Mixed drill bits

Abstract

A hybrid drill bit includes a fixed cutting structure and a rolling cutting structure. The fixed cutting structure includes a plurality of fixed cutting elements. The rolling cutting structure is coupled to the fixed cutting structure and includes a journal hole extending from the front through the rolling cutting structure to the rear, and a radial outer surface. The rolling cutting structure also includes a plurality of cutting elements extending from the radial outer surface of the rolling cutting structure.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Patent Application No. 62 / 850,619, filed May 21, 2019, the entire contents of which are incorporated herein by reference. Background Art

[0003] Downhole drill bits include two categories: fixed drill bits or "drag" drill bits, and rotary drill bits. Fixed drill bits include fixed cutting structures that do not move relative to the drill bit as the drill bit rotates. Rotary drill bits include one or more rotating cutting structures that rotate relative to the drill bit as the drill bit rotates. Hybrid drill bits include certain aspects of fixed drill bits and rotary drill bits. Summary of the invention

[0004] In some aspects, a drill bit includes a wheel-like rolling cutting structure including a plurality of cutting elements located on a radially outer surface of the drill bit.

[0005] In other aspects, a hybrid drill bit includes one or more fixed cutting structures and one or more rolling cutting structures including a plurality of tapered cutting elements. The rolling cutting structures may be tapered or non-tapered.

[0006] In other embodiments, a kit for drilling includes a conical or non-conical rolling cutting structure having cutting elements located on a radially outward surface of the rolling cutting structure. The kit may include a plurality of sleeves, each sleeve being configured to adjust the height of the rolling cutting structure.

[0007] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. It is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to help limit the scope of the claimed subject matter.

[0008] Additional features and advantages of the embodiments of the present disclosure will be set forth in the subsequent description, and in part will be apparent from the description, or may be learned through the practice of such embodiments. The features and advantages of these embodiments may be realized and obtained through the instruments and combinations specifically pointed out in the appended claims. These and other features will become more apparent from the following description and the appended claims, or may be learned through the practice of such embodiments as set forth below. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In order to describe the manner in which the above and other features of the present disclosure can be obtained, a more particular description will be given by reference to specific embodiments thereof shown in the accompanying drawings. For better understanding, the same elements are represented by the same reference numerals in the various drawings. Although some of the drawings may be schematic or exaggerated representations of the concepts, at least some of the drawings may be drawn to scale. It should be understood that the drawings depict some exemplary embodiments, and the embodiments will be described and explained with additional specificity and detail through the use of the drawings, in which:

[0010] Figure 1 is a schematic diagram of a drilling system according to at least one embodiment of the present disclosure;

[0011] Figure 2-1 is a perspective view of a rolling cutting structure according to at least one embodiment of the present disclosure;

[0012] Figure 2-2 According to at least one embodiment of the present disclosure Figure 2-1 Cross-sectional view of rolling cutting structure;

[0013] Figure 3-1 is a perspective view of a drill bit according to at least one embodiment of the present disclosure;

[0014] Figure 3-2 According to at least one embodiment of the present disclosure Figure 3-1 Bottom view of the drill bit;

[0015] Figure 3-3 According to at least one embodiment of the present disclosure Figure 3-1 A cross-sectional view of a drill bit;

[0016] Figure 3-4 According to at least one embodiment of the present disclosure Figure 3-1 The cutting element profile of the drill bit;

[0017] Figure 3-5 According to at least one embodiment of the present disclosure Figure 3-1 Another cross-sectional view of the drill bit;

[0018] Figure 4 is a perspective view of a sleeve according to at least one embodiment of the present disclosure;

[0019] Figure 5-1 is a perspective view of a drill bit according to at least one embodiment of the present disclosure;

[0020] Figure 5-2 According to at least one embodiment of the present disclosure Figure 5-1 Bottom view of the drill bit;

[0021] Figure 5-3According to at least one embodiment of the present disclosure Figure 5-1 A side view of a drill bit;

[0022] Figure 6 is a bottom view of a drill bit according to at least one embodiment of the present disclosure;

[0023] Figure 7-1 is a perspective view of a drill bit according to at least one embodiment of the present disclosure;

[0024] Figure 7-2 According to at least one embodiment of the present disclosure Figure 7-1 Bottom view of the drill bit;

[0025] Figure 7-3 According to at least one embodiment of the present disclosure Figure 7-1 A cross-sectional view of a drill bit;

[0026] Figure 7-4 According to at least one embodiment of the present disclosure Figure 7-1 Another cross-sectional view of the drill bit;

[0027] Figure 7-5 According to at least one embodiment of the present disclosure Figure 7-1 The cutting profile of the drill bit; and

[0028] Figure 8 is a method diagram according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0029] The present disclosure generally relates to apparatus, systems, and methods for drill bits including cutting elements. Figure 1 One example of a drilling system 100 for drilling into a formation 101 to form a wellbore 102 is shown. The drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 extending downwardly into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottom hole assembly ("BHA") 106, and a drill bit 110, which is attached to the downhole end of the drill string 105.

[0030] The drill string 105 may include multiple joints of drill pipe 108 connected end to end by tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drilling rig 103 to the BHA 106. In some embodiments, the drill string 105 may also include additional components, such as a sub, a pup joint, etc. The drill pipe 108 provides a hydraulic passage through which the drilling fluid is pumped from the surface. The drilling fluid is discharged through a nozzle, jet, or other orifice of a selected size in the drill bit 110 and is used to cool the drill bit 110 and the cutting structure thereon, clean the drill bit 110 and the cutting structure thereon of any cuttings, drill cuttings, or other materials that may have accumulated on the drill bit 110 and / or the cutting structure, and is used to lift the cuttings out of the wellbore 102 while drilling.

[0031] The BHA 106 may include a drill bit 110 or other components. The example BHA 106 may include additional or other components (e.g., coupled between the drill string 105 and the drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement while drilling (“MWD”) tools, logging while drilling (“LWD”) tools, downhole motors, underreamers, segment mills, hydraulic disconnects, jars, vibration or damping tools, steering tools, other components, or combinations thereof.

[0032] In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kellys, blowout preventers, and safety valves). The additional components included in the drilling system 100 may be considered part of the drilling tool assembly 104, the drill string 105, or the BHA 106, depending on their location in the drilling system 100.

[0033] The drill bit 110 in the BHA 106 can be any type of drill bit suitable for degrading downhole materials. For example, the drill bit 110 can be a drill bit suitable for drilling the formation 101. An example type of drill bit for drilling the formation is a fixed cutter or drag drill bit. In other embodiments, the drill bit 110 can be a mill for removing metals, composites, elastomers, other materials downhole, or a combination thereof. For example, the drill bit 110 can be used with a whipstock to grind into a casing 107 lining the wellbore 102. The drill bit 110 can also be a junk mill for grinding away tools, plugs, cement, other materials, or a combination thereof within the wellbore 102. The cuttings or other drill cuttings formed using the mill may be lifted to the surface, or may fall into the wellbore.

[0034] Figure 2-12 is a perspective view of a rolling cutting structure 212 according to at least one embodiment of the present disclosure. In some embodiments, the rolling cutting structure 212 can be wheel-shaped, or substantially wheel-shaped. The rolling cutting structure 212 has an outer surface 214. A plurality of cutting elements 216 can be attached to the outer surface 214 or inserted into recesses in the outer surface 214. For example, the plurality of cutting elements 216 can be attached to the rolling cutting structure 212 using any method, including brazing, welding, mechanical fasteners, press fit, interference fit, or any other type of connection.

[0035] In some embodiments, the hard material forms the cutting element 216 or its substrate. According to the substrate of the embodiment of the present disclosure, it can be formed by cemented carbide, such as tungsten carbide, titanium carbide, chromium carbide, niobium carbide, tantalum carbide, vanadium carbide or a combination of them with iron, nickel, cobalt or their alloys. For example, the substrate can be formed by cobalt sintered tungsten carbide. According to the superhard layer of the embodiment of the present disclosure, it can be formed by, for example, polycrystalline diamond, for example, diamond crystals, thermally stable polycrystalline diamond (polycrystalline diamond with at least part or substantially all catalyst materials removed) or cubic boron nitride, which are combined together (sintered under HPHT conditions) by metal catalysts such as cobalt or other Group VIII metals at sufficiently high pressure and high temperature. In addition, it is also within the scope of the present disclosure that the superhard layer can be formed by one or more layers, and the diamond content in these layers can have a gradient or step transition. In such an embodiment, one or more transition layers (and another layer) can include metal carbide particles therein. In addition, when such a transition layer is used, the combined transition layer and outer layer can be collectively referred to as a superhard layer because the term has been used in this application. That is, the interface on which the superhard layer (or multiple layers including superhard material) can be formed is the interface of the cemented carbide substrate.

[0036] In some embodiments, the cutting element 216 may be conical or frustoconical. In other embodiments, the cutting element 216 may have a convex or concave outer surface. In other embodiments, the cutting element 216 may have an outer surface having multiple cone angles, multiple radii of curvature, different concave surfaces, at least one straight and at least one curved portion, any other cutting element geometry or a combination thereof. The cutting element 216 may have a non-planar surface pointing radially outward from the outer surface 214. In other embodiments, the cutting element 216 may be vertex-shaped, pointed, ridge-shaped or any other shape. In further embodiments, the cutting element may be a cross-sectional shape including one or more of a circle (e.g., a circle, an ellipse), a polygon (e.g., a hexagon, a pentagon, a square or a polygon of any side) or a non-polygon (e.g., a straight side and a curved side). In some embodiments, the cutting element 216 may be radially symmetrical. The cutting element 216 may include one, two, three, four, five, six or more symmetry planes. In other embodiments, the cutting element 216 may be asymmetric or may not include a symmetry plane. In the same or other embodiments, the cutting element may have an asymmetric three-dimensional shape including a point that is distal from a longitudinal axis of the cutting element.Cutting element 216 may include diamond, such as polycrystalline diamond, or may be any suitable cutting element.

[0037] As described above, a plurality of cutting elements 216 may be attached to the outer surface 214 or inserted into pockets in the outer surface 214. In some embodiments, the cutting elements 216 extend only in a radial direction from the outer surface 214 of the rolling cutting structure 212, and not from the front or rear of the rolling cutting structure 212. In some embodiments, each cutting element 216 has a respective cutting element axis 215 that generally extends through the center of the base of the cutting element 216 and the center of the cutting face of the cutting element. The cutting element axis 215 may extend radially from the outer surface 214 of the rolling cutting structure 212. In some embodiments, one or more rows of cutting element axes 215 may be perpendicular to the axis 213 (e.g., the journal axis) of the rolling cutting structure 212. Due to the shape and contour of the outer surface 214, the angle between the cutting element axis and the outer surface 214 to which the cutting element is attached may be different from the angle between the cutting element axis and the axis 213 of the rolling cutting structure 212.

[0038] Although the wheel is generally described throughout the specification with respect to a rotating cutting structure 212, in some embodiments, the wheel is a conical or frusto-conical rolling cutting structure.

[0039] In some embodiments, the rolling cutting structure 212 may include one or more rows of cutting elements 216. The first row (e.g., front row) of cutting elements 216 may include one or more primary cutting elements 216, and the second row (e.g., rear row) of cutting elements may include one or more secondary cutting elements 217 attached to the outer surface 214 of the rolling cutting structure 212. The primary cutting elements 216 and the secondary cutting elements 217 may be diamond inserts, or may be any cutting elements used in downhole drilling. In some embodiments, the rolling cutting structure 212 may include only cutting elements 216 without secondary cutting elements 217. In some embodiments, at least 50% of the cutting elements have a superhard coating. In some embodiments, at least 90% of the cutting elements have a superhard coating. In some embodiments, all cutting elements have a superhard coating.

[0040] In some embodiments, the rolling cutting structure 212 may include three or more rows of cutting elements. The shape of the cutting elements may vary between rows or within rows. For example, the main or front row may have conical cutting elements, and the secondary or rear row may have dome-shaped cutting elements. In addition, the nominal size of the cutting elements (e.g., diameter, characteristic width, extension from the outer surface 214) may vary between rows or within a row of cutting elements. For example, the cutting elements of the front row may have a smaller diameter than the cutting elements of the rear row, and the cutting elements of the third row may be approximately the same size or smaller than the cutting elements of the front row. In addition, the extension of the cutting elements from the outer surface 214 may vary between rows. The extension of the cutting elements 216 in the front row may be greater than the extension of the secondary cutting elements 217 in one or more rear rows. Due to the journal angle of the rolling cutting structure 212 of some embodiments, the secondary cutting elements 217 of one or more secondary rows may extend farther relative to one side of the drill bit than the main cutting elements 216 of the front row, even though the secondary cutting elements 217 extend from the outer surface 214 shorter than the main cutting elements 216. That is, in some embodiments, the cutting profile of the secondary cutting elements 217 may extend further from the front of the drill bit than the cutting profile of the primary cutting elements 216. The primary and any third rows of cutting elements may be configured to engage the formation and reduce wear on the trailing edge of the blade by rolling the cutting structure 212.

[0041] Rolling cutting structure 212 may include a journal hole 218. Journal hole 218 may extend a width 219 of rolling cutting structure 212. In some embodiments, a journal and a journal shaft may be configured to be inserted into journal hole 218, and rolling cutting structure 212 may rotate about the journal shaft.

[0042] Figure 2-2 is in accordance with at least one embodiment of the present disclosure Figure 2-12. A cross-sectional view of the longitudinal or rotational axis of the rolling cutting structure 212 is shown. The rolling cutting structure 212 can be cylindrical, or approximately cylindrical. The rolling cutting structure 212 has a wheel width 219. The wheel width 219 can be less than the wheel diameter 220. For example, the wheel width 219 can be less than 50% of the wheel diameter 220. In other examples, the wheel width 219 can be less than 40% of the wheel diameter 220. In other examples, the wheel width 219 can be less than 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 17.5%, 15%, 12.5%, 10%, 8%, 6%, or 5% of the wheel diameter 220. Therefore, because the wheel width 219 is less than, or even much less than, the wheel diameter 220, the rolling cutting structure 212 can be wheel-shaped. In other words, the wheel-shaped rolling cutting structure 212 has a wheel width 219 that is less than or significantly less than the wheel diameter 220. In at least one embodiment, it may be critical that the wheel width 219 is less than 50% of the wheel diameter 220. In other embodiments, it may be critical that the wheel width 219 is less than 35% of the wheel diameter 220. These percentages may strike a balance between being supported by the blades (not shown) of the drill bit and the strength of the rolling cutting structure 212.

[0043] In some embodiments, the wheel-shaped rolling cutting structure 212 is non-conical (e.g., partially conical, truncated conical, truncated conical, dome-shaped, spherical, hemispherical, partially spherical, elliptical, egg-shaped, parabolic, etc.). In other embodiments, the wheel-shaped rolling cutting structure 212 is, for example, partially conical, truncated conical, truncated conical, etc.

[0044] The wheel-shaped rolling cutting structure 212 may include a bevel, such as an inclined portion 222. The bevel 222 may be of different sizes and / or geometries on each side of the wheel-shaped rolling cutting structure, such as Figure 2-2 The bevel 222 shown may be the same on each side of the wheel-like rolling cutting structure, or may be located only on one side of the wheel-like rolling cutting structure. When the bevel 222 is located only on one side of the wheel-like rolling cutting structure or is different on both sides, it may appear to be partially conical, and such geometry is considered to be within the scope of the present disclosure. In some embodiments, the wheel diameter 220 may be the same or approximately the same (i.e., within 5%) at the first side 223-1 and the second side 223-2 of the rolling cutting structure. In some embodiments, the rolling cutting structure 212 may be symmetrical about a plane that is transverse or perpendicular to the wheel width 219.

[0045] In some embodiments, the wheel width 219 can be within a range having an upper limit, a lower limit, or both, including 0.3 inches (7.62 mm), 0.4 inches (10.16 mm), 0.5 inches (12.70 mm), 0.6 inches (15.24 mm), 0.7 inches (17.78 mm), 0.8 inches (20.32 mm), 0.9 inches (22.86 mm), 1.0 inches (25.40 mm), 1. The wheel width 219 may be any of 25 inches (31.75 mm), 1.5 inches (38.1 mm), 1.75 inches (44.45 mm), 2.0 inches (50.8 mm), 2.25 inches (57.15 mm), 2.5 inches (63.50 mm), 2.75 inches (69.85 mm), 3.0 inches (76.2 mm), 3.5 inches (88.90 mm), 4.0 inches (101.6 mm), or any value therebetween. For example, the wheel width 219 may be greater than 0.3 inches (7.62 mm). In another example, the wheel width 219 may be less than 4.0 inches (101.6 mm). In other examples, the wheel width 219 may be any value within a range between 0.3 inches (7.62 mm) and 4.0 inches (101.6 mm).

[0046] In some embodiments, the wheel diameter 220 can be within a range having an upper value, a lower value, or both, including 2.0 inches (5.08 cm), 2.5 inches (6.35 cm), 3.0 inches (7.62 cm), 3.5 inches (8.89 cm), 4.0 inches (10.16 cm), 4.5 inches (11.43 cm), 5.0 inches (12.70 cm), 5.5 inches (13.97 cm), 6.0 inches (15.24 cm), 7.0 inches (17.78 cm), 8.5 inches (19.87 cm), 9.0 inches (20.97 cm), 10.0 inches (21.3 cm), 11.0 inches (23.9 cm), 12.0 inches (24.9 cm), 13.0 inches (25.9 cm), 14.0 inches (26.9 cm), 15.0 inches (27.9 cm), 16.0 inches (28.9 cm), 17.0 inches (29.9 cm), 18.0 inches (30.9 cm), 19.0 inches (31.9 cm), 20.0 inches (32.9 cm), 21.0 inches (33.9 cm), 22.0 inches (34.9 cm), 23.0 inches (35.9 cm), 24.0 inches (36.9 cm), 25.0 inches (37.9 cm), 26.0 inches (38.9 cm), 27.0 inches (39.9 cm), 28.0 inches (39.9 cm), 29.0 inches (40.9 cm), 30.0 inches (41.9 cm), The wheel diameter 220 may be any of 8.0 inches (20.32 cm), 9.0 inches (22.86 cm), 10.0 inches (25.40 cm), 12 inches (30.48 cm), 14 inches (35.56 cm), 16 inches (40.64 cm), 18 inches (45.72 cm), 20 inches (50.80 cm), 21 inches (53.34 cm), 22 inches (55.88 cm), 24 inches (60.96 cm), 25 inches (63.50 cm), or any value therebetween. For example, the wheel diameter 220 may be greater than 1.0 inch (2.54 cm). In another example, the wheel diameter 220 may be less than 10.0 inches (25.40 cm). In other examples, the wheel diameter 220 may be any value within a range between 1.0 inches (2.54 cm) and 10.0 inches (25.40 cm).

[0047] In some embodiments, the wheel diameter 220 can be a percentage of the diameter of the drill bit diameter. In some embodiments, the percentage of diameter can be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, including any of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or any value therebetween. For example, the percentage of diameter can be greater than 10%. In another example, the percentage of diameter can be less than 75%. In other examples, the percentage of diameter can be any value within a range between 10% and 75%. In some embodiments, it may be critical that the percentage of diameter is at least 50% to provide a greater percentage of formation cutting by the rolling cutting structure 212.

[0048] The outer surface 214 can be located on the radial outer surface of the rolling cutting structure 212. In some embodiments, the outer surface 214 can include an upper portion 221. In at least one embodiment, the upper portion 221 can be flat. In some embodiments, the upper portion 221 can be curved (e.g., elliptical, semicircular) or frustoconical. In the illustrated embodiment, the wheel diameter 220 can remain constant, can remain constant, or can only vary slightly longitudinally through the upper portion 221. The cutting element 216 can be attached to the outer surface 214 at the upper portion 221. In some embodiments, the rolling cutting structure 212 can include an inclined portion 222 along the outer surface 214. For example, across the inclined portion 222, the wheel diameter 220 can decrease toward the side edge 223 of the rolling cutting structure 212. When the rolling cutting structure engages the formation, the inclined portion 222 can help prevent the rolling cutting structure 212 from contacting the bottom of the wellbore. In addition, the inclined portion 222 can help reduce stress in the rolling cutting structure 212 at the intersection between the outer surface 214 and the side edge 223, and thereby reduce cracking, flaking, and fracture thereof. In some embodiments, the outer surface 214 can be inclined along both edges of the rolling cutting structure 212. In other embodiments, the outer surface 214 can be inclined along a single edge of the rolling cutting structure. One or more cutting elements 216 or rows of cutting elements can be disposed on the inclined portion of the outer surface 214. For example, the front and / or rear rows of cutting elements can be disposed on the inclined portion of the outer surface 214. One or more cutting elements 216 may not extend axially beyond the front or rear of the rolling cutting structure 212.

[0049] In some embodiments, the rolling cutting structure 212 may include an axial race 225. The axial race 225 may be configured to receive an axial bearing or an axial seal. The rolling cutting structure 212 may include a thrust washer cavity 227. A thrust washer (not shown) may be inserted between the thrust washer cavity 227 and a blade (not shown) to provide bearing support between the rolling cutting structure 212 and the blade. In at least one embodiment, the thrust washer cavity 227 may be located on either side of the rolling cutting structure 212.

[0050] Figure 3-1 310 is a representation of a drill bit 310 according to at least one embodiment of the present disclosure. The drill bit 310 may include one or more blades 324. The drill bit 310 may be formed of a base material, an alloy material (e.g., steel), or any combination thereof. In some embodiments, one or more portions of the drill bit 310 are formed by an additive manufacturing process. The blades 324 may include a fixed cutting structure and a rolling cutting structure 312. The rolling cutting structure 312 may include at least some of the Figure 2-1 and Figure 2-2 The rolling cutting structure 212 has the same features and characteristics as described.

[0051] In some embodiments, the fixed cutting structure 330 may include one or more fixed cutting elements 332. In some embodiments, the fixed cutting elements 332 may be standard PDC cutting elements. In other embodiments, the fixed cutting elements 332 may be any other type of cutting elements used in downhole drilling tools. In some embodiments, the fixed cutting elements 332 may be brazed or welded to the blades 324. In other embodiments, the fixed cutting elements 332 may be attached to the blades 324 by a rotating connection so that each fixed cutting element 332 rotates independently around its own longitudinal axis. Therefore, the fixed cutting structure 330 means that the position of the fixed cutting elements 332 relative to the blades 324 does not change.

[0052] A journal shaft (not shown) can be inserted into a journal cavity 331 in the front surface of the blade 324. The journal shaft can be secured to the blade 324 using a fastener inserted through a cavity 333 at the rear surface of the blade 324. For example, a threaded fastener can be inserted into the bolt cavity 333. The journal shaft can secure the rolling cutting structure 312 to the blade 324. The rolling cutting structure 312 can then rotate about the journal shaft. The rolling cutting structure 312 can be secured within a slot 348 of the blade 324. In some embodiments, as shown in FIG. Figure 3-1 As shown, one or more slots 348 may open into the central cavity 385 of the drill bit 310. Figure 3-1 As shown, the central cavity 385 may be open to the drill bit axis 334 and one or more chip removal slots of the drill bit 310, or as shown in FIG. Figure 5-1As shown, the rolling cutting structure 312 and the fixed cutting structure 330 can be disposed between the central cavity 385 and the cross-sectional dimensions of the drill bit 310 .

[0053] Figure 3-2 According to at least one embodiment of the present disclosure Figure 1 310. The blade 324 has a leading edge 326 and a trailing edge 328. In some embodiments, the fixed cutting structure 330 can be located at the leading edge 326 of the blade 324. The rolling cutting structure 312 can be located at or near the trailing edge 328 of the blade 324. Thus, the fixed cutting structure 330 and the rolling cutting structure 312 can be located on the same blade (e.g., blade 324). The rolling cutting structure 312 can be located within a slot 348 of the blade 324.

[0054] exist Figure 3-2 In the illustrated embodiment, the drill bit 310 includes three blades 324. The three blades 324 may be evenly spaced around the circumference of the drill bit 310. In other words, the blades 324 may be spaced 120° apart. In other embodiments, the drill bit 310 may include less than or more than three blades. For example, the drill bit 310 may include two blades spaced 180° apart. In other examples, the drill bit 310 may include four blades spaced 90° apart. In other examples, the drill bit 310 may include five, six, seven, eight, nine, ten, or more blades evenly spaced around the circumference of the drill bit 310. In at least one embodiment, two or more blades may be unevenly spaced around the circumference of the drill bit 310. In other words, two or more blades may have different angular spacings relative to other blades of the drill bit 310, which may, for example, result in rolling cutting structures that are unevenly spaced around the drill bit. The blade 324 may include a fixed cutting structure 330 located on a leading edge 326 of the blade 324, and a rolling cutting structure 312 located on a trailing edge 328 of the blade 324. In at least one embodiment, rolling cutting structure 312 may be at leading edge 326 of blade 324 .

[0055] In some embodiments, each blade 324 may include a rolling cutting structure 312. In other embodiments, at least one blade 324 may not include a rolling cutting structure 312. A drill bit having multiple rolling cutting structures 312 that are not located on each blade 324 of the drill bit may have one, two, three, four, five, six, seven, eight, nine, ten, or more rolling cutting structures 312. More rolling cutting structures 312 may be evenly spaced around the circumference of the drill bit 310. For example, the drill bit 310 may include two rolling cutting structures 312 spaced 180° apart. In other examples, the drill bit 310 may include three rolling cutting structures 312 spaced 120° apart. In other examples, the drill bit 310 may include four, five, six, seven, eight, nine, ten, or more rolling cutting structures 312 evenly spaced around the circumference of the drill bit 310. In at least one embodiment, two or more rolling cutting structures 312 may be unevenly spaced around the circumference of the drill bit 310. In other words, two or more rolling cutting structures 312 can have different angular spacing relative to other rolling cutting structures 312 of the drill bit 310. For example, the drill bit 310 can include two rolling cutting structures 312 spaced within 30° of 180°. That is, the drill bit 310 can include a first rolling cutting structure 312 spaced between 150° and 210° of a second rolling cutting structure 312. The asymmetric spacing of the rolling cutting structures 312 about the drill bit axis 334 can reduce harmonic vibrations when drilling.

[0056] In some embodiments, the rolling cutting structure 312 performs the majority of formation removal during drilling, while the fixed cutting structure 330 cleans up the cutting profile of the rolling cutting structure 312. In other embodiments, the fixed cutting structure 330 may perform the majority of formation removal during drilling, while the rolling cutting structure 312 cleans up the cutting profile of the fixed cutting structure 330. Including both the fixed cutting structure 330 and the rolling cutting structure 312 on the blade may increase the rate or penetration rate and / or number of feet drilled before reinstalling or repairing the drill bit 310. In addition, the rolling cutting structure 312 located on the drill bit 310 may provide the operator with greater control over the drill bit, which may improve control of azimuth and inclination when drilling straight or dogleg.

[0057] Each rolling cutting structure 312 has a journal axis 355 about which the rolling cutting structure 312 rotates. The journal axis 355 may be offset from the drill bit rotation axis 334 by a roller offset 336. The reference circle 337 may be centered on the drill bit rotation axis 334 and have a radius equal to the roller offset 336. In some embodiments, the roller offset 336 may be a percentage of the drill bit diameter 338. In some embodiments, the percentage of the roller offset 336 may be within a range having an upper limit, a lower limit, or both, including any of 5%, 10%, 15%, 20%, 22%, 24%, 25%, 26%, 28%, 30%, 35%, 40%, 45%, or any value therebetween. For example, the percentage of the roller offset 336 may be greater than 5%. In another example, the percentage of the roller offset 336 may be less than 45%. In other examples, the percentage of roller offset 336 may be any value within a range between 5% and 45%. In some embodiments, a percentage of roller offset 336 of 20% or more may be critical to the operation of drill bit 310.

[0058] As roller offset 336 increases, the rotation rate of rolling cutting structure 312 can change, and cutting elements 316 can scrape the formation with a longer scrape compared to a lower roller offset 336. This increased contact scrape along the formation can allow each cutting element 316 to remove more material. The conical shape of cutting elements 316 can be wear and corrosion resistant. In this way, by using high roller offset 336 and tapered cutting elements 316, drill bit 310 can experience increased penetration rate and / or greater drill bit durability.

[0059] A reference line 357 perpendicular to the drill bit rotation axis 334 may extend from the drill bit rotation axis 334 to the journal axis 355. The reference circle 337 may be centered on the drill bit rotation axis and have a radius equal to the roller offset 336. In other words, the reference circle 337 may be circumscribed around each journal axis 355 at the roller offset 336. The tangent line 339 may be tangent to the reference circle 337 at the journal axis 355. The journal axis orientation angle 341 may be an angle between the journal axis 355 and the tangent line 339. In some embodiments, the journal axis orientation angle 341 may be within a range having an upper limit value, a lower limit value, or an upper limit value and a lower limit value, including any one of 0°, 5°, 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, or any value therebetween. For example, the journal axis orientation angle 341 may be 45° or less. In another example, the journal axis orientation angle 341 may be 30° or less. In other examples, the journal axis orientation angle 341 may be 15° or less. In other embodiments, the journal axis orientation angle may be greater than 30°.

[0060] In at least one embodiment, reference line 357, which is perpendicular to both drill bit rotation axis 334 and tangent line 339, may be cutting element distance 311 from cutting element tip 313. Cutting element tip 313 may be the farthest extent of cutting element 316 from rolling cutting structure 312, or the portion of cutting element 316 that first engages the formation during drilling. Cutting element distance 311 may be the closest distance from reference line 357 to cutting element tip 313 in a plane perpendicular to drill bit rotation axis 334 when cutting element top 313 is at the bottommost point of rotation of rolling cutting structure 312 about journal shaft axis 355. In some embodiments, cutting element distance 311 can be within a range having an upper limit, a lower limit, or both, including any of 0.1 inches (2.54 mm), 0.2 inches (5.08 mm), 0.3 inches (7.62 mm), 0.4 inches (10.16 mm), 0.5 inches (12.70 mm), 0.6 inches (15.24 mm), 0.7 inches (17.78 mm), 0.8 inches (20.32 mm), 0.9 inches (22.86 mm), 1.0 inches (25.40 mm), or any value therebetween. For example, cutting element distance 311 can be greater than 0.1 inches (2.54 mm). In another example, cutting element distance 311 can be less than 1.0 inches (25.40 mm). In other examples, cutting element distance 311 can be any value within a range between 0.1 inches (2.54 mm) and 1.0 inches (25.40 mm).

[0061] The cutting element distance 311 can be offset in a positive direction or a negative direction. The offset direction can help determine the direction in which the rolling cutting structure 312 rolls around the journal 346. In other words, the cutting element distance 311 can be offset in the direction of rotation of the drill bit (e.g., a positive offset) or offset against the direction of rotation of the drill bit (e.g., a negative offset). As the drill bit rotates, the offset direction of the cutting element distance 311 can change the direction of rotation of the rolling cutting structure. A positive offset can cause the rolling cutting structure 312 to rotate from the center of the drill bit (e.g., from the drill bit's axis of rotation or near the drill bit's axis of rotation) toward the outside or gauge of the drill bit. A negative offset can cause the rolling cutting structure 312 to rotate from the outside or gauge of the drill bit toward the center of the drill bit. In some embodiments, because material removed by the cutting element 316 can be pushed away from the drill bit's axis of rotation and the center fluid port (e.g., Figure 3-2The drill bit 310 is provided with a center fluid port 340 of the drill bit, and thus may need to be rotated from the center of the drill bit toward the outside or gauge of the drill bit, thereby helping to prevent the center fluid port from becoming clogged. In some embodiments, the first rolling cutting structure 312 is arranged on the drill bit 310 with a positive offset and the second rolling cutting structure 312 is arranged on the drill bit 310 with a negative offset, thereby configuring the first rolling cutting structure and the second rolling cutting structure to rotate in opposite directions.

[0062] The drill bit 310 may include a central fluid port 340. In some embodiments, the central fluid port 340 may be located on the drill bit rotation axis 334. In other embodiments, the central fluid port 340 may be located at the junction or center of all the slots 348 of the rolling cutting structure 312. In this way, the central fluid port 340 can flush the cuttings from the rolling cutting structure 312. In addition, the central fluid port 340 can clean the rolling cutting structure 312. In some embodiments, the drill bit 310 may include more than one central fluid port 340 in the central cavity 385. For example, the drill bit 310 may include the same number of central fluid ports 340 as the rolling cutting structure 312. In other examples, the drill bit 310 may include more central fluid ports 340 than the rolling cutting structure 312. In other examples, the drill bit 310 may include fewer central fluid ports 340 than the rolling cutting structure 312. In some embodiments, the central fluid port 340 may include a nozzle that pressurizes and directs the drilling fluid out of the drill bit 310. In other embodiments, central fluid port 340 may not include a nozzle, but may instead discharge directly from a fluid cavity within the drill bit body.

[0063] The drill bit 310 may include a blade nozzle 342. The blade nozzle 342 may be located in a recess or chip slot between the blades 324. In some embodiments, the blade nozzle 342 may direct drilling fluid through the fixed cutting structure 330. This may help wash the chips off the fixed cutting structure 330 and clean the cutting elements of the fixed cutting structure 330. In some embodiments, each blade 324 may have a blade nozzle 342. In some embodiments, each blade 324 may include more than one blade nozzle 342 to better clean the fixed cutting structure.

[0064] The blade 324 may include a support leg 344 at the trailing edge 328 of the blade 324. The support leg 344 may support one end of the rolling cutting structure 312. For example, a journal shaft may be inserted into a cavity of the blade 324 at the leading edge 326 or the trailing edge 328. A first end of the journal shaft may be supported by the leading edge 326 of the blade 324, and a second end of the journal shaft may be supported by the support leg 344.

[0065] Figure 3-334 is a cross-sectional view of a blade 324 according to at least one embodiment of the present disclosure. The blade 324 may include a journal cavity 331 and a rolling groove 348. The rolling groove 348 may be wide enough to allow the rolling cutting structure 312 to be inserted into the rolling groove 348. In order to fix the rolling cutting structure 312 to the blade 324, when the rolling cutting structure 312 is inserted into the rolling groove 348, the journal 346 may be inserted into the journal cavity 331 and pass through the journal hole 318 in the rolling cutting structure 312.

[0066] In some embodiments, the journal 346 can be fixed to the blade 324 with a journal attachment 350. The journal attachment can include a threaded fastener 351, such as a screw or bolt. The threaded fastener 351 can be inserted into a matching thread in the journal 346 through a bolt hole 352. As the threaded fastener 351 is tightened, the journal 346 can be pulled toward the bolt hole 352. The washer 353 can distribute the load of the tightened threaded fastener 351 on the bolt hole 352. Therefore, the journal 346 can be securely fastened to the blade 324 in the journal cavity 331. The threaded fastener 351 can enter through the bolt cavity 333 in the blade 324.

[0067] In some embodiments, the journal cavity 331 can extend through the rolling groove 348 to the other side of the blade 324 (i.e., the trailing edge 328). Therefore, the journal 346 can be supported on the journal first end 354-1 and the journal second end 354-2. The blade 324 may include a support leg 344 located at the trailing edge 328 of the blade 324. The bolt cavity 333 and the bolt hole 352 can be located in the support leg 344, and the journal cavity 331 can extend into the support leg 344. Therefore, the journal 346 can be inserted into the journal cavity 331, inserted through the journal hole 318 of the rolling cutting structure 312, inserted into a portion of the journal cavity 331 on the support leg 344, and fixed to the blade 324 at the journal attachment 350. In this manner, the journal 346 may be supported at the journal first end 354-1 near or at the leading edge 326 and supported at the journal second end at the support leg 344 near or at the trailing edge 328. Because the journal 346 supports the rolling cutting structure 312, the rolling cutting structure 312 is supported by the blade near the leading edge 326 and the support leg 344 near or at the trailing edge 328.

[0068] In at least one embodiment, blade 324 may not include support legs 344. In this manner, journal cavity 331 may extend through blade 324 and rolling cutting structure 312 may be cantilevered in the trailing direction behind blade 324. For example, journal cavity 331 may be reinforced using hardened material or additively manufactured structures inside the leading edge of blade 324. This may account for any additional forces caused by cantilevered rolling cutting structure 312 on blade 324.

[0069] In some embodiments, the journal cavity 331 can be located on the leading edge 326 of the blade 324. For example, the journal cavity 331 can be located below the fixed cutting structure 330 on the leading edge 326 of the blade 324. The bolt cavity 333 can be located on the support leg 344, or in other words, on the trailing edge 328 of the blade 324. In other embodiments, the journal cavity 331 can be located on the trailing edge 328 of the blade 324 and the bolt cavity 333 can be located on the leading edge 326 of the blade 324.

[0070] In some embodiments, the journal 346 can be a journal shaft. Grease for the journal 346 can be located in a grease reservoir 356. The grease reservoir 356 can be integrally formed within the journal 346, or can be a separate component disposed within the journal 346. Grease can be delivered to the journal shaft through a grease port 358 in the journal 346. The journal 346 can have an increased diameter or cross-sectional area in the portion of the cavity 331 that supports the journal 346. This can increase the volume of the grease reservoir 356, thereby allowing for better lubrication and / or service life of the journal 346. In at least one embodiment, the grease reservoir 356 can be offset from the journal shaft axis 355 to accommodate the placement of one or more grease ports 358. The journal shaft can include a sleeve extending around the outside of the journal 346. In some embodiments, the sleeve can extend at least partially into the journal cavity 331. The sleeve can help secure the journal 346 in place and disperse any loads borne by the journal 346. A compensating hole 364 through the journal 346 and the journal attachment 350 can facilitate the distribution of grease from the reservoir 356 by exposure to downhole pressure. In addition, a fastener 365 (eg, a snap ring) can be configured to secure the grease reservoir 356 within the journal 346.

[0071] In some embodiments, a plurality of bearings 323 are disposed in a bearing race 325 between the rolling cutting structure 312 and the blade 324. In some embodiments, the friction bearings provide axial support along the journal shaft axis 355 between the rolling cutting structure 312 and the portion of the blade 324 along the groove 348. Figure 2-2 As described, the thrust washer 360 can be arranged in the thrust washer cavity 327 of the rolling cutting structure 312. These thrust washers 360 and the bearing 323 can be configured to center the rolling cutting structure in the groove 348. In some embodiments, the thrust washer 360 is radially outside the bearing 323 or the friction bearing. One or more journal seals 361 are configured to reduce or eliminate the intrusion of drilling fluid into the journal system. In some embodiments, one or more reservoir seals 362 are configured to isolate grease in the journal. The journal seals 361 and the reservoir seals 362 may include but are not limited to O-rings, oval seals, bullet seals or other types of seals.

[0072] The cutting elements 316 of the rolling cutting structure 312 can have an exposure, which is the distance that the cutting elements 316 can cut into the formation. In addition, the fixed cutting elements 332 of the fixed cutting structure 330 can have an exposure. In some embodiments, the exposure of the fixed cutting elements 332 can be the same as the exposure of the cutting elements 316. In some embodiments, the exposure of the fixed cutting elements 332 can be different from the exposure of the cutting elements 316. The different exposures can be seen in the view where the fixed cutting elements 332 and the cutting elements 316 are rotated into the same plane about the drill bit axis 334 for comparison.

[0073] For example, the cutting elements 316 of the rolling cutting structure 312 can have a greater exposure than the fixed cutting elements 332. In other words, at a given location, the cutting elements 316 can extend further into the formation than the fixed cutting elements 332. Thus, in at least one embodiment, the cutting elements 316 extend further beyond the end of the drill bit 310 than the fixed cutting elements 332. In this way, the cutting elements 316 can cut more of the formation than the fixed cutting elements. In some embodiments, the fixed cutting elements 332 can clean the bottom of the wellbore from material that was not cut by the cutting elements 316.

[0074] The exposure of the cutting element 316 can be positive or negative. As used in the present disclosure, positive exposure is the extent to which the cutting element 316 extends beyond other cutting elements (e.g., fixed cutting elements or cutters on other rolling cutting structures). Negative exposure is the extent to which the cutting element 316 can be positioned below other cutting elements (e.g., fixed cutting elements or cutters on other rolling cutting structures). In some embodiments, the exposure of the cutting element 316 can be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, including -0.300 inches (-7.62 mm), -0.250 inches (-6.35 mm), -0.200 inches (-5.08 mm), -0.150 inches (-3.81 mm), -0.100 inches (-2.54 mm), -0.075 inches (-1.91 mm), -0.050 inches (1.27 mm), -0.060 inches (-1.3 mm), -0.080 inches (-1.4 mm), -0.090 inches (-2.1 mm), -0.100 inches (-3.81 mm), -0.080 inches (-1.4 mm), -0.090 inches (-2.1 mm), -0.080 inches (-1.4 ...80 inches (-1.4 mm), -0.080 inches (-1.4 mm), -0.080 inches (-1.4 mm), -0.090 inches (-1.4 mm), -0.080 inches (-1.4 mm), -0.080 inches (-1.4 mm), - inch (0.64 mm), 0.025 inch (0.64 mm), 0.050 inch (1.27 mm), 0.075 inch (1.91 mm), 0.100 inch (2.54 mm), 0.150 inch (3.81 mm), 0.200 inch (5.08 mm), 0.250 inch (6.35 mm), 0.300 inch (7.62 mm), or any value therebetween. For example, the cutting element 316 exposure may be greater than -0.300 inch (-7.62 mm). In another example, the cutting element 316 exposure may be less than 0.300 inch (7.62 mm). In other examples, the cutting element 316 exposure may be any value within a range between -0.300 inch (-7.62 mm) and 0.300 inch (7.62 mm). In some embodiments, the cutting element 316 exposure may be less than -0.300 inches (-7.62 mm) or greater than 0.300 inches (7.62 mm). In at least one embodiment, an exposure between -0.050 inches (-1.27 mm) and 0.050 inches (1.27 mm) may be critical to provide maximum penetration and prevent excessive wear of the cutting element 316. In some embodiments, different rolling cutting structures 312 may have different exposures. For example, one or more rolling cutting structures 312 may have a negative exposure, one or more rolling cutting structures 312 may have a positive exposure, and one or more rolling cutting structures 312 may have an exposure of 0 inches (0 mm), or any combination thereof.

[0075] In some embodiments, the exposure of cutting element 316 may be adjustable. For example, a larger diameter rolling cutting structure 312 may increase the exposure of cutting element 316. In other examples, a larger cutting element 316 may increase the exposure of cutting element 316. A combination of changing the diameter of rolling cutting structure 312 and the size of cutting element 316 may change the exposure of cutting element 316.

[0076] The journal 346 has a journal axis 355. The rolling cutting structure 312 can rotate around the journal 346 on the journal axis about the journal axis 355. In some embodiments, the journal axis 355 can be parallel to a reference line 357, which is perpendicular to the drill bit rotation axis (e.g., Figure 3-2 The journal angle 359 may be an angle between the journal axis 355 and the reference line 357. In some embodiments, the journal angle 359 may be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, including any of 0°, 5°, 10°, 11°, 12°, 13°, 14°, 15°, 16°, 17°, 18°, 19°, 20°, 21°, 22°, 23°, 24°, 25°, 30°, 40°, 45°, or any value therebetween. For example, the journal angle 359 may be greater than 0°. In another example, the journal angle 359 may be less than 45°. In other examples, the journal angle 359 may be any value within a range between 0° and 45°. In some embodiments, the journal angle 359 may be greater than 45°.

[0077] In some embodiments, the journal angle 359 can affect the angle at which the cutting element 316 engages the formation. Therefore, the journal angle 359 can be optimized for the angle at which the cutting element 316 engages the formation. A journal angle of 17° or within 10° of 17° is critical to optimizing drill bit drilling. The journal angle 359 can be positive or negative. In some embodiments, the cutting elements 316 can be attached to the rolling cutting structure to affect the angle at which the cutting elements 316 engage the formation. For example, the first row of cutting elements 316 can be arranged so that the cutting element axis is perpendicular to the axis of the rolling cutting structure 312, and the second row of cutting elements 317 can be arranged so that the cutting element axis is at a different angle to the axis of the rolling cutting structure 312. Therefore, in some embodiments, the cutting elements 316 of the rolling cutting structure 312 can be attached to provide a desired engagement angle with the formation regardless of the journal angle 359.

[0078] Figure 3-4 According to at least one embodiment of the present disclosure Figure 3-1 The cutting element profile 329 represents the rolling cutting structure (e.g., Figure 3-2 The cutting elements (e.g., Figure 3-2 The outermost extent of the cutting element 316 of the drill bit. The secondary cutting element profile 335 represents the secondary cutting element (e.g., Figure 2-1 The outermost extent of the secondary cutting element 217). The fixed cutting element profile 345 represents the fixed cutting element (e.g., Figure 3-3 The outermost range of the fixed cutting element 332).

[0079] As can be seen, cutting element profile 329 extends farthest downward, or has the highest exposure approximately halfway between the drill bit rotation axis 334 and the borehole wall. The highest exposed cutting element is likely to be subject to the greatest forces and remove the majority of the formation while drilling. Thus, cutting element profile 329 indicates that the cutting element performs the majority of the cutting in the drill bit. In other embodiments, fixed cutting element profile 345 may extend further downward than cutting element profile 329. Thus, the fixed cutting element profile will cut the majority of the formation in the midway region between the borehole wall and the drill bit axis 334. From the center portion of the profile extending furthest inward downward from fixed cutting element profile 345, cutting element profile 329 may extend further downward than secondary cutting element profile 335 and therefore will cut the majority of the formation in this region.

[0080] The exposure of the cutting elements 316 of one or more rolling cutting structures 312 may be different from the exposure of the fixed cutting elements 332 on the blade 324. The fixed cutting elements 332 may be configured to engage the formation in one or more gauge portions 370, shoulder portions 372, nose portions 374, or any combination thereof. In some embodiments, the fixed cutting elements 332 on the blade 324 may be configured not to engage the formation in a tapered region 376 of the drill bit closest to the drill bit axis 334. Figure 3-4 As shown, the exposure 345 of the fixed cutting element 322 may not include the tapered region 376 closest to the drill bit axis 334 . Figure 3-1 and 3-2An embodiment of drill bit 310 is shown without fixed cutting elements in tapered region 376. That is, cutting elements 316 of rolling cutting structure 312 may be the only cutting structures within tapered region 376. One or more rows of cutting elements 316 may be exposed to the formation at least in tapered region 376. Exposures 329 and 335 of cutting elements 316 on rolling cutting structure 312 may overlap with exposures 345 of fixed cutting elements 332 in one or more of nose region 374, shoulder region 372, and gauge region 370. In some embodiments, exposures 329 and 335 of cutting elements 316 on rolling cutting structure 312 are less than or equal to exposure 345 of fixed cutting elements 332, as long as the respective exposures overlap.

[0081] Figure 3-5 According to at least one embodiment of the present disclosure, Figure 3-3 The view shown is taken from Figure 3-2 and 3-3 324. The journal cavity 331 has a journal cavity height 343 extending from a journal cavity top 375 to a journal cavity bottom 347. The journal cavity 331 also has a journal cavity width 349.

[0082] In some embodiments, the journal cavity 331 can have a generally circular cross section. In other embodiments, the journal cavity 331 can have a cross section with a domed top portion and a domed bottom portion and a straight middle portion. In other embodiments, the journal cavity can have an elliptical cross section. In other embodiments, the journal cavity 331 can be approximately rectangular, or rectangular with rounded corners. In other embodiments, the journal cavity 331 can have a polygonal cross section (including a polygon with 5 or more sides).

[0083] In some examples, the journal cavity width 349 can be the same as the journal cavity height 343. For example, the journal cavity 331 can be approximately square or circular. In other examples, the journal cavity 331 can be rectangular or oval, which means that the journal cavity width 349 can be smaller than the journal cavity height 343. In some embodiments, the rectangular journal cavity 331 can have a more favorable force distribution for the forces borne by the blade 324.

[0084] Figure 4 is an embodiment of a sleeve 460 according to at least one embodiment of the present disclosure. The sleeve 460 may include a back plate 461. In some embodiments, the back plate 461 may be configured to abut against a rolling cavity (e.g., Figure 3-2 In some embodiments, two sleeves 460 may be placed in the rolling groove (e.g., Figure 3-3 Thus, a plurality of sleeves may be configured to support a rolling cutting structure (e.g., Figure 2-1 Rolling cutting structure 212).

[0085] A sleeve extension 462 may extend from the back plate 461 with a sleeve extension journal hole 463 extending therethrough. The sleeve extension has a top surface 464 and a bottom surface 465. A top thickness 466 may be the thickness of the sleeve extension 462 between the sleeve extension journal hole 463 and the top surface 464. A bottom thickness 467 may be the thickness of the sleeve extension 462 between the journal hole and the bottom surface 465.

[0086] In some embodiments, sleeve 460 may have a matching journal cavity (e.g., Figure 3-5 The outer contour of the journal cavity 331) contour, and the matching journal (e.g., Figure 3-3 The sleeve 460 may be configured to have a profile that is different from the profile of the journal cavity. In this manner, the sleeve 460 may distribute the forces experienced by the rolling cutting structure to the journal cavity. Thus, the journal cavity may be designed to distribute the forces from the rolling cutting structure (e.g., Figure 3-1 The rolling cutting structure 312) is assigned to the blade, and the sleeve 460 can be designed to nest the journal in the journal cavity and transfer the force experienced by the journal from the rolling cutting structure to the journal cavity.

[0087] In some embodiments, the top thickness 466 can be the same as the bottom thickness 467. In other embodiments, the top thickness 466 can be different from the bottom thickness 467. In this way, the relative position of the journal within the journal cavity can be adjusted by providing a sleeve 460 having a different top thickness 466 and a different bottom thickness 467. In other words, the height of the journal within the journal cavity can be adjusted by changing the sleeve 460 to a sleeve 460 having a different top thickness 466 and a different bottom thickness 467. Thus, the rolling cutting structure can have an adjustable height. This can allow the height of the rolling cutting structure to be changed relative to the rest of the drill bit. Specifically, the height or position of the rolling cutting structure relative to the fixed cutting structure can be changed. In other words, by changing the sleeve 460, the height or position of the rolling cutting structure relative to the fixed cutting structure can be changed. Figure 3-3 The fixed cutting element 332) changes or adjusts the cutting element (e.g., Figure 3-3 The cutting element 316 of the shaft journal is exposed. In other embodiments, other adjustment mechanisms can be used. For example, a ratchet mechanism, a flow control valve, a stepper motor, or other adjustment mechanisms can be used to adjust the height of the journal. Examples of adjustment mechanisms can be seen in U.S. Patent Publication No. 2018 / 0087323 filed on March 27, 2016, which is incorporated herein by reference in its entirety for all purposes.

[0088] Similarly, the side thickness 469 of the sleeve 460 can be adjusted. In this way, the offset (e.g., Figure 3-2 In other words, the offset of the rolling cutting structure can be adjustable. For example, a sleeve 460 with different side thicknesses 469 can be inserted into the journal cavity to change the offset of the rolling cutting structure. In some embodiments, the side thickness 469, the top thickness 466, and the bottom thickness 467 can be changed simultaneously. In other words, the journal offset and the journal height can be adjusted simultaneously.

[0089] In some embodiments, sleeve 460 can be reversible. In other words, sleeve 460 can be installed so that top surface 464 engages the bottom surface of the journal cavity and bottom surface 465 engages the top surface of the journal cavity, or vice versa. In this way, the height and exposure of the journal and rolling cutting structure can be quickly adjusted, such as at a drilling rig site.

[0090] Figure 5-1 is a perspective view of a representation of a drill bit 510 according to at least one embodiment of the present disclosure. The drill bit 510 may include at least some Figure 2-1 to Figure 4 The rolling cutting structure and drill bit described have the same features and characteristics. The drill bit 510 may include a plurality of blades 524. In the illustrated embodiment, the drill bit 510 includes a plurality of fixed cutting structures 530 and a rolling cutting structure 512. The rolling cutting structure 512 may be attached to the blades 524 using a journal 546 mounted in a journal cavity 531. The fixed cutting structure of the blade 524 having the rolling cutting structure 512 may be divided into an upper blade portion 580 and a lower blade portion 581 to facilitate the journal cavity 531. The upper blade portion 580 and the lower blade portion 581 may each have a plurality of fixed cutting elements disposed thereon.

[0091] Figure 5-2 yes Figure 5-1 510. As can be seen, in some embodiments, the drill bit 510 may include four blades (collectively referred to as 524). The first blade 524-1 may include a first fixed cutting structure 530-1 at a leading edge 526 of the first blade 524-1. A rolling cutting structure (collectively referred to as 512) may be attached to the first blade 524-1 at a trailing edge 528. The rolling cutting structure 512 may be attached to the first blade 524-1 and supported by support legs 544. The second blade 524-2 may include a single cutting structure, namely a second fixed cutting structure 530-2. In some embodiments, as Figure 5-2 As shown, the groove 548 for the rolling cutting structure 512 can open into the central cavity 585.

[0092] In some embodiments, the drill bit 510 includes a first set of blades and a second set of blades. The first set of blades may include two or more first blades 524-1. The second set of blades may include two or more second blades 524-2.

[0093] The drill bit 510 may have twice as many fixed cutting structures (collectively referred to as 530) as rolling cutting structures 512. In some embodiments, the secondary blades or fixed cutting structures 530 may be located on either or both sides of each rolling cutting structure 512. In other words, each fixed cutting structure 530 may have a rolling cutting structure 512 located on a first side of the fixed cutting structure 530, and a fixed cutting structure 530 located on a second side of the fixed cutting structure.

[0094] In some embodiments, the first blade 524-1 may include only the rolling cutting structure 512 without the first fixed cutting structure 530-1. In such an embodiment, the drill bit 510 has six blades 524, each blade 524 including a single cutting structure.

[0095] In some embodiments, the drill bit 510 may include a first rolling cutting structure 512-1 and a second rolling cutting structure 512-2. Both rolling cutting structures 512-1 and 512-2 may have a journal angle (e.g., Figure 3-3 journal angle 359). Because the first rolling cutting structure 512-1 is located on the opposite side of the drill bit 510 from the second rolling cutting structure 512-2, the first rolling cutting structure 512-1 appears to be angled in a different direction than the second rolling cutting structure 512-2. However, the rolling cutting structures 512-1, 512-2 are angled in the same rotational direction. However, in some embodiments, due to the journal angle, the formation may not be completely worn near the drill bit rotation axis 534. In some embodiments, the spacing distance between cutting elements through the drill bit rotation axis 534 can be between 0 and 1.0 inches, 0.25 to 0.75 inches, 0.3 to 0.6 inches, or approximately 0.5 inches. Therefore, the rolling cutting structures 512-1, 512-2 may include a second row of secondary cutting elements (e.g., Figure 2-1 The secondary cutting elements 217 may be provided at the drill bit rotation axis 534 to assist in removing the formation.

[0096] Figure 5-3 According to at least one embodiment of the present disclosure Figure 5-1546 mounted in the journal cavity 531. In some embodiments, the journal cavity can be mounted in the slot 548 of the blade 524 below the fixed cutting structure 530. However, this may reduce the amount of space available for the fixed cutting elements 532 on the fixed cutting structure 530. Therefore, in some embodiments, one or more standard cutting elements 568 can be located near or above the rolling cutting structure 512. Therefore, in at least one embodiment, the fixed cutting structure 530 can have a set of fixed cutting elements 532 positioned separately from the standard cutting elements 568. That is, the fixed cutting structure 530 of the blade 524 can have an upper blade portion 580 and a lower blade portion 581.

[0097] Figure 6 is a bottom view of a representation of a drill bit 610 according to at least one embodiment of the present disclosure. The drill bit 610 may include at least some Figure 2-1 to Figure 5-3 The drill bit 610 may include a plurality of blades 624. Each blade 624 may include a fixed cutting structure 630 at a leading edge 626 of the blade 624 and a rolling cutting structure 612 at a trailing edge 628.

[0098] In this manner, the drill bit 610 may include the same number of fixed cutting structures 630 as rolling cutting structures 612. In other words, the fixed cutting structures 630 may be located on either side of each rolling cutting structure 612, and the rolling cutting structures 612 may be located on either side of each fixed cutting structure 630.

[0099] A central gap 670 (e.g., a central cavity) can be located at the confluence of multiple rolling cutting structures 612. The central gap 670 can include multiple central fluid jets 672. The multiple central fluid jets 672 can be directed toward the rolling cutting structures 612 so that the central fluid jets 672 clean the rolling cutting structures 612 and flush the chips from the central gap 670. In some embodiments, the drill bit 610 can include a central fluid jet 672 for each rolling cutting structure 612. In other embodiments, there can be more central fluid jets 672 than rolling cutting structures. In other embodiments, there can be fewer central fluid jets 672 than rolling cutting structures.

[0100] In some embodiments, the cutting elements 616 may not completely reach the center of the drill bit 610. Therefore, there may be a separation distance 676 between two opposing rolling cutting structures 612. The separation distance 676 may generally be the result of the journal offset, the journal angle, the placement of the rolling cutting structure 612, or any combination of the foregoing. In some embodiments, one or more center cutting elements 674 may be placed on the drill bit 610 at the center of the center gap 670 to break any formation that is not broken by the rolling cutting structure 612. The separation distance 676 may be between about 0.1 to 1.0 inches, 0.25 to 0.75 inches, 0.3 to 0.6 inches, or about 0.5 inches. In some embodiments, the spacing distance 676 between the opposing rolling cutting structures 612 may be negative. That is, the cutting elements 616 of the opposing rolling cutting structures 612 may overlap with a plane passing through the drill bit axis 634, so that the cutting profile extends through the drill bit axis 634. These rolling cutting structures 612 are arranged on different planes, which are configured to eliminate interference of the cutting elements 616.

[0101] In other embodiments, the two opposing rolling cutting structures 612 can be positioned or adjusted to reduce the separation distance 676. For example, the two opposing rolling cutting structures 612 can be positioned with a smaller roller offset than the other two rolling cutting structures 612. In other examples, the two opposing rolling cutting structures 612 can have a larger wheel diameter (e.g., wheel diameter 220 of FIG. 202) than the other two rolling cutting structures 612. In other examples, some combinations of rolling cutting structure arrangements, wheel diameters, and center cutting elements 674 can help break up formations that are not cut in the center gap 670.

[0102] The blade nozzle 678 may be located between each blade 624. The blade nozzle 678 may be configured to clean the fixed cutting structure 630. In some embodiments, the blade nozzle 678 may be oriented at a blade nozzle angle relative to the drill bit rotation axis 634. In some embodiments, the blade nozzle angle may be parallel to the drill bit rotation axis 634. In other embodiments, the blade nozzle angle may be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, including any of 5°, 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, or any value therebetween. For example, the blade nozzle angle may be greater than 5°. In another example, the blade nozzle angle may be less than 85°. In other examples, the blade nozzle angle may be any value within a range between 5° and 85°. In some embodiments, a blade nozzle angle of approximately 45° may be critical for effectively cleaning the fixed cutting structure 630.

[0103] Figure 7-1 is a perspective view of a drill bit 710 according to at least one embodiment of the present disclosure. The drill bit 710 may include at least some Figure 2-1 to Figure 6 The rolling cutting structure and the drill bit described in the foregoing have the same features and characteristics. For example, the drill bit 710 may include two first blades 724-1 arranged opposite to each other, and two second blades 724-2 arranged transversely to the first blades 724-1 and opposite to each other. Each first blade 724-1 may include a fixed cutting structure 730. Each second blade 724-2 may include a first rolling cutting structure 712-1 and a second rolling cutting structure 712-2. The first rolling cutting structure 712-1 may be separated from the second rolling cutting structure 712-2 by a central support leg 772.

[0104] Figure 7-2 yes Figure 7-1 710. Each second blade 724-2 may include a second blade leading edge 726-2 and a second blade trailing edge 728-2. The first rolling cutting structure 712-1 may be located on the second blade leading edge 726-2, and the second rolling cutting structure 712-2 may be located on the second blade trailing edge 728-2.

[0105] The drill bit 710 may include one or more central fluid ports 740. The central fluid port 740 may be located near the drill bit rotation axis 734 between the second blades 724-2 and configured to flush chips away from the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2. The blade nozzle 742 may be located on one or more first blades 724-1 and configured to clean and wash chips away from the fixed cutting structure 730. The external nozzle 774 may be located on the outer periphery of the drill bit 710. The external nozzle 774 may be configured to further clean the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2.

[0106] Figure 7-3 yes Figure 7-1 and 7-2 A cross-sectional view of a second blade 724-2 of a drill bit 710 is shown. The second blade 724-2 can support a first rolling cutting structure 712-1 at a second blade leading edge 726-2 and a second rolling cutting structure 712-2 at a second blade trailing edge 728-2. A first journal 746-1 can secure the first rolling cutting structure 712-1 to the first support leg 744-1 and the center support leg 772. A second journal 746-2 can secure the second rolling cutting structure 712-2 to the second support leg 744-2 and the center support leg 772.

[0107] In some embodiments, one or more of the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2 can be angled relative to the drill bit rotation axis 734. For example, the first journal 746-1 can have a first journal axis 755-1, and the first rolling cutting structure 712-1 can rotate around the first journal axis. The second journal 746-2 can have a second journal axis 755-2, and the second rolling cutting structure 712-2 can rotate around the second journal axis. In some embodiments, the first journal axis 755-1 and the second journal axis 755-2 can be perpendicular to the drill bit rotation axis 734.

[0108] In other embodiments, the first journal axis 755-1 can be at a first journal angle 759-1 relative to a reference line 757, the reference line 757 being perpendicular to the drill bit rotation axis 734. Similarly, the second journal axis 755-2 can have a second journal angle 759-2 relative to the reference line 757. In some embodiments, the first journal angle 759-1 and the second journal angle 759-2 can have different signs. For example, the first journal angle 759-1 can be negative and the second journal angle 759-2 can be positive. In other examples, the first journal angle 759-1 can be positive and the second journal angle 759-2 can be negative. In other embodiments, the first journal angle 759-1 and the second journal angle 759-2 can have the same sign. For example, both the first journal angle 759-1 and the second journal angle 759-2 can be positive. In other examples, both the first journal angle 759-1 and the second journal angle 759-2 can be negative.

[0109] As the drill bit 710 rotates, the rolling cutting structures 712-1, 712-2 can rotate about the journal axis axes 755-1, 755-2. In some embodiments, the rolling cutting structures 712-1, 712-2 can rotate from the drill bit rotation axis 734 to the periphery of the drill bit 710. In other embodiments, the rolling cutting structures 712-1, 712-2 can rotate from the periphery of the drill bit 710 to the drill bit rotation axis 734. In some embodiments, the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2 can both rotate in the same direction (i.e., from the drill bit rotation axis 734 to the periphery of the drill bit 710 or from the periphery of the drill bit 710 to the drill bit rotation axis 734). In other embodiments, the first rolling cutting structure 712-1 can rotate in a direction different from the second rolling cutting structure 712-2. For example, the first rolling cutting structure 712-1 can be rotated from the drill bit rotation axis 734 to the outer periphery of the drill bit 710, and the second rolling cutting structure 712-2 can be rotated from the outer periphery of the drill bit 710 to the drill bit rotation axis 734. In another example, the first rolling cutting structure 712-1 can be rotated from the outer periphery of the drill bit 710 to the drill bit rotation axis 734, and the second rolling cutting structure 712-2 can be rotated from the drill bit rotation axis 734 to the outer periphery of the drill bit 710.

[0110] Rolling cutting structures 712-1, 712-2 rotating in opposite directions, or rolling cutting structures 712-1, 712-2 rotating in opposite directions, can cut the formation in different ways, which can improve the penetration rate of the drill bit 710, the life of the drill bit 710, and / or reduce the maintenance of the drill bit 710. For example, the first cutting element 716-1 on the first rolling cutting structure 712-1 can cut a first path in the formation along a first direction. The secondary cutting element 716-2 on the second rolling cutting structure 712-2 can cut a second path in the formation along a second direction. Because the second direction is different from the first direction, the secondary cutting element 716-2 may not engage the formation in the same groove or pit left by the first cutting element 716-1. This can reduce the wear on the rolling cutting structures 712-1, 712-2. In addition, the fracture mode of the formation caused by the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2 can be different. This may cause the formation to be more easily broken and / or broken into smaller pieces.

[0111] The second blade 724-2 may include a journal cavity 731. The journal cavity 731 may extend through at least a portion of the first support leg 744-1 and the second support leg 744-2. In order to install the rolling cutting structure 712-1, 712-2, the second journal 746-2 may be inserted through the second rolling cutting structure 712-2 into the journal cavity 731 located in the second support leg 744-2. The second journal 746-2 may be fixed to the central support leg 772. Then, the first journal 746-1 may be inserted into the journal cavity 731 located in the first support leg 744-1 through the first rolling cutting structure 712-1 and fixed to the central support leg 772. Therefore, the central support leg 772 may support one or both of the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2.

[0112] In some embodiments, the first journal 746-1 and the second journal 746-2 can be independently fixed to the center support leg 772. In other embodiments, the connector bolt 776 can pass through a portion of the center support leg 772. The connector bolt 776 can be connected to the first journal 746-1 and the second journal 746-2. When the connector bolt 776 is in tension, the first journal 746-1 and the second journal 746-2 can be pulled toward and fixed to the center support leg. In some embodiments, the connector bolt 776 can be a screw with a head in a cavity of one journal and a threaded portion in a cavity including matching threads of the other journal. In other embodiments, the connector bolt 776 can be any type of mechanical connector.

[0113] In some embodiments, the bolt cavity 733 can be located in the second support leg 744-2. The threaded fastener 751 inserted into the bolt cavity 733 can fix the second journal 746-2 to the second support leg 744-2. Therefore, the first journal can be connected to the central support leg 772 and the second journal 746-2 by the connector bolt 776 and fixed in the journal cavity 731.

[0114] In some embodiments, the center support leg 772 can be integrally formed with the drill bit body 773. In other words, the center support leg 772 can be formed as a single piece with the drill bit body 773. In other embodiments, the center support leg 772 can be formed separately and connected to the drill bit body 773. For example, the center support leg 772 can be connected to the drill bit body 773 by brazing, welding, screws, bolts, interference fit (e.g., dovetail joint), friction fit, or other connection methods.

[0115] In some embodiments, center support leg 772 may include one or more wear pads or hard facing layers located at the bottom of center support leg 772. In this manner, center support leg 772 may be protected from any portion of the formation that is not cut by rolling cutting structures 712-1, 712-2.

[0116] The first rolling cut structures 712-1, 712-2 may have different exposures. In some embodiments, the parameters of the first rolling cut structure 712-1 and the second rolling cut structure 712-2 may be varied to ensure that the first rolling cut structure 712-1 and the second rolling cut structure 712-2 have the same or approximately the same exposure.

[0117] In some embodiments, the first journal 746-1 can be coaxial with the second journal 746-2. In other words, the first journal shaft axis 755-1 can be the same as or coincident with the second journal shaft axis 755-2. In other embodiments, the first journal shaft axis 755-1 can be different from the second journal shaft axis 755-2, or offset from the second journal shaft axis 755-2 by a vertical axis offset of 780°. In some embodiments, the vertical axis offset can be in a range having an upper limit, a lower limit, or an upper and lower limit, including any of 0.1 inches (2.54 mm), 0.2 inches (5.08 mm), 0.3 inches (7.62 mm), 0.4 inches (10.16 mm), 0.5 inches (12.70 mm), 0.6 inches (15.24 mm), 0.7 inches (17.78 mm), 0.8 inches (20.32 mm), 0.9 inches (22.86 mm), 1.0 inches (25.40 mm), 1.5 inches. (38.1 mm), 2 inches (50.8 cm), or any value therebetween. For example, the vertical axis offset 780 can be greater than 0.1 inches (2.54 mm). In another example, the vertical axis offset 780 can be less than 2.0 inches (50.8 mm). In other examples, the vertical axis offset 780 can be any value within a range between 0.1 inches (2.54 mm) and 2.0 inches (50.8 mm). Thus, the vertical axis offset 780 can completely or partially offset the exposure difference between the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2.

[0118] In some embodiments, the first rolling cutting structure 712-1 may have the same wheel diameter as the second rolling cutting structure 712-2 (eg, Figure 2-2Wheel diameter 220). In other embodiments, the first rolling cutting structure 712-1 may have a different wheel diameter than the second rolling cutting structure 712-2. In some embodiments, the second rolling cutting structure 712-2 may have a wheel diameter that is a percentage of the first rolling cutting structure 712-1. In some embodiments, the percentage may be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, including any of 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, 130%, 140%, 150%, or any value therebetween. For example, the percentage may be greater than 50%. In another example, the percentage may be less than 150%. In other examples, the percentage may be any value within a range between 50% and 150%. Therefore, changing the wheel diameter may fully or partially offset the exposure difference between the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2.

[0119] Figure 7-4 yes Figure 7-1 , 7-2 7-3 and a bottom-up cross-sectional view of the drill bit 710. In some embodiments, the first journal shaft axis 755-1 and the second journal shaft axis 755-2 can be coaxial, or can share a common axis. In other embodiments, the first journal shaft axis 755-1 can be offset from the second journal shaft axis 755-2 by a radial axis offset 782. In some embodiments, the radial axis offset 782 can be within a range having an upper limit value, a lower limit value, or an upper limit value and a lower limit value, including any of 0.1 inches (2.54 mm), 0.2 inches (5.08 mm), 0.3 inches (7.62 mm), 0.4 inches (10.16 mm), 0.5 inches (12.70 mm), 0.6 inches (15.24 mm), 0.7 inches (17.78 mm), 0.8 inches (20.32 mm), 0.9 inches (22.86 mm), 1.0 inches (25.40 mm), or any value therebetween. For example, the radial axis offset 782 can be greater than 0.1 inches (2.54 mm). In another example, the radial axis offset 782 can be less than 1.0 inches (25.40 mm). In other examples, the radial axis offset 782 can be any value within a range between 0.1 inches (2.54 mm) and 1.0 inches (25.40 mm). Thus, the radial axis offset 782 can completely or partially offset the exposure difference between the first rolling cutting structure 712-1 and the second rolling cutting structure 712-2. Although reference Figure 7-4 However, this offset difference may also apply to other embodiments described herein where the rolling cutting structures are located on different blades.

[0120] Figure 7-5 is an embodiment of a cutting profile 775 according to at least one embodiment of the present disclosure. Different areas along the cutting profile 775 can be primarily cut by different cutting elements. In other words, different cutting elements can have the highest exposure along different areas of the cutting profile 775. Figure 7-5 In the illustrated embodiment, the central first region 777 may be mainly composed of secondary cutting elements (e.g., Figure 7-2 The secondary cutting element 717 of the rolling cutting structure 712-1, 712-2 shown in the figure cuts. The secondary cutting element can be added to the rolling cutting structure, especially to cut the central first area 777, because otherwise the main cutting element (for example, Figure 7-3 The first cutting element 716-1) may not cut or may not fully cut the central first region 777.

[0121] The second region 779 may be mainly composed of the main cutting elements of the second rolling cutting structure (e.g., Figure 7-3 The third region 781 may be mainly cut by the main cutting element (e.g., Figure 7-3 As can be seen, in some embodiments, the third region 781 may include the "nose" region of the drill bit. Thus, the main cutting elements of the first rolling cutting structure may remove the greatest amount of material. The outermost fourth region 783 may be formed by a fixed cutting structure (e.g., Figure 7-2 The fixed cutting element of the fixed cutting structure 730) is cut. This outermost fourth region 783 may include the "shoulder" and / or "spec" area of ​​the drill bit. Figure 3-4 As discussed, the nose region 781 may be cut by fixed cutting elements of the fixed cutting structure 730 and / or by primary cutting elements of the rolling cutting structure 712 .

[0122] As can be seen, one main rolling cutting structure may have the largest cutting load. However, the remaining cutting structure can support the rolling cutting structure. Specifically, the remaining cutting structure can mainly cut the formation portion that the main rolling cutting structure cannot fully reach.

[0123] Figure 8is a method diagram of a method 884 of forming a drill bit according to at least one embodiment of the present disclosure. Method 884 may include selecting a drill bit body at 886. Selecting a drill bit body may include selecting a drill bit body having a particular geometry. The geometry may include one or more fixed cutting structures, one or more rolling cutting structures, and the like. In some embodiments, selecting a drill bit body may include forming the drill bit body. For example, the drill bit body may be cast, machined, or manufactured using additive manufacturing. The drill bit body may be a matrix, a steel body, an additively manufactured body, or any combination thereof. In other examples, selecting a drill bit body may include selecting a design for the drill bit body and manufacturing the drill bit body or having a third party manufacture the drill bit body.

[0124] Method 884 may include installing a rolling cutting structure at 888. Installing the rolling cutting structure may include inserting the rolling cutting structure into a rolling cavity of the drill bit body and inserting the journal into the journal cavity of the drill bit body. Installing the rolling cutting structure may also include arranging any seals, sleeves, washers or bearings with the journal, or any combination thereof. As described above, the journal and sleeve may be selected and installed to adjust the exposure of the cutting elements of the rolling cutting structure.

[0125] The method may further include securing the rolling cutting structure to the drill bit body at 890. Securing the rolling cutting structure to the drill bit body may include securing a journal to the drill bit body. Securing the journal to the drill bit body may include securing the journal to a trailing edge of the blade. Securing the journal to the drill bit body may also include securing the journal to a support leg of the blade and a body of the blade.

[0126] Embodiments of the hybrid drill bits have been described primarily with reference to wellbore drilling operations; the hybrid drill bits described herein may be used in applications other than drilling wellbores. In other embodiments, hybrid drill bits according to the present disclosure may be used outside of a wellbore or other downhole environment used for natural resource exploration or production. For example, the hybrid drill bits of the present disclosure may be used in a borehole used to place utility pipelines. Therefore, the terms "wellbore," "borehole," and the like should not be construed to limit the tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0127] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the currently disclosed technology. In addition, in order to provide a concise description of these embodiments, all features of the actual embodiments may not be described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, many embodiment-specific decisions will be made to achieve the developer's specific goals, such as meeting system-related and business-related constraints, which may vary from embodiment to embodiment. In addition, it should be understood that such development efforts may be complex and time-consuming, but for ordinary technicians who benefit from the present disclosure, this is still a routine task of design, manufacturing and manufacturing.

[0128] The articles "one", "an" and "the" are intended to indicate that there are one or more elements in the preceding description. The terms "including", "comprising" and "having" are intended to be inclusive and mean that in addition to the listed elements, there may be additional elements. In addition, it should be understood that reference to "one embodiment" or "an embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also contain the features. For example, any element described with respect to the embodiments herein may be combined with any element of any other embodiment described herein. The numbers, percentages, ratios or other values ​​described herein are intended to include the value, as well as other values ​​of "approximately" or "approximately" the value, as understood by those of ordinary skill in the art included in the embodiments of the present disclosure. Therefore, the value should be interpreted broadly enough to include a value at least close enough to the value, so as to perform the desired function or achieve the desired result. The value includes at least the expected variation in a suitable manufacturing or production process, and may include values ​​within 5%, within 1%, within 0.1% or within 0.01% of the value.

[0129] In view of this disclosure, those of ordinary skill in the art should recognize that equivalent constructions do not depart from the spirit and scope of the disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of the disclosure. Equivalent structures, including functional "means plus function" clauses, are intended to cover structures described herein that perform the functions described, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. It is the express intent of the applicant not to invoke means plus function or other functional requirements for any claim unless the term "means for..." appears with the relevant function. Every addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims will be encompassed by the claims.

[0130] As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount that still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within less than 5%, within less than 1%, within less than 0.1%, and within less than 0.01% of a stated amount. Furthermore, it should be understood that any directions or reference frames in the foregoing description are merely relative directions or motions. For example, any references to "up" and "down," or "above" or "below," are merely descriptions of the relative positions or motions of the associated elements.

[0131] The present disclosure may be implemented in other specific forms without departing from its spirit or characteristics. The described embodiments are considered to be illustrative rather than restrictive. Changes within the equivalent meaning and range of the claims will be included within their scope.

Claims

1. A hybrid drill bit, comprising: a fixed cutting structure including a plurality of fixed cutting elements, the fixed cutting structure including a journal cavity; a first rolling groove in the fixed cutting structure, the first rolling groove having a plurality of sleeves disposed on either side of the first rolling groove such that a portion of each of the plurality of sleeves abuts against an inner surface of the first rolling groove, and wherein each of the plurality of sleeves partially extends into the journal cavity; A rolling cutting structure coupled to the first rolling groove of the fixed cutting structure such that the plurality of sleeves are configured to support the rolling cutting structure, the rolling cutting structure comprising: a journal hole extending through the rolling cut structure; radial outer surface; and A plurality of cutting elements extend from a radially outer surface of the rolling cutting structure.

2. The hybrid drill bit according to claim 1 further includes a blade, the blade including a leading edge and a trailing edge, and wherein the first rolling groove is located between the leading edge and the trailing edge, the fixed cutting structure is located on the leading edge, the rolling cutting structure is located on the trailing edge, and wherein the rolling cutting structure is inserted into the first rolling groove, the trailing edge includes a support leg, and the rolling cutting structure is supported by the leading edge and the support leg.

3. The hybrid drill bit according to claim 2, wherein: The leading edge of the blade includes an upper blade portion of the fixed cutting structure having a first set of fixed cutting elements of the plurality of fixed cutting elements, and the supporting leg of the trailing edge includes a lower blade portion of the fixed cutting structure having a second set of fixed cutting elements of the plurality of fixed cutting elements.

4. The hybrid drill bit according to claim 1, wherein: The fixed cutting structure includes a first blade and a second blade, the first blade is between a first leading edge and a first trailing edge, the second blade has a second rolling groove between a second leading edge and a second trailing edge, and the rolling cutting structure includes a first rolling cutting structure arranged in the first rolling groove and a second rolling cutting structure arranged in the second rolling groove, wherein the first rolling groove and the second rolling groove lead to a central cavity of the hybrid drill bit.

5. The hybrid drill bit of claim 1 further comprising a first set of blades and a second set of blades, the first set of blades comprising a rolling cutting structure, the second set of blades comprising a fixed cutting structure, and the secondary blades of the second set of blades being located on either side of each first blade of the first set of blades.

6. The hybrid drill bit of claim 1 , wherein the rolling cutting structure is configured to rotate about the journal shaft axis, a reference line perpendicular to the drill bit rotation axis extends the roller offset from the drill bit rotation axis to the journal shaft axis, a reference circle is centered on the drill bit rotation axis with a radius equal to the roller offset, a tangent line is tangent to the reference circle at the journal shaft axis, and a journal shaft orientation angle between the journal shaft axis and the tangent line is 45° or less.

7. The hybrid drill bit of claim 1, wherein the rolling cutting structure includes a roller offset greater than or equal to 20% of the drill bit diameter.

8. The hybrid drill bit of claim 1, further comprising a central fluid port located substantially in the center of the hybrid drill bit.

9. The hybrid drill bit of claim 1, wherein the plurality of cutting elements are attached to the rolling cutting structure such that a cutting element axis is substantially perpendicular to a journal shaft axis of the rolling cutting structure.

10. The hybrid drill bit of claim 1, wherein the plurality of cutting elements are attached at an angle of 17° between a cutting element axis and a plane normal to the drill bit axis.

11. The hybrid drill bit of claim 1, further comprising a journal angle of the rolling cutting structure that is within 5° of 17° of the rotational axis of the hybrid drill bit.

12. The hybrid drill bit of claim 1, wherein an outermost periphery of the plurality of cutting elements rotates to within 0.25 inches of the drill bit's axis of rotation.

13. The hybrid drill bit of claim 1, wherein an outermost periphery of the plurality of cutting elements rotates beyond the drill bit rotation axis.

14. The hybrid drill bit of claim 1, the plurality of cutting elements being located on a leading edge of a straight line that is perpendicular to the bit rotation axis and perpendicular to the journal shaft axis at a bottommost rotation of the rolling cutting structure.

15. A drill bit comprising: a fixed cutting structure comprising a plurality of fixed cutting elements and a journal cavity disposed in the fixed cutting structure, wherein the fixed cutting structure comprises a first blade having a first rolling groove between a first leading edge and a first trailing edge, and a second blade having a second rolling groove between a second leading edge and a second trailing edge, wherein the first rolling groove and the second rolling groove lead to a central cavity of the drill bit including a central fluid port; wherein each of the first rolling groove and the second rolling groove has a plurality of sleeves disposed on either side of the first rolling groove and the second rolling groove such that a portion of each of the plurality of sleeves abuts against an inner surface of each of the first rolling groove and the second rolling groove, and wherein each of the plurality of sleeves partially extends into the journal cavity, and A rolling cutting structure comprising a plurality of cutting elements, the rolling cutting structure comprising a first rolling cutting structure arranged in a first rolling groove so that a portion of a plurality of sleeves is configured to support the first rolling structure, and a second rolling cutting structure arranged in a second rolling groove so that another portion of the plurality of sleeves is configured to support the second rolling structure, wherein each of the rolling cutting structures is wheel-shaped having a journal hole extending through the corresponding rolling cutting structure, and the plurality of cutting elements are located on a radial outer surface of each of the rolling cutting structures.

16. The drill bit of claim 15, wherein the rolling cutting structure has an adjustable height.

17. The drill bit of claim 15, wherein the plurality of cutting elements includes a first row of cutting elements and a second row of cutting elements on a first rolling cutting structure, and the plurality of cutting elements includes a third row of cutting elements and a fourth row of cutting elements on a second rolling cutting structure.

18. A method of forming a hybrid drill bit, comprising: Select a drill bit body, wherein the drill bit body comprises: A plurality of blades, wherein the plurality of blades comprises: a first fixed cutting structure including a first journal cavity and having a first fixed cutting element disposed on a first leading edge of the first fixed cutting structure; a first rolling groove between the leading edge and the trailing edge of the first fixed cutting structure; a second fixed cutting structure having a second journal cavity and including a second fixed cutting element disposed on a second leading edge of the second leading cutting structure; a second rolling groove between the second leading edge and the second trailing edge of the second fixed cutting structure; a central cavity of the drill bit body leading to the first rolling groove and the second rolling groove, the central cavity including a central fluid nozzle; a first rolling cutting structure comprising a plurality of first cutting elements extending in a first radial direction from a first outer surface of the first rolling cutting structure, wherein the first rolling cutting structure is wheel-shaped; a second rolling cutting structure comprising a plurality of second cutting elements extending in a second radial direction from a second outer surface of the second rolling cutting structure, wherein the second rolling cutting structure is wheel-shaped; Installing the first rolling cutting structure in the first rolling groove comprises: disposing a plurality of first sleeves between the first rolling cutting structure and the first fixed cutting structure in the first rolling groove, such that the plurality of first sleeves are positioned on either side of the first rolling groove, and a portion of the plurality of first sleeves abuts an inner surface of the first rolling groove, and wherein the plurality of first sleeves partially extend into the first journal cavity; and inserting a first journal through a plurality of first sleeves, a first rolling cutting structure, and the first rolling groove; The second rolling cutting structure is installed in the second rolling groove, comprising: inserting a second journal through the plurality of second sleeves, the second journal cavity, the second rolling cutter structure, and the second rolling groove; disposing a plurality of second sleeves between the second rolling cutting structure and the second fixed cutting structure in the second rolling groove, such that the plurality of second sleeves are positioned on either side of the second rolling groove and a portion of the plurality of second sleeves abuts against an inner surface of the second rolling groove, and wherein the plurality of second sleeves partially extend into the second journal cavity; and A first rolling cutting structure and a second rolling cutting structure are secured to the drill bit body.

19. The method according to claim 18, wherein: Installing the first rolling cutting structure in the first rolling groove includes selecting the first plurality of sleeves to adjust exposure of the first plurality of cutting elements of the first rolling cutting structure.

20. The method according to claim 18, wherein: The first journal includes a first reservoir configured to supply a first lubricant to the first rolling cutting structure, and the second journal includes a second reservoir configured to supply a second lubricant to the second rolling cutting structure.

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