toward the cutting face 108. The second hole 126 may extend over a second distance 128 partially through the cutting element 100 from the back side 106 of the cutting element 100 toward the cutting face 108, which second distance 128 may be shorter than the first distance 110. For example, the second distance 128 over which the first hole 104 may extend may be between about 20% and about 60% of the longitudinal extent of the cutting element 100. More specifically, the first distance 110 over which the first hole 104 may extend may be, for example, between about 25% and about 50% of the longitudinal extent of the cutting element 100. As a specific, nonlimiting example, the first distance 110 over which the first hole 104 may extend may be, for example, between about 30% and about 45% (e.g., about 35%, about 40%) of the longitudinal extent of the cutting element 100. A geometrically central axis of the second hole 126 may be oriented, for example, at least substantially parallel to the longitudinal axis 112 of the cutting element 100. More specifically, the geometrically central axis of the second hole 126 forming an at least substantially straight line may be, for example, at least substantially aligned with the longitudinal axis 112 of the cutting element 100. In other words, the second hole 126 may be located geometrically centrally with respect to the back side 106 of the cutting element 100.
As a result of the length, position, and orientation of the second hole 126 and the length, position, and orientation of the first hole 104, the second hole 126 may be in fluid communication with the first hole 104. For example, fluids may be capable of flowing from the second hole 126 to the first hole 104 and vice versa when the second hole 126 and the first hole 104 are devoid of obstructions therebetween (e.g., are exposed to environmental fluids, such as air, and are otherwise empty). More specifically, the first hole 104 and the second hole 126 may intersect with one another, such that access to an intermediate portion of the first hole 104 spaced from the terminus 114 and the back side 106 may be granted via the second hole 126. This communication between the first hole 104 and the second hole 126 may also enable a sensor 102 to be inserted at least partially into the first hole 104 via the second hole 126. For example, a sensor 102 and/or associated wiring for the sensor 102 may extend from the terminus 114 of the first hole 104 or proximate to the terminus 114 of the first hole 104, through a portion of the first hole 104, through the second hole 126, and beyond the back side 106 of the cutting element 100 via the second hole 126 to be wired to a receiving device.
The second hole 126 may have a second, larger maximum diameter 130 (i.e., a maximum distance between walls defining the second hole 126 on opposite sides thereof as measured through a geometrically central axis of the second hole 126) when compared to the first maximum diameter 124 of the first hole 104. The second, larger maximum diameter 130 may be, for example, between about 0.1 inch and about 0.4 inch. More specifically, the second, larger maximum diameter 130 may be, for example, between about 0.125 inch and about 0.3 inch. As a specific, nonlimiting example, the second, larger maximum diameter 130 may be between about 0.15 inch and about 0.25 inch (e.g., about 0.175 inch, about 0.2 inch).
The cutting element 100 may include an extension 132 (which may also be referred to as a “plug” in some embodiments) located at least partially within the second hole 126. The extension 132 may be sized, shaped, and configured to enable a sensor 102 to pass through the extension 132 and the second hole 126 into the first hole 104 while inhibiting flow of other materials into the extension 132, the second hole 126, and at least a portion of the first hole 104. For example, the extension 132 may be configured generally as a tube, and may include a passageway 134 extending longitudinally through the extension 132 and sidewalls 136 defining the passageway 134 and circumferentially surrounding the passageway 134. A cross-sectional shape of the extension 132, as taken in a plane perpendicular to the longitudinal axis 112, may be, for example, circular, oval, rectangular, hexagonal, or otherwise polygonal. More specifically, the extension 132 may be generally configured as a right cylinder. In some embodiments, the sidewalls 136 of the extension 132 may extend beyond the back side 106 of the cutting element 100, such that the passageway 134 may likewise extend from within the cutting element 100 (optionally from a point of intersection with the first hole 104), beyond the back side 106 of the cutting element 100, to an opening located on a side of the extension 132 opposite the cutting face 108.
In some embodiments, the extension 132 may be a discrete component from the substrate 140 for insertion at least partially into the second hole 126. The extension 132 may be affixed to the substrate 140. For example, sidewalls 136 of the extension 132 may be affixed to the substrate 140 by an interference fit with sidewalls of the second hole 126, by a shrink fit with sidewalls of the second hole 126, by a weld, by a braze, by a threaded connection (e.g., threads on the exterior of the extension 132 engaged with mating threads in the sidewalls of the substrate 140 defining the second hole 126), or by an adhesive. More specifically, the extension 132 may be affixed to the substrate 140 by, for example, frictional interference with sidewalls 136 of the second hole 126. In other embodiments, particularly those where the first hole 104 does not include a trailing portion proximate to the back side 106 of the cutting element 100 (see, e.g.,
The extension 132 may include and/or be formed from a material or materials suitable for use in the downhole environment. For example, the extension 132 may include and/or be formed from metal, metal alloy, ceramic, particle-matrix, and/or fiber-matrix composite materials. More specifically, the extension 132 may include and/or be formed from a steel material.
A sensor 102 may be located at least partially within the first hole 104. The sensor 102 may be configured to detect, for example, temperature. More specifically, the sensor 102 may include, for example, a thermocouple. The sensor 102 and/or the sensor 102 and associated wiring may extend, for example, from the terminus 114 or proximate to the terminus 114 of the first hole 104, through a first portion of the first hole 104 extending between the terminus 114 and the second hole 126, into the second hole 126 and the passageway 134 within the extension 132, through the second hole 126 and beyond the back side 106 of the cutting element 100, through the passageway 134 and beyond the extension 132, toward a receiving device, such as, for example, a local storage and/or computing device or a local transmission device for transmission to a remote storage and/or computing device. A remainder of the first hole 104 extending from the second hole 126 to the back side 106 of the cutting element 100 may be exposed to the environment, and environmental may be able to flow at least substantially unimpeded from the back side 106 of the cutting element 100, into the remainder of the first hole 104, up to a location where the first hole 104 intersects with the second hole 126 and is obstructed by the sidewalls 136 of the extension 132.
The cutting element 100 may generally be shaped as, for example, a cylinder, disc, dome-topped cylinder, a cone-topped cylinder, a tombstone, a chisel, an indenter. More specifically, the cutting element 100 may generally be shaped as a right cylinder including the first hole 104 and the second hole 126 therein, and optionally including one or more chamfer surfaces at transition regions between the cutting face 108 and the side surface 118 and between the back side 106 and the side surface 118.
In some embodiments, the cutting element 100 may include a table 138 of or including a polycrystalline, superabrasive material affixed to an end of a substrate 140 of or including a hard material suitable for use in the downhole environment. For example, the table 138 may be formed of or include polycrystalline diamond and/or polycrystalline cubic boron nitride, and many include a metal or metal alloy material (e.g., a solvent catalyst material, such as Group VIII-A metals and/or alloys including Group VIII-A metals) in some or all of the interstitial spaces among interbonded grains of the diamond and/or cubic boron nitride material. More specifically, the table 138 may be formed from and/or include a polycrystalline diamond material having one or more regions including cobalt, nickel, iron, alloys and/or mixtures thereof in the interstitial spaces among interbonded diamond grains and one or more other regions lacking solid material in the interstitial spaces. The substrate 140 may include, for example, a metal, metal alloy (e.g., steel), particle-matrix, or fiber-matrix material. More specifically, the substrate 140 may include, for example, particles of or including ceramic material bound in a matrix of or including a metal or metal alloy material. As a specific, nonlimiting example, the substrate 140 may include tungsten carbide particles bound in a matrix of cobalt, nickel, iron, alloys and/or mixtures thereof. In other embodiments, the cutting element 100 may lack a dedicated table 138, and may include a substrate 140 (e.g., an insert) of or including hard and/or superabrasive materials suitable for use in the downhole environment. For example, the cutting element 100 may include a cobalt-cemented tungsten carbide substrate 140, optionally impregnated with particles of or including superabrasive material (e.g., diamond-impregnated).
The cutting element 100 may be affixed to an earth-boring tool 1900, and may be positioned and oriented to contact and remove an adjacent earthen material in response to applied force in an intended direction of removal and movement (e.g., rotation) of the earth-boring tool 1900. For example, the earth-boring tool 1900 may be configured as a fixed-cutter earth-boring drill bit, and may include a body 142 having blades 144 extending longitudinally and radially outward from a remainder of the body 142 with junk slots between rotationally adjacent blades 144. Each blade 144 may include one or more pockets 146 extending into the blade 144, such as, for example, from a rotationally leading surface of the blade 144 into the rotationally trailing mass of the blade 144. Each pocket 146 may be sized and shaped to receive a corresponding cutting element therein, optionally an instrumented cutting element 100 as shown in
The cutting element 100 may be affixed within the pocket 146 by, for example, a braze material 148 interposed between, and affixed to, at least portions of the sidewalls 136 of the cutting element 100 and portions of the surfaces of the blade 144 defining the pocket 146. More specifically, the braze material 148 may be interposed between, and affixed to, portions of the sidewalls 136, portions of the back side 106, and portions of the extension 132 of the cutting element 100100 and portions of the surfaces of the blade 144 defining the pocket 146. As a specific, nonlimiting example, the braze material 148 may be interposed between, and affixed to, a majority of the sidewalls 136 around a circumference of the cutting element 100, an at least substantial entirety of the back side 106 around the extension 132, an at least substantial entirety of a radial exterior of the extension 132 rotationally trailing the back side 106 at least over those portions of the longitudinal extent of the extension 132 where the pocket 146 is at its maximum diameter and at least those surfaces of the blade 144 defining the pocket 146 where the pocket 146 is at or proximate to its maximum diameter.
In embodiments where the angle 120 between the first hole 104 and the longitudinal axis 112 is sufficiently large that there is a portion of the first hole 104 extending between the back side 106 of the cutting element 100 and the second hole 126, which may be obstructed by the sidewalls 136 of the extension 132 from establishing fluid communication with the second hole 126, that portion of the first hole 104 may be exposed to the braze material 148. For example, the portion of the first hole 104 extending between the back side 106 and the second hole 126 and located on a lateral side of the longitudinal axis 112 opposite a lateral side on which the portion of the first hole 104 proximate to the cutting face 108 is located may be at least substantially free of mechanical obstructions (e.g., extensions, walls, barriers) that would impede the flow of fluid into the first hole 104 up to the location where the first hole 104 is blocked by the extension 132. More specifically, the only obstacle to the flow of fluid, such as the braze material 148 in a flowable state, into the portion of the first hole 104 extending between the back side 106 and the second hole 126 may be, for example, any difficulty of displacing fluid already located therein, such as, for example, air. As a specific, nonlimiting example, at least trace amounts of the braze material 148 may be located in the first hole 104 proximate to the back side 106, and up to at least substantially an entirety of the portion of the first hole 104 extending between the back side 106 and the second hole 126 may be at least substantially filled with the braze material 148. In other embodiments where the angle 120 between the first hole 104 is sufficiently low, there may not be any remaining portion of the first hole 104 extending from the second hole 126 to the back side 106 because that portion of the first hole 104 may be subsumed into the second hole 126.
The hole formation system 300 may further include a support 304 shaped, positioned, and configured to support the cutting element 100 (see
Returning to
Returning again to
With collective reference to
Once the braze material 148 has been flowed around the circumference of at least a portion of the cutting element 100 and at least a portion of the extension 132 within the pocket 146, the braze material 148 may be permitted to cool and solidify, affixing the cutting element 100 to the body 142 of the earth-boring tool 1900 within the pocket 146. The braze material 148 may at least substantially fill, for example, those portions of the pocket 146 not occupied by the cutting element 100, the extension 132, the passageway 134 extending through the extension 132, the second hole 126 extending partially through the cutting element 100 from the back side 106 toward the cutting face 108, and the portion of the first hole 104 extending from the second hole 126 to the terminus 114. More specifically, the braze material 148 may completely fill the aforementioned regions of the pocket 146 but for any air pockets formed due to manufacturing limitations and any air not displaced from the portion of the first hole 104 extending form the second hole 126 to the back side 106 in embodiments where the first hole 104 includes such a portion as reflected at act 214.
Referring now collectively to
The conduit system 250 may extend along the external portion of the blade 144 through the junk slot 152 and couple to the earth-boring tool 1900 at a connection point with seal 258. The extended conductive wiring may be further routed within the earth-boring tool 1900 to reach the data collection, processing, and/or transmission module 1902. The conduit system 250 may include multiple sections that may be coupled together at different joints. For example, a first section 252 may extend into the aperture formed within the blade 144 and bend along the outer surface of the back side of the blade 144. The first section 252 may connect to a second section of 254 at joint 255 and continue to extend up the surface of the body 142 until a connection point for further entry into the body 142. Brackets 256 may be placed over the conduit system 250 to secure the conduit system to the blade 144. In some embodiments, the conduit system 250 may include a single section extending from the bottom of the blade 144 to the top region where the connection point to the body 142 is located. Having multiple sections may have the benefit of more easily replacing the wiring and/or the instrumented cutting element 100 by removing a second section 254 to access and disconnect the wiring.
The earth-boring tool 1900 may also optionally include non-instrumented cutting elements 160 affixed to the blades 144, in addition to the one or more instrumented cutting elements 100.
Techniques for forming instrumented cutting elements and affixing cutting elements to earth-boring tools, as well as the configurations for features of the cutting elements, in accordance with this disclosure may enable introduction of the sensor into the cutting element following affixation of the cutting element to the earth-boring tool. This change in timing may reduce exposure of the sensor to potentially harmful conditions that may occur during the process of affixing the cutting element to the earth-boring tool, such as elevated temperatures beyond the recommended operating temperatures for the sensor, which may cause the sensor to produce inaccurate signals, render the sensor inoperable, or otherwise damage the sensor. This change may also render affixing the cutting element to the earth-boring tool easier, as the operator and/or equipment performing the affixation process may not need to worry about keeping conditions during affixation, such as maximum temperatures and/or positioning of flowing braze material, within limits tied to protecting the sensor. In addition, techniques for forming instrumented cutting elements and affixing cutting elements to earth-boring tools, as well as the configurations for features of the cutting elements, in accordance with this disclosure may enable the sensor to be more easily introduced into, and properly positioned within, the cutting element. For example, the geometries and relative positions for features of instrumented cutting elements disclosed herein may better guide sensors into position, particularly when the cutting element has already been affixed to an earth-boring tool.
Additional nonlimiting embodiments within the scope of this disclosure include:
A method of forming an instrumented cutting element and affixing the instrumented cutting element to an earth-boring tool, comprising: forming a first hole over a first distance partially through a cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face, the first hole comprising a first maximum diameter; forming a second hole over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, the second hole comprising a second, larger maximum diameter, the second hole in fluid communication with the first hole; placing an extension comprising a passageway extending through the extension at least partially into the second hole, the passageway in fluid communication with the first hole; affixing the cutting element in a pocket extending into a body of an earth-boring tool; and inserting a thermocouple through the passageway and into the first hole after affixing the cutting element in the pocket.
The method of Embodiment 1, wherein forming the first hole comprises forming the first hole to be at least substantially straight.
The method of Embodiment 2, wherein forming the first hole comprises forming the first hole such that an angle between a geometrically central axis of the first hole and a geometrically central axis extending at least substantially perpendicular to the cutting face is between about 0° and about 60°.
The method of any one of Embodiments 1 through 3, wherein forming the first hole comprises positioning a terminus of the first hole proximate to the cutting face or proximate to a cutting edge of the cutting element.
The method of any one of Embodiments 1 through 4, further comprising forming additional first holes partially through the cutting element from the back side of the cutting element toward the cutting face, each first hole comprising the first maximum diameter, wherein forming the second hole comprises placing the second hole in fluid communication with each first hole, and further comprising inserting an additional thermocouple through the second hole and into a corresponding first hole until each first hole comprises a corresponding additional thermocouple inserted therein.
The method of any one of Embodiments 1 through 5, wherein forming the second hole comprises orienting a geometrically central axis of the second hole at least substantially parallel to a geometrically central axis of the cutting element extending at least substantially perpendicular to the cutting face.
The method of any one of Embodiments 1 through 6, wherein forming the second hole comprises causing the second diameter of the second hole to taper from the second, maximum diameter to a second, minimum diameter as the second hole approaches an intersection with a portion of the first hole extending from the second hole toward the cutting face.
The method of Embodiment 7, wherein placing the extension at least partially within the second hole comprises placing the extension within an untapered portion of the second hole.
The method of any one of Embodiments 1 through 6, further comprising placing a temporary material in a portion of the second hole and into the first hole, filling a remainder of the second hole with a filler material, and removing the temporary material, and wherein inserting the thermocouple through the second hole and into the first hole comprises inserting the thermocouple through the second hole and into the first hole via a pathway previously occupied by the temporary material.
The method of any one of Embodiments 1 through 9, wherein forming the first hole comprises removing material of the cutting element by laser drilling or electrical discharge machining the material of the cutting element to form the hole.
The method of claim 1, wherein affixing the cutting element in the pocket comprises brazing the cutting element in the pocket and further comprising exposing a portion of the first hole located proximate to the back side of the cutting element to a braze material.
An earth-boring tool, comprising: a cutting element brazed within a pocket extending into a body of the earth-boring tool, the cutting element comprising: a first hole extending over a first distance partially through the cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face, the first hole comprising a first maximum diameter; and a second hole extending over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, the second hole comprising a second, larger maximum diameter, the second hole in fluid communication with the first hole; an extension located at least partially within the second hole, the extension comprising a passageway extending through the extension and in fluid communication with the first hole; and a thermocouple extending through the passageway and into the first hole; and braze material affixing the cutting element within the pocket and exposed to a portion of the first hole located proximate to the back side of the cutting element.
The earth-boring tool of Embodiment 12, wherein an angle between a geometrically central axis of the first hole and a geometrically central axis extending at least substantially perpendicular to the cutting face is between about 0° and about 60°.
The earth-boring tool of Embodiment 12 or Embodiment 13, wherein a terminus of the first hole is located proximate to the cutting face or proximate to a cutting edge of the cutting element.
The earth-boring tool of claim 12, further comprising a filler material at least substantially filling a remainder of the second hole not occupied by the thermocouple.
The earth-boring tool of Embodiment 15, wherein the first hole is at least substantially straight along at least substantially an entirety of a length of the first hole.
The earth-boring tool of any one of Embodiments 12 through 16, wherein the second diameter of the second hole tapers from the second, maximum diameter to a second, minimum diameter as the second hole approaches an intersection with a portion of the first hole extending from the second hole toward the cutting face.
A method of forming an earth-boring tool including one or more instrumented cutting elements, comprising: brazing a cutting element in a pocket extending into a body of an earth-boring tool; exposing a portion of a first hole located proximate to a back side of the cutting element opposite the cutting face to flow of a braze material, the first hole extending over a first distance partially through the cutting element from the back side toward the cutting face, the first hole comprising a first maximum diameter; inhibiting flow of the braze material into a second hole and into a remainder of the first hole utilizing an extension located at least partially within the second hole, the second hole extending over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, the second hole comprising a second, larger maximum diameter, the second hole in fluid communication with the first hole located the portion of the first hole, the extension comprising a passageway extending through the extension and in fluid communication with the remainder of the first hole; and inserting a thermocouple through the passageway defined by the extension and into the remainder of the first hole.
The method of Embodiment 18, wherein inserting the thermocouple comprises inserting the thermocouple after brazing the cutting element in the pocket.
The method of Embodiment 18 or Embodiment 19, further comprising placing a temporary material in a portion of the second hole and into the first hole, filling a remainder of the second hole with a filler material, and removing the temporary material, and wherein inserting the thermocouple through the second hole and into the first hole comprises inserting the thermocouple through the second hole and into the first hole via a pathway previously occupied by the temporary material.
A method of making an earth-boring tool comprising one or more instrumented cutting elements, the comprising: placing a cutting element partially within a pocket extending into a body of an earth-boring tool, the cutting element comprising: a first hole extending over a first distance partially through the cutting element from a back side of the cutting element opposite a cutting face of the cutting element toward the cutting face, the first hole comprising a first maximum diameter; a second hole extending over a second, shorter distance partially through the cutting element from the back side of the cutting element toward the cutting face, the second hole comprising a second, larger maximum diameter, the second hole in fluid communication with the first hole; and an extension comprising a passageway extending through the extension located at least partially within the second hole, the passageway in fluid communication with the first hole; affixing the cutting element in the pocket; and inserting a thermocouple through the passageway and into the first hole after affixing the cutting element in the pocket.
The method of Embodiment 21, wherein placing the cutting element partially within the pocket comprises placing the cutting element, the cutting element comprising an at least substantially straight first hole, partially within the pocket.
The method of Embodiment 22, wherein placing the cutting element partially within the pocket comprises placing the cutting element, an angle between a geometrically central axis of the first hole and a geometrically central axis extending at least substantially perpendicular to the cutting face is between about 0° and about 60°, partially within the pocket.
The method of any one of Embodiments 21 through 23, wherein placing the cutting element partially within the pocket comprises placing the cutting element, a terminus of the first hole being located proximate to the cutting face or proximate to a cutting edge of the cutting element, partially within the pocket.
The method of any one of Embodiments 21 through 24, wherein placing the cutting element partially within the pocket comprises placing the cutting element, the cutting element comprising additional first holes partially through the cutting element from the back side of the cutting element toward the cutting face, each first hole comprising the first maximum diameter, the second hole being in fluid communication with each first hole, partially within the pocket, and further comprising inserting an additional thermocouple through the second hole and into a corresponding first hole until each first hole comprises a corresponding additional thermocouple inserted therein.
The method of any one of Embodiments 21 through 25, wherein placing the cutting element partially within the pocket comprises placing the cutting element, a geometrically central axis of the second hole being oriented at least substantially parallel to a geometrically central axis of the cutting element extending at least substantially perpendicular to the cutting face, partially within the pocket.
The method of any one of Embodiments 21 through 26, wherein placing the cutting element partially within the pocket comprises placing the cutting element, the second diameter of the second hole being tapered from the second, maximum diameter to a second, minimum diameter as the second hole approaches an intersection with a portion of the first hole extending from the second hole toward the cutting face, partially within the pocket.
The method of Embodiment 7, wherein placing the cutting element partially within the pocket comprises placing the cutting element, the extension being located within an untapered portion of the second hole, partially within the pocket.
The method of any one of Embodiments 21 through 28, further comprising placing a temporary material in a portion of the second hole and into the first hole, filling a remainder of the second hole with a filler material, and removing the temporary material, and wherein inserting the thermocouple through the second hole and into the first hole comprises inserting the thermocouple through the second hole and into the first hole via a pathway previously occupied by the temporary material.
The method of any one of Embodiments 21 through 29, further comprising forming by removing material of the cutting element by laser drilling or electrical discharge machining the material of the cutting element to form the hole.
The method of any one of Embodiments 21 through 30, wherein affixing the cutting element in the pocket comprises brazing the cutting element in the pocket and further comprising exposing a portion of the first hole located proximate to the back side of the cutting element to a braze material.
While certain illustrative embodiments have been described in connection with the figures, those of ordinary skill in the art will recognize and appreciate that the scope of this disclosure is not limited to those embodiments explicitly shown and described in this disclosure. Rather, many additions, deletions, and modifications to the embodiments described in this disclosure may be made to produce embodiments within the scope of this disclosure, such as those specifically claimed, including legal equivalents. In addition, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being within the scope of this disclosure, as contemplated by the inventors.