Solid pcd cutter

Abstract

A method of forming a cutting element may include placing a plurality of diamond particles adjacent to a substrate in a reaction cell and subjecting the plurality of diamond particles to high pressure high temperature conditions to form a polycrystalline diamond body. The polycrystalline diamond body may include a cutting face area to thickness ratio ranging from 60:16 to 500:5. The polycrystalline diamond body may have at least one dimension greater than 8 mm.

Description

RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application Ser. No. 61 / 581,707, filed on Dec. 30, 2011, and U.S. application Ser. No. 13 / 719,326, filed on Dec. 19, 2012, which are incorporated by reference herein.BACKGROUND[0002]Technical Field[0003]Embodiments disclosed herein relate generally to polycrystalline diamond cutters. In particular, embodiments disclosed herein related to bulk polycrystalline diamond bodies for use in downhole drilling applications.[0004]Background Art[0005]Drill bits used to drill wellbores through earth formations generally are made within one of two broad categories of bit structures. Depending on the application / formation to be drilled, the appropriate type of drill bit may be selected based on the cutting action type for the bit and its appropriateness for use in the particular formation. Drill bits in the first category are generally known as “roller cone” bits, which include a bit body having one or more roller c...

AI Technical Summary

Benefits of technology

The solution enhances the thermal stability and wear resistance of cutting elements, allowing for more efficient heat dissipation and extended tool life by increasing the bulk thermal conductivity and reducing thermal mismatch issues.

Problems solved by technology

Additionally, the bit and the PDC cutters may be subjected to substantial abrasive forces.

In some instances, impact, vibration, and erosive forces have caused drill bit failure due to loss of one or more cutters, or due to breakage of the blades.

Without proper flow characteristics, insufficient cooling of the cutters 150 may result in cutter failure during drilling operations.

During manufacture of the cutting elements, the materials are typically subjected to sintering under high pressures and high temperatures.

These manufacturing conditions result in dissimilar materials being bonded to each other.

The residual stress induced on the diamond layer and substrate can often result in insert breakage, fracture or delamination under drilling conditions.

Conventional polycrystalline diamond is stable at temperatures of up to 700-750° C. in air, above which observed increases in temperature may result in permanent damage to and structural failure of polycrystalline diamond.

Exposure to heat (through brazing the cutters to a cutting tool or through frictional heat generated from the contact of the cutter with the formation) can cause thermal damage to the diamond table and eventually result in the formation of cracks (due to differences in thermal expansion coefficients) which can lead to spalling of the polycrystalline diamond layer, delamination between the polycrystalline diamond and substrate, and conversion of the diamond back into graphite causing rapid abrasive wear.

As a cutting element contacts the formation, a wear flat develops and frictional heat is induced.

As the cutting element is continued to be used, the wear flat will increase in size and further induce frictional heat.

The heat may build-up that may cause failure of the cutting element due to thermal mis-match between diamond and catalyst material used to form the PCD.

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