Earth-boring tool geometry and cutter placement and associated apparatus and methods

Abstract

A drill tool can include at least one blade including a shoulder region and a face. A plurality of cutting elements can be disposed on the face of the blade, and at least one cutting element can be positioned in the shoulder region such that a cutting face of the at least one cutting element is spaced a distance behind the face of the blade. A recessed portion of the blade can extend below at least one cutting element of the plurality of cutting elements disposed on the face of the blade and to the at least one cutting element positioned in the shoulder region.

Description

[0001] Priority Statement

[0002] This application claims the benefit of U.S. Patent Application Serial No. 17 / 071,844, entitled "Earth-Boring Tool Geometry and Cutter Placement and Associated Apparatus and Methods", filed on October 15, 2020. Technical Field

[0003] The embodiments of this disclosure generally relate to drilling operations. Specifically, the embodiments of this disclosure relate to the geometry of drilling tools and the arrangement of cutting tools, as well as associated equipment and methods. Background Technology

[0004] Well drilling operations may involve the use of drilling tools at the ends of a long tubing string, commonly referred to as a drill string. Drilling tools can be used to drill through formations such as rock, soil, sand, tar, etc. In some cases, drilling tools may be constructed to drill through additional elements that may be present in the wellbore, such as cement, casing (e.g., well casing), discarded or broken equipment (e.g., fallen fish, fallen objects, etc.), packers, etc. In some cases, drilling tools may be constructed as drill-through plugs (e.g., fracturing plugs, bridge plugs, cement plugs, etc.). In some cases, the plug may include slips or other types of anchoring elements, and drilling tools may be constructed as drill-through plugs as well as any slips, anchoring elements, and other components.

[0005] Drilling tools may include a cutting structure formed from abrasives with high hardness. The cutting structure can be configured to engage the formation and additional components to remove material from them. When the cutting structure engages the formation and additional components, debris (e.g., fragments, chips, loose material, etc.) generates a significant amount of heat. If this debris and heat are not dissipated, they can cause premature failure of the cutting structure, necessitating disassembly of the drilling tool for repair and / or replacement. This can result in substantial time losses, reducing efficiency and increasing the cost of drilling operations. Summary of the Invention

[0006] Embodiments of this disclosure may include a drilling tool. The drilling tool may include at least one cutting blade, the at least one cutting blade including a shoulder region and a face. The drilling tool may further include a plurality of cutting elements disposed on the face of the cutting blade. The drilling tool may also include at least one cutting element positioned in the shoulder region such that the cutting faces of the at least one cutting element are spaced apart behind the face of the cutting blade by a distance. The drilling tool may further include a recessed portion of the cutting blade extending below at least one of the plurality of cutting elements disposed on the face of the cutting blade and extending to the at least one cutting element positioned in the shoulder region.

[0007] Another embodiment of this disclosure may include a drilling tool. The drilling tool may include at least two blades extending from the body of the drilling tool. The drilling tool may further include a chip removal groove located between the at least two blades. The drilling tool may also include one or more tool recesses formed in the faces of the at least two blades. The drilling tool may further include at least one tool recess formed in a shoulder portion of at least one of the at least two blades, the at least one tool recess being spaced from the face of the at least one blade. The drilling tool may also include a recess connecting the at least one tool recess formed in the shoulder portion of the at least one blade to the chip removal groove. The recess may extend below an outer tool recess among the one or more tool recesses formed in the faces of the at least two blades.

[0008] Another embodiment of this disclosure may include a method of forming a drilling tool. The method may include forming a tool body comprising one or more cutting blades and a tool recess defined in the surface of the one or more cutting blades. The tool recess may be defined in at least one face of the one or more cutting blades and in a shoulder region of the one or more cutting blades spaced apart from the face of the one or more cutting blades. The method may further include forming a chip removal groove in a region of the tool body adjacent to the face of the one or more cutting blades. The method may further include forming a nozzle within the chip removal groove, the nozzle being configured to supply fluid into the chip removal groove. The method may further include forming a recess extending at an angle from the face of the one or more cutting blades to at least one tool recess defined in the tool recess in the shoulder region of the one or more cutting blades. The recess may be located below at least one tool recess defined in the tool recess in the face of the one or more cutting blades. Attached Figure Description

[0009] Although the specification is appended with claims that specifically point out and clearly claim protection for embodiments of the present disclosure, the various advantages of the embodiments of the present disclosure can be readily identified from the following description of certain embodiments when read in conjunction with the accompanying drawings, wherein:

[0010] Figure 1A perspective view of a drilling tool according to one embodiment of the present disclosure is shown;

[0011] Figure 2 An embodiment according to this disclosure is shown. Figure 1 Hydraulic flow diagram of drilling tools;

[0012] Figure 3 A perspective view of a drilling tool according to one embodiment of the present disclosure is shown;

[0013] Figure 4 An embodiment according to this disclosure is shown. Figure 3 A magnified view of the shoulder area of ​​the drilling tool;

[0014] Figure 5 An embodiment according to this disclosure is shown. Figure 4 A magnified view of the shoulder area of ​​the drilling tool;

[0015] Figure 6 An embodiment according to this disclosure is shown. Figures 4 to 7 A top view of the drilling tool shown in the image; and

[0016] Figure 7 An embodiment according to this disclosure is shown. Figures 3 to 7 The diagram shows the hydraulic flow chart of the drilling tool. Detailed Implementation

[0017] The illustrations presented herein are not intended to be actual views of any particular drilling tool or its components, but are merely idealized representations used to describe exemplary embodiments. The figures are not necessarily drawn to scale.

[0018] As used herein, the term "drilling tool" means and includes any type of drill bit or tool used for drilling during the formation or enlargement of a wellbore in underground formations. For example, drilling tools include fixed-cutting-edge drill bits, roller cone drill bits, percussion drill bits, core drill bits, eccentric drill bits, bicentric drill bits, reamers, milling drills, scraper drill bits, hybrid drill bits (e.g., rolling elements combined with fixed cutting elements), and other drill bits and tools known in the art.

[0019] As used herein, the term “substantially” with reference to the meaning of a given parameter means and includes satisfying a given parameter, characteristic, or condition to the extent that a person skilled in the art would understand, while with minimal deviation, such as within acceptable manufacturing tolerances. For example, a parameter substantially satisfied could be satisfied by at least about 90%, at least about 95%, at least about 99%, or even at least about 100%.

[0020] As used herein, relational terms such as “first,” “second,” “top,” “bottom,” etc., are generally used for clarity and convenience in understanding this disclosure and the accompanying drawings, and do not imply or depend on any particular preference, orientation, or order unless the context clearly indicates otherwise.

[0021] As used herein, terms such as front and rear are used with reference to the direction of movement of the relevant elements. For example, when the drill string moves into the borehole, the bottom of the borehole is in front of the drill string elements, and the surface is behind the drill string elements. In another example, regarding the cutting elements on a rotary drilling tool, a portion of the formation not yet contacted by the cutting element is in front of the cutting element, while a portion of the formation already contacted by the cutting element is behind the cutting element.

[0022] As used herein, the term “and / or” means and includes any and all combinations of one or more associated listed items.

[0023] As used in this article, the terms "vertical" and "horizontal" refer to the orientation shown in the figure.

[0024] Drilling tools may include cutting structures, such as cutting elements or cutters, formed from abrasives with high hardness properties. The cutting structure may be configured to engage formations and additional elements to remove material from them. As the cutting structure engages formations and additional elements, debris (e.g., fragments, chips, loose material, etc.), it wears out and must eventually be replaced. Replacing the cutting structure may require removing the drilling tool from the associated wellbore. Increasing the number of cutting structures in the area of ​​the drilling tool reduces the load on each cutting structure, thereby increasing the amount of time before the cutting structure must be replaced. Fluids may flow through the cutting structure to remove debris and cool it, further increasing its cutting life.

[0025] Figure 1 An embodiment of a drilling tool 100 is shown. The drilling tool 100 may include one or more cutting blades 102 arranged around the body of the drilling tool 100. Figure 1 As shown, the drilling tool 100 may be a hybrid drill bit including blades 102 and roller cones 104. In some embodiments, the drilling tool 100 may include only roller cones 104, such as a roller cone bit, or the drilling tool 100 may include only blades 102, such as a scraper bit. Blades 102 and / or roller cones 104 may be separated by a chip flush 106. The chip flush 106 may include a nozzle 108. The nozzle 108 may be configured to supply (e.g., discharge) fluids such as water, drilling mud, etc., into the chip flush 106.

[0026] The insert 102 may include a face 110 and a shoulder region 112. The face 110 may be oriented to face the front of the insert 102, and the shoulder region 112 may be a radially outer region of the insert 102 in the transition portion between the nose region 114 and the gauge region 116 of the insert 102. The insert 102 may include a plurality of tool recesses 118 formed along the edge of the face 110 of the insert 102. The tool recesses 118 may be configured to receive a cutting element, such as a polycrystalline diamond composite (PDC) cutting element. The cutting element may be arranged such that the cutting face of the cutting element is in substantially the same plane as the face 110 of the insert 102. Fluid flowing from the nozzle 108 may be configured to remove debris and formation material from the cutting element and the face 110 of the insert 102 while cooling the cutting element. The shoulder region 112 of at least some of the inserts 102 may include a shoulder tool recess 120. The shoulder tool recess 120 may also be configured to receive a cutting element. In some cases, the cutting element can be arranged such that the cutting surface of the cutting element and the surface 110 of the insert 102 are in substantially the same plane.

[0027] One or more blades in the insert 102 may include a recessed shoulder tool recess 122. The recessed shoulder tool recess 122 may be defined in the outer surface of the shoulder region 112, spaced apart behind the face 110 of the insert 102. The recessed shoulder tool recess 122 may be configured to receive a cutting element. Due to the distance between the face 110 of the insert 102 and the recessed shoulder tool recess 122, the cutting surfaces of the cutting elements disposed in the recessed shoulder tool recess 122 may be spaced apart behind the face 110 of the insert 102. A recess 124 may be formed on the surface of the insert 102 in the shoulder region 112 in front of the recessed shoulder tool recess 122, such that the cutting surfaces of the cutting elements disposed in the recessed shoulder tool recess 122 can engage the substrate. The recess 124 may be defined by a recessed tool wall 126, a shelf 128, and a recessed surface 130. The recess 124 can be recessed by a distance at least equal to the diameter of the cutting surface of the cutting element disposed in the recessed shoulder tool recess 122. For example, the distance between the outer surface 132 of the shoulder region 112 of the insert 102 and the recessed surface 130 can be between about 0.090 inches (in) (2.286 mm) and about 1 inch (25.4 mm), such as between about 0.25 inches (6.35 mm) and about 0.75 inches (19.05 mm), or about 0.5 inches (12.7 mm).

[0028] A recessed shoulder tool recess 122 may be arranged on a recessed tool wall 126. The recessed tool wall 126 may extend at an angle relative to the face 110 of the insert 102. Arranging the recessed shoulder tool recess 122 at an angle relative to the face 110 of the insert 102 on the recessed tool wall 126 allows more cutting elements and / or cutting surface areas to be positioned in the same area of ​​the insert 102. For example, as... Figure 1 As shown, a cutting insert 102 with a standard shoulder tool recess 120 may have two shoulder tool recesses 120, while a cutting insert 102 with recessed shoulder tool recesses 122 may have three recessed shoulder tool recesses 122 in the same area of ​​the cutting plane. Having more cutting elements reduces the amount of material removed by each cutting element, thereby increasing the life of the cutting elements. In some cases, having more cutting elements in the shoulder region 112 can generate more lateral cutting forces, which can improve control of the drilling tool 100, such as maneuverability and responsiveness to different formation materials.

[0029] The shelf 128 may extend from the face 110 in a substantially perpendicular direction. A recessed tool wall 126 may intersect the shelf 128 at a distance from the face 110 of the blade 102. The recessed tool wall 126 may extend from the shelf 128 at an angle relative to both the shelf 128 and the face 110 of the blade 102. For example, the face 110 of the blade 102 may lie in a plane substantially aligned along the y-direction, as defined in coordinate system 134. Coordinate system 134 may be defined such that the y-direction is substantially aligned with the central axis of the drilling tool 100, the x-direction is along the direction of rotation of the drilling tool 100, and the z-direction is a radial direction extending away from the central axis of the drilling tool 100. The shelf 128 may extend from the face 110 along the x-direction. The recessed tool wall 126 can extend from the shelf 128 at an angle between the x and y directions, such that the recessed tool wall 126 extends at an angle of less than about 90° with the y direction and less than about 90° with the x direction. The angle formed between the recessed tool wall 126 and the shelf 128 can be between about 90° and about 180°, such as between about 90° and about 135°, or between about 110° and about 130°.

[0030] Figure 2 It shows Figure 1 Flowchart 200 of the drilling tool 100. Flowchart 200 shows the flow of fluid from nozzle 108 to chip discharge groove 106. Figure 2As shown, the fluid velocity can be highest at nozzle 108, and this velocity can dissipate as the fluid flows through the chip removal groove 106. In the higher velocity region, the fluid can remove debris around the components of the drilling tool 100, thereby essentially preventing premature wear due to debris accumulation. The higher fluid velocity can also dissipate heat from the components of the drilling tool 100, thereby essentially preventing premature wear and / or failure due to overheating.

[0031] like Figure 2 As shown, the fluid velocity can be substantially low in the recessed portion 124 of the shoulder region 112 of the cutting tool 102. For example, the recessed portion 124 can cause fluid flow stagnation, such that when fluid enters the recessed portion 124, it may not circulate and may not leave the recessed portion 124. Therefore, fluid may be trapped or stagnant in the recessed portion 124. Low fluid velocity and / or stagnant fluid can lead to debris buildup and / or overheating of the cutting element in the recessed shoulder tool recess 122. Debris buildup can reduce the efficiency of the cutting element, resulting in less material removal and higher cutting element temperatures. Overheating may cause the cutting element to wear faster and / or experience damage such as cracking, spalling, abrasion, etc. When the cutting element wears or is damaged, the drilling tool 100 can be pulled out of the wellbore to repair the drilling tool 100 and / or replace the worn or damaged cutting element. Pulling out of the drilling tool 100 may take several days to complete, resulting in a loss of time and productivity, as well as the drilling operation cost of pulling out the drilling tool 100 over several days.

[0032] Figure 3 One embodiment of a drilling tool 300 is shown. Although the drilling tool 300 is shown as a hybrid drill bit comprising a plurality of inserts 302 and roller cones 304, it should be noted that the tool arrangement and design discussed herein can be incorporated into any drilling tool, including fixed tools mounted to inserts, such as fixed tool drills, eccentric drills, dual-center drills, reamers, end mills, scraper drills, hybrid drills, and other drills and tools known in the art.

[0033] The cutting inserts 302 may define chip removal channels 306 located between the cutting inserts 302. Chip removal channels 306 may include nozzles 308 configured to supply fluids such as water, drilling mud, etc., into the chip removal channels 306 to remove chips and debris from the cutting inserts 302 and dissipate heat from the cutting inserts 302 and their components. The cutting inserts 302 may include a face 310, a shoulder region 312, and a plurality of tool recesses 314 formed thereon. A plurality of tool recesses 314 may be formed on the cutting inserts 302 such that cutting elements fixed in the tool recesses 314 are positioned such that the cutting face of the cutting element is substantially coplanar with the face 310 of the respective cutting insert 302 (e.g., located in substantially the same plane). Some tool recesses 314 may be located on the shoulder region 312. For example, the shoulder region 312 may include a plurality of shoulder tool recesses 316, which are positioned such that the cutting surface of the cutting element attached to the shoulder tool recess 316 is substantially coplanar with the surface 310 of the corresponding insert 302.

[0034] Some inserts 302 may include recessed shoulder tool recesses 318, positioned such that the cutting faces of the cutting elements attached thereto are spaced apart by a distance behind the face 310 of the respective insert 302. The recessed shoulder tool recesses 318 may be arranged such that they are linearly related to the face 310 of the insert 302 at an angle 326. A coordinate system 328 may be defined such that the y-direction is substantially aligned with the central axis of the drilling tool 100, the x-direction is along the direction of rotation of the drilling tool 100, and the z-direction is a radial direction extending away from the central axis of the drilling tool 100. The angle 326 between the linear relationship between the recessed shoulder tool recesses 318 and the face 310 of the insert 302 may extend between the x and y directions. As described above, the angled arrangement of the recessed shoulder tool recesses 318 allows a large number of cutting elements to be arranged within the same surface area of ​​the insert 302. The angle 326 between the linear relationship between the recessed shoulder tool recess 318 and the face 310 of the blade 302 can be between about 20 degrees and about 45 degrees, such as between about 40 degrees and about 30 degrees, or about 33 degrees.

[0035] The insert 302, including the recessed shoulder tool recess 318, may include a recess 320 passing between the face 310 of the insert 302 and the shoulder region 312 of the insert 302. This recess is configured to provide a flow path for fluid from the chip removal groove 306 to the recessed shoulder tool recess 318 by connecting the chip removal groove 306 to the recessed shoulder tool recess 318. The recess 320 may extend below at least one external tool recess 322 on the insert 302, such that a portion of the insert 302 supporting the external tool recess 322 forms a flange 324 extending above the recess 320.

[0036] Figure 4 An enlarged view of the recessed shoulder tool recess 318 on the insert 302 is shown. In some embodiments, the recess 320 may include a substantially planar (e.g., straight, flat, etc.) surface that extends at an angle relative to the face 310 of the insert 302. For example, a transition region 402 between the recess 320 and the face 310 of the insert 302 may form an angle. The recess 320 may maintain this angle until the surface of the recess 320 reaches the shoulder region 312 adjacent to the recessed shoulder tool recess 318. In some embodiments, the transition region 402 may be a hard angle (e.g., a linear edge). In other embodiments, the transition region 402 may be a gradual transition, such as a bevel, a rounded edge, a chamfered edge, etc. In some embodiments, the recess 320 may be curved such that the recess 320 is substantially coplanar with the surface 310 at the transition region 402 and is substantially perpendicular to the surface 310 in the region near the recessed shoulder tool recess 318.

[0037] In some embodiments, the transition region 402 between the face 310 of the blade 302 and the recess 320 may extend at an angle downward from the transition region 406 between the recess 320 and the flange 324 to the shoulder region 312 of the drilling tool 300. For example, the shoulder region 312, the transition region 402 between the recess 320 and the face 310 of the blade 302, and the transition region 406 between the recess 320 and the flange 324 may define a substantially triangular surface.

[0038] The flange 324 may extend above the recess 320, such that the outer tool recess 322 supported by the flange 324 may be positioned above the recess 320. The outer tool recess 322 may be configured to position a cutting element such that the cutting path (e.g., the path of the cutting face of the cutting element) is close to the cutting path of the cutting element positioned in the first recessed shoulder tool recess 318a. The bottom surface 404 of the flange 324 may be substantially aligned with the top portion of the second recessed shoulder tool recess 318b.

[0039] In some embodiments, the recess 320 may extend in the plane of the first recessed shoulder tool recess 318a, allowing the recess 320 to provide a larger area, thereby enabling more fluid to flow into the recessed shoulder tool recess 318, since the first recessed shoulder tool recess 318a is the most recessed of the shoulder tool recesses 318. In other embodiments, the recess 320 may extend in the plane of the second recessed shoulder tool recess 318b or the third recessed shoulder tool recess 418c. For example, to ensure that the thickness of the flange 324 is sufficient to support the outer tool recess 322, the recess 320 may be positioned in the plane of the second recessed shoulder tool recess 318b or the third recessed shoulder tool recess 318c, which may be positioned at a vertical position lower than the first recessed shoulder tool recess 318a.

[0040] The flange 324 may have a thickness (e.g., the distance between the outer tool recess 322 and the bottom surface 404 of the flange 324) sufficient to support the cutting element mounted in the outer tool recess 322 under the loads present during drilling. For example, the flange 324 may have a thickness greater than about 0.25 inches (6.35 mm), such as between about 0.25 inches (6.35 mm) and about 0.5 inches (12.7 mm) or between about 0.25 inches (6.35 mm) and about 0.4 inches (10.16 mm). In some embodiments, the structure of the flange 324 may provide further support. For example, the transition region 406 between the bottom surface 404 of the flange 324 and the recess 320 may include a bevel or curved surface configured to reinforce the flange 324. In some embodiments, the bottom surface 404 of the flange 324 may extend at an angle relative to the recess 320, such that the flange 324 has a greater thickness at the transition region 406 than at the outer surface 408 of the flange 324. In some embodiments, the flange 324 may include additional structures, such as gussets, ridges, etc., extending from the recess 320 to the bottom surface 404 of the flange 324 to provide additional support to the flange 324.

[0041] The outer surface 408 of the flange 324 may be recessed from the shoulder region 312 of the insert 302 by a distance substantially equal to or greater than the diameter of the cutting surface of the cutting element fixed in the first recessed shoulder tool recess 318a. For example, the outer surface 408 of the flange 324 may be recessed between about 0.090 inches (2.286 mm) and about 1 inch (25.4 mm), such as between about 0.25 inches (6.35 mm) and about 0.75 inches (19.05 mm), or about 0.5 inches (12.7 mm).

[0042] As described above, the recessed shoulder tool recesses 318a, 318b, and 318c are recessed a certain distance from the surface 310 of the insert 302 and are linearly arranged at an angle relative to the surface 310 of the insert 302. Therefore, the distance between the first recessed shoulder tool recess 318a and the surface 310 can be greater than the distance between the third recessed shoulder tool recess 318c and the surface 310. Therefore, the cutting element fixed in the third recessed shoulder tool recess 318 can define a minimum distance between the associated cutting surface and the surface 310. The distance between the cutting surface of the cutting element fixed in the third recessed shoulder tool recess 318 and the surface 310 of the insert 302 can be substantially equal to or greater than the depth of the tool recess 314 in the insert 302. For example, the distance between the cutting face and the face 310 of the insert 302 can be greater than about 0.125 inches (3.175 mm), such as between about 0.125 inches (3.175 mm) and about 2.80 inches (71.12 mm).

[0043] In some embodiments, the recessed shoulder tool recess 318 may be configured to position a cutting element therein such that the cutting face is angled relative to the cutting plane (e.g., having a backslope or sideslope angle). For example, the cutting element may be positioned such that the cutting face is angled relative to a vertical plane (e.g., relative to the longitudinal axis of the drilling tool 100), commonly referred to in the art as a backslope angle. The recessed shoulder tool recess 318 is capable of positioning the associated cutting element with a backslope angle between about 0° and about 50°, such as between about 15° and about 45°. In some embodiments, the cutting element may be positioned such that the cutting face is angled relative to a radial plane (e.g., relative to a radial line extending along the insert 302), commonly referred to in the art as a sideslope angle. In some embodiments, the recessed shoulder tool recess 318 is capable of positioning the associated cutting element with a sideslope angle between about -20° and about 20°, such as between about -10° and about 10°.

[0044] In some embodiments, portions of the drilling tool 300 may include wear-resistant weld overlays. Wear-resistant weld overlays may include a high-hardness or wear-resistant coating or treatment on the surface of the drilling tool 300. For example, surfaces most likely to come into contact with the formation or cuttings from the formation may include wear-resistant weld overlay materials to reduce wear on the corresponding surfaces of the drilling tool 300. Surfaces that may include wear-resistant weld overlays may include the surface of the recess 320 and / or the surface of the blade 302, such as face 310 and shoulder region 312.

[0045] In some embodiments, the recess 320 may have a substantially smooth surface (e.g., a surface without ridges, valleys, protrusions, etc.). A substantially smooth surface allows for increased fluid flow into the recess 320 and over the cutting element fixed in the recessed shoulder tool recess 318.

[0046] In some embodiments, the recess 320 may be formed in the same process as forming the drilling tool 300, such as a molding or forging process. For example, the mold or model used to form the drilling tool 300 may include features corresponding to the recess 320. In some embodiments, the recess 320 may be cut into the cutting tool 302 after the drilling tool 300 has been formed, such as by a machining process.

[0047] Figure 5 An enlarged view of an embodiment of the shoulder region 312 of the cutting edge 302 of a drilling tool 300 is shown. In some embodiments, the recess 320 may include multiple peaks 502 and valleys 504. Peaks 502 and valleys 504 may cause the surface of the recess 320 to be uneven. Peaks 502 and / or valleys 504 may disrupt the flow path of fluid, thereby generating turbulence in the fluid flow. Turbulence may increase the velocity of at least some of the fluid. Therefore, peaks 502 and valleys 504 may increase the fluid flow velocity in the recess 320, which may result in the fluid flow cleaning and / or cooling more efficiently the cutting element attached to the recessed shoulder tool recess 318. Therefore, forming a recess 320 including one or more peaks 502 and / or valleys 504 may improve the cleaning and / or cooling efficiency of the fluid flowing into the recess 320.

[0048] In some embodiments, the recesses 320 may be formed in the same process as forming the drilling tool 300, such as molding or forging. For example, the mold or model used to form the drilling tool 300 may include features corresponding to the recesses 320, including features corresponding to the respective peaks 502 and valleys 504. In some embodiments, the recesses 320 may be cut into the cutting tool 302 after the drilling tool 300 has been formed, such as by machining. For example, a cut-in drilling operation may be used to form the peaks 502 and valleys 504. A cut-in drilling operation may include a plurality of adjacent boreholes, wherein the peaks correspond to the material between the boreholes, and the valleys 504 correspond to the area of ​​the recesses 320 located at the center point of each borehole along a plane parallel to the plane of the recesses 320.

[0049] Figure 6An enlarged top view of a portion of the drilling tool 300 is shown. The face 310 of the blade 302 may be substantially straight, such that face 310 may lie substantially within a radial plane 602. The radial plane 602 may extend along a substantially straight line through the longitudinal axis 604 of the drilling tool 300. The recess 320 may lie substantially within a plane corresponding to a recessed line 606 extending from the radial plane 602 at an angle 608. The transition region 406 between the flange 324 and the recess 320 may substantially follow the recessed line 606. The angle 608 may be between about 10° and about 60°, such as between about 30° and about 50°, or about 43°.

[0050] The recessed line 606 may intersect the radial plane 602 at the intersection 610 between the longitudinal axis 604 of the drilling tool 300 and the shoulder region 312 of the blade 302. The intersection 610 may correspond to the point where the transition region 402 between the recess 320 and the face 310 of the blade 302 intersects with the transition region 406 between the flange 324 and the recess 320. The intersection 610 may be a point along the radial plane 602 that lies more than halfway between the longitudinal axis 604 and the shoulder region 312, such as between approximately five-eighths and seven-eighths of the distance between the longitudinal axis 604 and the shoulder region 312, or approximately three-quarters of the distance between the longitudinal axis 604 and the shoulder region 312. For example, if the shoulder region 312 of the blade 302 is 6.125 inches (155.575 mm) from the longitudinal axis 604, then the intersection 610 can be located between approximately 3 inches (76.2 mm) and approximately 5.5 inches (139.7 mm) from the longitudinal axis 604, such as between approximately 4 inches (101.6 mm) and approximately 5 inches (127 mm), or approximately 4.5 inches (114.3 mm).

[0051] Figure 7 It shows Figures 4 to 7 Flowchart 700 of the drilling tool 300. Flowchart 700 shows the flow of fluid from nozzle 308 to chip discharge groove 306. Figure 3 As shown, the fluid velocity can be highest at nozzle 308, and this velocity can dissipate as the fluid flows through the chip removal groove 306. In the higher velocity region, the fluid can remove debris around the components of the drilling tool 300, thereby essentially preventing premature wear due to debris accumulation. The higher fluid velocity can also dissipate heat from the components of the drilling tool 300, thereby essentially preventing premature wear and / or failure due to overheating.

[0052] When compared with flowchart 200 ( Figure 2 In contrast, the shape of the recess 320 allows the fluid flow to maintain a higher velocity. For example... Figure 7As shown, the fluid flow maintains a relatively high velocity upon entering the recess 320 and circulates within the recess 320 before exiting through the chip removal groove 306. This relatively high velocity provides improved cleaning and cooling for the cutting elements fixed to the recessed shoulder tool recess 318.

[0053] The embodiments of this disclosure can achieve higher flow rates and / or velocities in the shoulder region of a drilling tool with a recessed shoulder cutter. Increased flow rates and velocities improve the cleaning and / or cooling of the recessed shoulder cutter. Improved cleaning and / or cooling extends the life of the recessed shoulder cutter. Increasing the life of the cutting elements on the drilling tool extends the amount of time the drilling tool can be used before the drilling assembly must be pulled from the borehole for repair or replacement. Many drilling operations cost millions of dollars per day. Pulling the drilling assembly out can result in the loss of several days of production, costing millions of dollars. Furthermore, the loss of several days further delays the time it takes for the wellbore to mature and become a highly productive and profitable well. Therefore, extending the trip-out interval can increase the profitability of the associated wellbore.

[0054] Non-limiting embodiments of this disclosure may include:

[0055] Implementation Scheme 1: A drilling tool comprising: at least one blade including a shoulder region and a face; a plurality of cutting elements arranged on the face of the blade; at least one recessed shoulder cutting element positioned in the shoulder region such that the cutting faces of the at least one recessed shoulder cutting element are spaced apart at a distance behind the face of the blade; a recessed portion of the blade extending below at least one of the plurality of cutting elements arranged on the face of the blade and extending to the at least one recessed shoulder cutting element.

[0056] Implementation Scheme 2: The drilling tool according to Implementation Scheme 1 further includes a nozzle configured to discharge fluid close to the blade.

[0057] Implementation Scheme 3: The drilling tool according to Implementation Scheme 2, wherein the recessed portion is configured to guide fluid to at least one recessed shoulder cutting element.

[0058] Implementation Scheme 4: The drilling tool according to any one of Implementation Schemes 1 to 3, wherein the recessed portion includes a triangular surface.

[0059] Implementation Scheme 5: The drilling tool according to any one of Implementation Schemes 1 to 4, the drilling tool further includes a transition region located between the face of the blade and the recessed portion.

[0060] Implementation Scheme 6: The drilling tool according to Implementation Scheme 5, wherein the transition area includes rounded edges.

[0061] Implementation Scheme 7: A drilling tool according to any one of Implementation Schemes 1 to 6, wherein the recessed portion extends at an angle from the face of the blade to the shoulder region of the blade.

[0062] Implementation Scheme 8: The drilling tool according to Implementation Scheme 7, wherein the angle is between about 10° and about 60°.

[0063] Implementation Scheme 9: A drilling tool according to any one of Implementation Schemes 1 to 8, wherein the recessed portion includes a curved surface.

[0064] Implementation Scheme 10: A drilling tool comprising: at least two blades extending from a body of the drilling tool; a chip removal groove located between the at least two blades; one or more tool recesses formed in the faces of the at least two blades; at least one shoulder tool recess formed in a shoulder portion of at least one of the at least two blades, the at least one shoulder tool recess being at a distance from the face of at least one of the at least two blades; and a recess connecting the at least one shoulder tool recess to the chip removal groove, wherein the recess extends below an outer tool recess in one or more tool recesses formed in the faces of the at least two blades.

[0065] Implementation Scheme 11: The drilling tool according to Implementation Scheme 10, wherein the recess extends from a point in the face of at least one of the at least two blades for at least half the distance from the longitudinal axis of the drilling tool to the shoulder portion of at least one of the at least two blades.

[0066] Implementation Scheme 12: The drilling tool according to Implementation Scheme 10 or 11, wherein the recess includes a smooth surface.

[0067] Implementation Scheme 13: A drilling tool according to any one of Implementation Schemes 10 to 12, wherein the recess includes a surface having at least one peak.

[0068] Implementation Scheme 14: The drilling tool according to any one of Implementation Schemes 10 to 13, the drilling tool further includes a flange extending above the recess.

[0069] Implementation Scheme 15: The drilling tool according to Implementation Scheme 14, wherein the flange is configured to support the external tool recess.

[0070] Implementation Scheme 16: The drilling tool according to Implementation Scheme 14 or 15, wherein the flange includes a thickness of at least 0.25 inches (6.35 mm).

[0071] Implementation Scheme 17: A method of forming a drilling tool, the method comprising: forming a tool body including one or more blades and a tool recess defined in the surface of the one or more blades, wherein the tool recess is defined in at least one face of the one or more blades and in a shoulder region of the one or more blades spaced apart from the face of the one or more blades; forming a chip removal groove in a region of the tool body adjacent to the face of the one or more blades; forming a nozzle in the chip removal groove, the nozzle being configured to supply fluid into the chip removal groove; and forming a recess extending at an angle from the face of the one or more blades to at least one tool recess in the tool recess defined in the shoulder region of the one or more blades, wherein the recess is located below at least one tool recess in the tool recess defined in the face of the one or more blades.

[0072] Implementation Scheme 18: The method according to Implementation Scheme 17, wherein forming the recess includes machining the recess in the face of one or more cutting tools.

[0073] Implementation Scheme 19: The method according to Implementation Scheme 17 or 18, wherein forming the recess includes cutting into the recess from the shoulder region of one or more blades.

[0074] Implementation Scheme 20: The method according to any one of Implementation Schemes 17 to 19, wherein forming the recess includes forming the recess in a process substantially the same as forming the tool body.

[0075] The embodiments of this disclosure described above and illustrated in the accompanying drawings do not limit the scope of the invention, as these embodiments are merely examples of embodiments of the invention, the scope of which is defined by the appended claims and their legal equivalents. Any equivalent embodiments are within the scope of this disclosure. In fact, various modifications of this disclosure beyond those shown and described herein (such as alternative useful combinations of the described elements) will become apparent to those skilled in the art based on the description. Such modifications and embodiments also fall within the scope of the appended claims and their legal equivalents.

Claims

1. A drilling tool, the drilling tool comprising: At least one blade, said at least one blade including a shoulder region and a face; A plurality of cutting elements are arranged on the surface of the blade; At least one recessed shoulder cutting element, the at least one recessed shoulder cutting element being positioned in the shoulder region such that the cutting surfaces of the at least one recessed shoulder cutting element are spaced apart by a certain distance behind the face of the insert. and The recessed portion of the blade extends below at least one of the plurality of cutting elements arranged on the surface of the blade and extends to the at least one recessed shoulder cutting element, such that the at least one blade forms a flange extending above the recessed portion, and wherein the recessed portion lies in a plane corresponding to a recessed line extending at an angle from the surface of the at least one blade, and wherein the transition region between the flange and the recessed portion follows the recessed line.

2. The drilling tool of claim 1, further comprising a nozzle configured to discharge fluid near the blade.

3. The drilling tool of claim 2, wherein the recessed portion is configured to direct the fluid to the at least one recessed shoulder cutting element.

4. The drilling tool according to claim 1, wherein the recessed portion comprises a triangular surface.

5. The drilling tool according to any one of claims 1 to 4, the drilling tool further comprising a transition region located between the face of the blade and the recessed portion.

6. The drilling tool according to claim 5, wherein the transition region includes a rounded edge.

7. The drilling tool according to any one of claims 1 to 4, wherein the recessed portion extends from the face of the blade at the angle to the shoulder region of the blade.

8. The drilling tool according to claim 7, wherein the angle is between 10° and 60°.

9. The drilling tool according to any one of claims 1 to 4, wherein the recessed portion comprises a curved surface.

10. The drilling tool according to any one of claims 1 to 4, wherein the recessed portion extends between a chip removal groove located between the at least one blade and an adjacent blade and the at least one recessed shoulder cutting element.

11. The drilling tool of claim 10, wherein the recessed portion extends from a point in the face of the at least one blade, the point being located at at least half the distance from the longitudinal axis of the drilling tool to the shoulder region of the at least one blade.

12. A method for forming a drilling tool, the method comprising: A tool body is formed, the tool body including one or more blades and a tool recess defined in the surface of the one or more blades, wherein the tool recess is defined in at least one face of the one or more blades and in a shoulder region of the one or more blades spaced apart from the face of the one or more blades; A chip removal groove is formed in the area of ​​the face of the tool body near the one or more blades; A nozzle is formed within the chip removal groove, the nozzle being configured to supply fluid into the chip removal groove; as well as A recess is formed extending at an angle from the face of the one or more blades to at least one tool recess in the tool recess defined in the shoulder region of the one or more blades, wherein the recess is located below at least one tool recess in the tool recess defined in the face of the one or more blades, such that the one or more blades form a flange extending above the recess, and wherein the recess is located in a plane corresponding to a recessed line extending at an angle from the face of the one or more blades, and wherein the transition region between the flange and the recess follows the recessed line.

13. The method of claim 12, wherein forming the recess comprises machining the recess in the face of the one or more cutting tools.

14. The method of claim 12, wherein forming the recess comprises cutting into the recess from the shoulder region of the one or more blades.

15. The method of claim 12, wherein forming the recess comprises forming the recess in substantially the same process as forming the tool body.

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