Innovative cutting element and cutting structure using same

a cutting element and cutting structure technology, applied in earth drilling, drilling accessories, construction, etc., can solve the problems of reducing the cutting surface thickness,

Inactive Publication Date: 2016-10-06
SMITH INT INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This approach enhances the wear resistance and longevity of cutting elements by maintaining a thicker diamond surface, reducing thermal degradation, and allowing for a 1-cycle sintering process, thus improving drilling efficiency and reducing processing time and costs.

Problems solved by technology

While the substrate allows for attachment of the ultra hard cutting table to the bit, the use of the substrate tends to place a limit on the thickness of the ultra hard cutting table that is feasible without excessive stresses between the two bodies or excessive risk of delamination of the ultra hard cutting table.
Without proper flow characteristics, insufficient cooling of the cutters 150 may result in cutter failure during drilling operations.
This heat causes thermal damage to the PCD in the form of cracks (due to differences in thermal expansion coefficients) which lead to spalling of the polycrystalline diamond layer, delimitation between the polycrystalline diamond and substrate, and back conversion of the diamond to graphite causing rapid abrasive wear.
Conventional polycrystalline diamond is stable at temperatures of up to 700° C., after which observed increases in temperature may result in permanent damage to and structural failure of polycrystalline diamond.
Upon heating of polycrystalline diamond, the binder material and the diamond lattice will expand at different rates, which may cause cracks to form in the diamond lattice structure and result in deterioration of the polycrystalline diamond.
However, thermal fatigue does not only occur at temperatures above 700° C. Rather, the differential expansion (between the binder material and diamond) even occurs at temperatures as low as 300-400° C., still causing thermal fatigue in the diamond body.
Further, damage to polycrystalline diamond can also result from the loss of some diamond-to-diamond bonds (from the initiation of a graphitization process) leading to loss of microstructural integrity and strength loss.
Additionally, the design of conventional PDC cutters often results in failure due to wear and / or chipping of the diamond layer. FIGS. 2A and 2B show examples of the failure modes experienced by conventional PDC cutters brazed in a cutter pocket.

Method used

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  • Innovative cutting element and cutting structure using same
  • Innovative cutting element and cutting structure using same
  • Innovative cutting element and cutting structure using same

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Embodiment Construction

[0049]According to embodiments disclosed herein, a novel cutting structure is described that may allow for increased cutting element wear life. More particularly, embodiments disclosed herein relate to diamond shearing elements that are uniquely oriented on a drill bit or other cutting tool in a manner that allows for extended wear. While conventional cutting elements are a cylindrical compact of a disc or table of diamond bonded on a substrate, where the exposed flat surface of the diamond is facing and substantially co-planar with the leading face of the blade so that the axis extending through the compact points in the direction of the bit rotation, the present application departs from such conventional cutters. The present cutting elements do not include a conventional diamond table disc bonded to a substrate (or even bit body in a similar orientation as a conventional cutter). Various embodiments of the cutting elements are described herein as well as the mechanisms for attachi...

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Abstract

A cutting tool is disclosed that includes a tool body, a plurality of cutting element support structures extending from the tool body, at least one slot formed in at least one of the cutting element support structures, a cutting element having a diamond shearing element with a plurality of surfaces, and at least one mechanical retention mechanism adjacent to the cutting element. Each cutting element support structure has a leading face, a top side, and a trailing face, and the slot has two side surfaces, each side surface terminating at the leading face and top side of the cutting element support structure. Each surface of the cutting element has two dimensional values, wherein the cutting element is positioned in the at least one slot such that a plane in which the shortest dimensional value lies intersects the slot side surfaces.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional patent application of U.S. patent application Ser. No. 13 / 542,060, filed Jul. 5, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61 / 599,665, filed on Feb. 16, 2012, U.S. Provisional Application Ser. No. 61 / 512,624, filed Jul. 28, 2011, and U.S. Provisional Application Ser. No. 61 / 505,140, filed Jul. 7, 2011, which are incorporated by reference.BACKGROUND[0002]1. Field of the Invention[0003]Embodiments disclosed herein relate generally to drill bits and other cutting tools. In particular, embodiments disclosed herein relate to PDC drill bits having diamond shearing elements.[0004]2. Background Art[0005]Historically, there have been two main types of drill bits used for drilling earth formations, drag bits and roller cone bits. The term “drag bits” refers to those rotary drill bits with no moving elements. Drag bits include those having cutting elements attached to the bit body, which...

Claims

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Application Information

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Patent Type & AuthorityApplications(United States)
IPC IPC(8): E21B10/567E21B10/60E21B10/633E21B10/55
CPCE21B10/567E21B10/55E21B10/5673E21B10/633E21B10/60Y10T29/4973E21B10/56
InventorZHANG, YOUHESHI, JIBINBURHAN, YURI
OwnerSMITH INT INC