Drill insert for drill bit

Abstract

A drill bit includes a drill bit insert. A drill bit body of the drill bit includes an insert cavity. A drill insert is inserted into the insert cavity. The drill insert is secured to the insert cavity, for example by brazing or using a connection mechanism. The drill bit inserts may be replaceable, allowing a drilling operator to adjust the configuration of the drill bit based on which drill bit insert is used.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 369,153, filed on July 22, 2022, entitled “BIT INSERT FOR A DRILL BIT,” the disclosure of which is incorporated herein by reference. Background Art

[0003] Wellbores may be drilled into a surface location or into the seabed for a variety of exploration or production purposes. For example, wellbores may be drilled to access fluids stored in underground formations, such as liquid and gaseous hydrocarbons, and to extract fluids from the formations. Wellbores used to produce or extract fluids may be lined with casing around the wellbore walls. Various drilling methods may be utilized depending, in part, on the characteristics of the formation through which the wellbore is drilled.

[0004] Wellbores are drilled using various downhole drilling equipment. Downhole drilling equipment may include a drill bit. The drill bit includes cutting elements that may be arranged based on the expected drilling conditions (such as formation, rock type, etc.). Summary of the invention

[0005] In some embodiments, the drill bit includes a body having a plurality of blades, a hole and an insert cavity. Each of the plurality of blades includes a plurality of blade cutting elements. The hole is hydraulically connected to the insert cavity. The drill insert is inserted and fixed into the insert cavity. The insert cutting element is connected to the drill insert in the cone area of ​​the body.

[0006] In some embodiments, a kit for a drill bit includes a body having a plurality of blades. The body defines an insert cavity. Each of the plurality of blades includes a plurality of blade cutting elements. The body includes a hole connected to the insert cavity. The kit includes a plurality of drill inserts. Each of the plurality of drill inserts is configured to be inserted into the insert cavity and secured to the insert cavity. Each drill insert includes an insert cutting element connected to the drill insert.

[0007] In some embodiments, a method for manufacturing a drill bit includes preparing a drill bit body. The drill bit body defines an insert cavity that is hydraulically connected to a hole in the drill bit body. The insert cavity is located in a cone area of ​​the drill bit body. The insert cavity has a cavity profile. The method includes preparing a drill bit insert. The drill bit insert has an insert profile that is complementary to the cavity profile. The drill bit insert includes an insert cutting element. The method includes inserting the drill bit insert into the insert cavity and securing the drill bit insert to the insert cavity.

[0008] This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary 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. Additional features and aspects of the embodiments of the present disclosure will be set forth herein, and in part will be apparent from the description, or may be learned by practicing such embodiments. 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 specific description will be presented by reference to specific embodiments of the present disclosure 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 concepts, at least some of the drawings may be drawn to scale. It should be understood that the drawings depict some example 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 representation of a drilling system according to at least one embodiment of the present disclosure;

[0011] Figure 2 is a perspective view of a drill bit according to at least one embodiment of the present disclosure;

[0012] Figure 3-1 is a top view of a drill bit according to at least one embodiment of the present disclosure;

[0013] Figure 3-2 yes Figure 3-1 A cross-sectional view of a drill bit;

[0014] Figure 4-1 to Figure 4-3 is a representation of a drill insert according to at least one embodiment of the present disclosure;

[0015] Figure 5-1 and Figure 5-2 is a representation of a drill insert according to at least one embodiment of the present disclosure;

[0016] Figure 6 is a representation of a drill bit body having an insert cavity according to at least one embodiment of the present disclosure;

[0017] Figure 7 is a cross-sectional view of a drill bit according to at least one embodiment of the present disclosure;

[0018] Figure 8-1 and Figure 8-2 is a representation of a drill insert according to at least one embodiment of the present disclosure;

[0019] Fig. 9is a representation of a cross-sectional view of a drill bit according to at least one embodiment of the present disclosure; and

[0020] Fig.10 is a flow chart of a method for assembling a drill bit in accordance with at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0021] The present disclosure generally relates to apparatus, systems and methods for modular drill bits with removable drill inserts. A drill bit can be formed having a cavity. The drill insert can have a shape that is complementary or similar to the cavity. The drill insert can be inserted into the cavity and secured to the drill bit, such as by brazing or mechanical fasteners. The drill insert can help prevent cracks from forming on the drill bit body by absorbing drilling stresses. The drilling stresses can be absorbed by the drill insert, and any cracking or damage that may be caused by the drilling stresses can occur at the drill insert, rather than at the drill bit body. The drill insert can be replaced, thereby extending the life of the drill bit.

[0022] According to at least one embodiment of the present disclosure, a plurality of drill bit inserts may be configured to be inserted into and connected to a cavity in a drill bit body. Different drill bit inserts may have cutting elements of different configurations. By changing the drill bit inserts on the drill bit, the configuration of the cutting elements at the drill bit may be changed. This may allow for different drill bit designs. In some embodiments, the drill bit insert may include one or more hydraulic paths to allow drilling fluid to cool and clean the center portion of the drill bit.

[0023] The drill insert can be connected to the cavity in the drill body by any mechanism. For example, the drill insert can be brazed to the cavity. In some embodiments, the connecting mechanism can be inserted through the downstream portion of the drill bit. In some embodiments, the drill insert can be connected to the drill body by an interlocking connection (such as a threaded connection). This can help increase the connection of the drill insert to the drill body.

[0024] Figure 1 One example of a drilling system 100 is shown for drilling a formation 101 to form a wellbore 102. The drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 that extends 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 attached to the downhole end of the drill string 105.

[0025] The drill string 105 may include several 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 pup joints, short joints, etc. The drill pipe 108 provides hydraulic passages through which drilling fluid is pumped from the surface. The drilling fluid is discharged through nozzles, jets, or other orifices of selected sizes in the drill bit 110 for the purpose of cooling the drill bit 110 and the cutting structure on the drill bit 110, and for lifting drill cuttings out of the wellbore 102 while drilling the wellbore.

[0026] The BHA 106 may include a drill bit 110 or other components. An exemplary 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, reamer, profile cutters, hydraulic disconnects, jars, vibration or damping tools, other components, or combinations of the foregoing. The BHA 106 may also include a rotary steerable system (RSS). The RSS may include a directional drilling tool that changes the direction of the drill bit 110 and, thereby, the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference system (e.g., gravity, magnetic north, and / or true north). Using measurements obtained using the geostationary position, the RSS may position the drill bit 110, change the course of the drill bit 110, and guide the directional drilling tool on a projected trajectory.

[0027] Typically, the drilling system 100 may include other drilling components and accessories, such as specialized valves (e.g., kelly cocks, 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 part of the BHA 106, depending on their location in the drilling system 100.

[0028] 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 a drag drill bit. In other embodiments, the drill bit 110 can be a milling cutter used to remove metals, composites, elastomers, other downhole materials, or combinations thereof downhole. For example, the drill bit 110 can be used with a whipstock to mill into a casing 107 lining the wellbore 102. The drill bit 110 can also be a junk mill for milling out tools, plugs, cement, other materials, or combinations thereof within the wellbore 102. The cuttings or other cuttings formed by the use of the mill can be lifted to the surface, or can be allowed to fall downhole.

[0029] The drill bit 110 includes a plurality of cutting elements. The cutting elements may be arranged in a pattern around one or more blades to cut, erode or otherwise degrade the formation and advance the wellbore. In some embodiments, one or more cutting elements may be connected to a drill bit insert. The drill bit insert may be inserted into a cavity in the drill bit body of the drill bit 110. Forces applied to the drill bit that may crack or otherwise damage the drill bit 110 may be applied to the drill bit insert. Cracks or other damage to the drill bit may render the drill bit 110 inoperable, resulting in replacement of the entire drill bit body. The drill bit insert may be easily replaced. This may increase the operational life of the drill bit 110.

[0030] Figure 2 2 is an exploded perspective view of a drill bit 210 having a drill insert 212 according to at least one embodiment of the present disclosure. The drill bit 210 has a drill bit body 214. The drill bit body 214 can be formed of one or more matrix materials, such as carbide infiltrated with a binder. In some embodiments, the drill bit body 214 is machined from one or more blanks (such as steel blanks). A plurality of blades 216 can be connected to the drill bit body 214. The blade cutting elements can be connected to the pockets 217 of the blades 216. The blade cutting elements are configured to engage the formation, thereby advancing the wellbore. One or more insert cutting elements can be connected to the drill bit insert 212. The insert cutting elements can be arranged to erode or otherwise remove the formation. The cutting elements of the drill bit 210 arranged in the drill bit insert 212 and the blades 216 can be planar cutting elements, non-planar (e.g., conical) cutting elements, or any combination thereof.

[0031] The drill bit body 214 may form an insert cavity 218. The insert cavity 218 may be formed on an outer surface (e.g., a downhole surface) of the drill bit body 214. The drill bit insert 212 may be inserted into the insert cavity 218. The drill bit insert 212 may be fixed or attached to the drill bit body 214 at or in the insert cavity 218.

[0032] The insert cavity 218 has a cavity profile, which can be the shape and / or size of the inner surface of the insert cavity 218. The drill insert 212 can have an insert profile, which can be the shape and / or size of the outer surface of the drill insert 212. According to at least one embodiment of the present disclosure, the insert profile can be complementary to the cavity profile. In this way, the drill insert 212 can be inserted into the insert cavity 218 with a tight fit. In some embodiments, the drill insert 212 can have an interference fit with the insert cavity 218. In some embodiments, the drill insert 212 can have a clearance fit with a tolerance to facilitate brazing in the insert cavity 218.

[0033] During drilling activities, the drill bit body 214 may be subjected to forces, including impact forces, bit pressure, torque, any other drilling forces, and combinations thereof. Conventionally, the forces may weaken the material of the drill bit body 214 and / or induce cracks in the material of the drill bit body 214. Cracks in the drill bit body 214 may render the drill bit body 214 unsuitable for further drilling activities. This may cause the drilling operator to replace the entire drill bit, thereby increasing drilling costs.

[0034] According to at least one embodiment of the present disclosure, the drill bit insert 212 can be placed in one or more high-force or high-impact locations of the drill bit body 214. For example, in some embodiments, the cutting elements in the area of ​​the roller cone 220 of the drill bit 210 (which is close to the rotation axis 222 of the drill bit 210) may be subjected to high drilling forces. The drilling forces on the roller cone cutting elements may cause the cutting elements and / or the drill bit body 214 to break in the roller cone 220. In some embodiments, the drill bit insert 212 can have greater elasticity and / or toughness than the drill bit body 214. In some embodiments, the drill bit insert 212 can have less elasticity and / or toughness than the drill bit body 214. For example, the drill bit insert 212 can be easily or easily replaced. The drill bit insert 212 can be formed of a less elastic material and replaced when the drill bit insert 212 is worn or when a new geometry of the drill bit insert 212 is required (e.g., for a different application). By placing the drill bit insert 212 in a location where the drill bit body 214 may fracture, such as in the cone 220 , drilling forces may cause the drill bit insert 212 to fracture.

[0035] According to at least one embodiment of the present disclosure, the drill insert 212 may be replaceable. When drilling forces break or otherwise damage the drill insert 212, the drill insert 212 may be removed from the drill bit body 214. A new drill insert 212 may then be installed in the insert cavity 218. The drill bit 210 may then be returned downhole and used for additional drilling operations. In this manner, the drilling forces may only damage the drill insert 212, leaving the drill bit body 214 undamaged. This may extend the operational life of the drill bit 210, thereby reducing the cost of drilling operations.

[0036] As will be discussed in further detail herein, the drill insert 212 can have different configurations. For example, the drill insert 212 can have different shapes, cutting element arrangements, insert profiles, hydraulic paths, etc. This can allow for variations in the drill bit design at the location of the drill insert 212. For example, in Figure 2 In the embodiment of the present invention, the drill bit insert 212 is located at the roller cone 220, and changing the design of the drill bit insert 212 can cause a change in the design of the drill bit 210 at the roller cone 220. This can allow the drilling operator to adjust the drill bit 210 based on the drilling conditions, which can increase the drilling penetration rate and / or reduce the drilling cost.

[0037] As discussed herein, the insert profile of the drill insert 212 can be complementary to the cavity profile of the insert cavity 218. In some embodiments, the insert profile and the cavity profile can be non-circular. The non-circular insert profile and the cavity profile can help prevent the drill insert 212 from rotating in the insert cavity 218. This can help secure the drill insert 212 in the drill body 214, thereby preventing undesirable or unintentional rotation or removal of the drill insert 212 during operation.

[0038] Figure 3-1 3 is a top view of a drill bit 310 having a drill bit insert 312 located in a cone 320 region of the drill bit 310, in accordance with at least one embodiment of the present disclosure. The drill bit 310 includes a plurality of blades 316 having a plurality of blade cutting elements 324. The blades 316 extend from a drill bit body 314. The drill bit insert 312 includes one or more insert cutting elements 326. For example, the illustrated drill bit insert 312 includes four insert cutting elements 326, including three angled insert cutting elements 326 and a center insert cutting element 326 located at the axis of rotation of the drill bit 310. However, it should be understood that the drill bit insert 312 may include any number of insert cutting elements 326, including 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more insert cutting elements 326.

[0039] In some embodiments, the insert cutting elements 326 can have any shape, including cones, domes, wedges, hatchets, any other shapes of the insert cutting elements 326, and combinations thereof. In some embodiments, each insert cutting element 326 can have the same shape. In some embodiments, different insert cutting elements 326 can have different shapes. As discussed herein, the drill bit insert 312 can be configured with different numbers, arrangements, and / or types of insert cutting elements 326. In this way, the cutting structure of the drill bit insert 312 can be customized according to specific drilling conditions.

[0040] Figure 3-2 is a cross-sectional view of drill bit 310 along line II'. As shown, drill insert 312 is located in insert cavity 318 in drill bit body 314. Drill insert 312 can be secured to drill bit body 314 in any manner. For example, drill insert 312 can be secured to drill bit body 314 using brazing, soldering, or welding. In some examples, drill insert 312 can be secured to drill bit body 314 using mechanical fasteners and / or a press fit. In some embodiments, drill insert 312 can be secured to drill bit body 314 using an interlocking connection (such as threads or another interlocking connection).

[0041] To facilitate a secure connection, such as a secure brazed connection, one or more portions of the insert profile of the drill insert 312 may be complementary to one or more corresponding portions of the insert profile of the insert cavity 318. By having complementary profiles that fit within brazing tolerances, a secure brazed connection may be formed between the drill insert 312 and the drill body 314.

[0042] In the illustrated embodiment, the drill bit insert 312 includes one or more hydraulic paths 328. The hydraulic paths 328 may be connected to one or more openings 330. The hydraulic paths 328 may direct drilling fluid from a hole 332 in the drill bit 310. When the drilling fluid exits the hydraulic paths 328 through the openings 330, the drilling fluid may provide cleaning, cooling, and chip removal for the volume surrounding the drill bit insert 312. The drill bit insert 312 may include one or more hydraulic paths 328, including 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more hydraulic paths 328. The number of hydraulic paths 328 may be based on the size of the drill bit insert 312. For example, the number of hydraulic paths 328 may be determined based on how many hydraulic paths 328 may fit into the drill bit insert 312 without compromising the structural integrity of the drill bit insert 312. In some examples, the number of hydraulic paths 328 may be based on the number of insert cutting elements 326. For example, a drill insert 312 with more insert cutting elements 326 may have more hydraulic paths 328, and a drill insert 312 with fewer insert cutting elements 326 may have fewer hydraulic paths 328. In some embodiments, the hydraulic path opening size may vary based on the location, size, and / or shape of the cutting elements. In some embodiments, the hydraulic path opening size may be within an upper limit, a lower limit, or a range of upper and lower limits, including any of: 0.0625 inches (1.6 mm), 0.125 inches (3.2 mm), 0.25 inches (6.4 mm), 0.375 inches (9.5 mm), 0.5 inches (12.7 mm), 0.625 inches (15.9 mm), 0.75 inches (19.1 mm), or any value therebetween. For example, the hydraulic path opening size may be greater than 0.0625 inches (1.6 mm). In another example, the hydraulic path opening size may be less than 0.75 inches (19.1 mm). In other examples, the hydraulic path opening size can be any value within the range of 0.0625 inches (1.6 mm) and 0.75 inches (19.1 mm). In some embodiments, the hydraulic path opening shape can include any shape, such as circular, oval, elongated oval, rectangular, triangular, any other shape, and combinations thereof.

[0043] Conventionally, nozzles and other hydraulic paths in the cone 320 may be difficult to accurately direct or otherwise implement. The drill bit insert 312 of the present disclosure may allow for a specific geometry of the hydraulic path 328, thereby improving the cleaning ability of the drill bit 310 at the cone 320. In some embodiments, the opening 330 may be formed from the material of the drill bit insert 312. In some embodiments, the opening 330 may include a nozzle or other guide for the drilling fluid.

[0044] The drill insert 312 can be formed in any manner. For example, the drill insert 312 can be cast and machined to final size. In some embodiments, the drill insert 312 can be machined from a blank (such as a steel billet). In some examples, the drill insert 312 can include a hard material powder infiltrated with an infiltrant. In some examples, the drill insert 312 can be formed by an additive manufacturing process. Additive manufacturing can allow for rapid and relatively low-cost construction of the drill insert 312. In some embodiments, additive manufacturing of the drill insert 312 can allow for the construction of complex geometries of the drill insert 312, including curves and / or bends in the hydraulic path 328 to guide the drilling fluid in a desired direction.

[0045] The drill bit insert 312 includes an insert body 334 and an insert shaft 336. The insert body 334 can rest on or be supported by a seat 338 on the drill bit body 314. The insert shaft 336 can extend into the bore 332. This can allow drilling fluid from the bore 332 to enter the hydraulic path 328 through the insert shaft 336. The seat 338 can support the drill bit insert 312, including supporting uphole drilling forces caused by the bit pressure or other drilling forces.

[0046] Figure 4-1 to Figure 4-3 is a representation of the construction of a drill bit insert (collectively referred to as 412) according to at least one embodiment of the present disclosure. As discussed herein, the drill bit insert 412 can have different constructions, such as differently shaped insert bodies (collectively referred to as 434), differently shaped insert shafts 336, and the like. In some embodiments, the drill bit insert 412 can have differently constructed insert cutting elements (collectively referred to as 426), including different numbers, different arrangements, different shapes, inclinations, orientations, placements, and any other differently constructed drilling cutting elements. In some embodiments, the drill bit insert 412 can have differently constructed openings (collectively referred to as 430) that can receive drilling fluid from a hydraulic pathway in the drill bit insert 412, including different numbers, orientations, diameter openings, pressures, any other factors, and combinations thereof. Although Figure 4-1 to Figure 4-3 Specific examples of drill inserts 412 are shown, but it should be understood that these are illustrative examples and any configuration of drill inserts 412 may be used in accordance with the present disclosure.

[0047] exist Figure 4-1In the example shown, the first drill insert 412-1 has two first insert cutting elements 426-1. As shown, the first insert cutting element 426-1 can be conical. The first insert cutting element 426-1 can be positioned offset from the center of the first drill insert 412-1, and the first drill insert 412-1 can have no center cutting element. The first drill insert 412-1 can have two first openings 430-1. The first openings 430-1 can direct the drilling fluid to the overall cutting area of ​​the first insert cutting element 426-1. One or more of the openings 430 can be arranged in a front position relative to the insert cutting element 426.

[0048] The first drill insert 412-1 has a first insert body 434-1 connected to a first insert shaft 436-1. In the illustrated embodiment, the first insert body 434-1 has a non-circular shape. This can be inserted into an insert cavity having a complementary shape. The non-circular shape of the first insert body 434-1 can help prevent rotation or other unintentional movement of the first drill insert 412-1 in the drill body.

[0049] exist Figure 4-2 In the example shown, the second drill bit insert 412-2 has four second insert cutting elements 426-2. The second insert cutting elements 426-2 may include a central second insert cutting element 427 located at the center of the second insert body 434-2. Three second insert cutting elements 426-2 may surround the central second insert cutting element 426-2. The second insert cutting elements 426-2 are radially spaced from the central cutting element 427. In some embodiments, the radial spacing of the second insert cutting elements 426-2 varies, such as in a forward spiral or reverse spiral configuration. The radial spacing of the second insert cutting elements 426-2 may be the same.

[0050] The second drill insert 412-2 has three second openings 430-2. The second openings 430-2 shown are located between the three outer second insert cutting elements 426-2 and may be oriented to clean chips formed by the outer second insert cutting elements 426-2.

[0051] The second insert body 434-2 is connected to the second insert shaft 436-2. In the illustrated embodiment, the second insert body 434-2 has a non-circular shape. This can be inserted into an insert cavity having a complementary shape. The non-circular shape of the second insert body 434-2 can help prevent rotation or other unintentional movement of the second drill insert 412-2 in the drill body.

[0052] exist Figure 4-3In the example shown, the third drill bit insert 412-3 has seven third insert cutting elements 426-3. Three groups 429 of two third insert cutting elements 426-3 surround the central third insert cutting element 426-3. The third drill bit insert 412-3 has a plurality of third openings 430-3. The third openings 430-3 can guide drilling fluid to remove chips generated from the third insert cutting elements. In the embodiment shown, the third drill bit insert 412-3 has a cylindrical third insert body 434-3 connected to a third insert shaft 436-3. The cylindrical third insert body 434-3 can be easily interchanged between different drill bits with different drill bit designs, thereby increasing the modularity and replaceability of the drill bit based on the third drill bit insert 412-3.

[0053] In some embodiments, one or more of the insert cutting elements 426 can be a planar cutting element, a non-planar (e.g., conical) cutting element, or any combination thereof. In some embodiments, the shape of the insert body 434 can remain the same between different drill bit inserts. This can allow the insert body 434 to be interchangeable in different drill bits. In some embodiments, the cutting element type (e.g., planar or non-planar) can be changed between different insert bodies 434. For example, an insert cavity (e.g., insert cavity 218) can have a shape that matches the shape of the insert body 434. Based on drilling conditions and other factors, a drilling operator can prepare a plurality of different insert bodies 434 having the same insert body 434 shape but having different types and / or patterns of insert cutting elements 426. This can help increase the customizability of a particular drill bit.

[0054] Figure 5-1 1 is a side view of a first drill insert 512-1 having a first interlocking feature 540-1 of a first insert shaft 536-1 in accordance with at least one embodiment of the present disclosure. The first drill insert 512-1 has a first insert body 534-1 connected to the first insert shaft 536-1. The first insert shaft 536-1 includes a first interlocking feature 540-1. The first interlocking feature 540-1 extends radially from the first insert shaft 536-1.

[0055] The first interlocking feature 540-1 can be configured to interact with a similar cavity or detent in the insert cavity of the drill bit. For example, during installation of the first drill insert 512-1, the first insert shaft 536-1 can be inserted into the insert cavity. The first drill insert 512-1 can be rotated to move the first interlocking feature 540-1 into the interlocking groove in the insert cavity. The first drill insert 512-1 can be fixed to the drill bit body, wherein the first interlocking feature 540-1 is inserted into the interlocking groove. This can help prevent the first drill insert 512-1 from moving longitudinally outward from the insert cavity.

[0056] exist Figure 5-1 In the illustrated embodiment, the first interlocking feature 540-1 has a rectangular shape. However, the interlocking feature can have any shape. For example, Figure 5-2 A second drill insert 512-2 is shown having a second insert body 534-2 connected to a second insert shaft 536-2. The second drill insert 512-2 includes a second interlocking feature 540-2. In the illustrated embodiment, the second interlocking feature 540-2 may be fully round, or have a hemispherical or dome shape. The dome-shaped second interlocking feature 540-2 may help increase ease of insertion into the interlocking groove of the insert cavity.

[0057] Although Figure 5-1 and Figure 5-2 The interlocking feature 540 is shown as a protrusion of the insert shaft 536, but it should be understood that the interlocking feature 540 may include a cavity or depression in the insert shaft 536. The insert cavity may include one or more protrusions extending into the insert cavity. When the insert shaft 536 is inserted into the insert cavity, the protrusions may extend into the cavity or depression forming the interlocking feature 540 on the insert shaft 536. In some embodiments, the cavity or depression may extend around a portion of the insert shaft 536 to help prevent the drill insert from being longitudinally removed from the cavity.

[0058] Figure 6 is a representation of an insert cavity 618 in a drill bit body 614 according to at least one embodiment of the present disclosure. An interlocking groove 642 is located on the inner surface of the insert cavity 618. During installation, a drill bit insert (such as Figure 5-1 The first drill insert 512-1 or Figure 5-2 The second drill insert 512-2) can be inserted into the insert cavity 618. Interlocking features (such as Figure 5-1 The first interlocking feature 540-1 or Figure 5-2 The second interlocking feature 540-2) can be aligned with the interlocking groove 642. The drill insert can be rotated as it is inserted into the insert cavity 618. This can cause the interlocking feature to move further into the interlocking groove 642, thereby preventing axial removal of the drill insert without damaging the material of the drill body 614.

[0059] Figure 7 is a cross-sectional view of a drill bit 710 having a drill bit body 714, in accordance with at least one embodiment of the present disclosure. The drill bit body 714 includes a bore 732 into which drilling fluid may be pumped. An insert cavity 718 may be formed in the drill bit body 714. The insert cavity 718 may extend from the bore 732 through the drill bit body 714 to a downhole edge of the drill bit 710.

[0060] Drill bit insert 712 may be inserted into insert cavity 718. Drill bit insert 712 may have an insert cutting element 726 that may be configured to engage the formation. Drill bit insert 712 may be inserted into insert cavity 718 from downhole end 746 of drill bit 710. Insert cutting element 726 may have an exposure 748 that may be the distance from the end of the insert cutting element 726 to the blade cutting element at the downhole-most end 750 of drill bit 710. In the illustrated embodiment, drill bit insert 712 has a negative exposure, meaning that the end of the insert cutting element 726 may be located below the downhole-most end 750.

[0061] The attachment mechanism 744 can help secure the drill insert 712 to the drill body 714. The attachment mechanism 744 can be inserted from the hole 732 into the insert cavity 718. The attachment mechanism 744 can include one or more interlocking grooves 742. The drill insert 712 can include one or more interlocking features 740. The interlocking features 740 can engage with the interlocking grooves 742 to connect the drill insert 712 to the attachment mechanism 744.

[0062] In some embodiments, the attachment mechanism 744 can be brazed or otherwise connected to the insert cavity 718. The interlocking feature 740 and the interlocking groove 742 can engage to secure the drill insert 712 to the drill body 714. In some embodiments, the interlocking groove 742 can include threads, and the interlocking feature 740 can be screwed or threaded into the interlocking groove 742. This can help axially retain the drill insert 712 within the insert cavity 718.

[0063] In some embodiments, twisting the interlocking feature 740 into the interlocking groove 742 may place the attachment mechanism 744 and the drill insert 712 in tension. Placing the attachment mechanism 744 and the drill insert 712 in tension may help further secure the drill insert 712 to the drill bit body 714 without placing the material of the drill bit body 714 in tension. This may help increase the strength of the connection between the drill bit insert 712 and the drill bit body 714, thereby reducing the chance of cracking or breaking the drill bit body 714.

[0064] The attachment mechanism 744 can be connected to the drill bit body 714 in any manner. For example, the attachment mechanism 744 can be brazed to the drill bit body 714, welded to the drill bit body 714, threaded into the drill bit body 714, connected to the drill bit body 714 by mechanical attachment, connected to the drill bit body 714 in any other manner, and combinations thereof.

[0065] In some embodiments, the drill insert 712 may be connected only to the attachment mechanism 744. The drill insert 712 may be threaded into the attachment mechanism 744 to secure the drill insert 712 to the drill body 714. In some embodiments, the drill insert 712 may be connected to the attachment mechanism 744 with a secondary mechanism. For example, the drill insert 712 may be brazed, welded, or otherwise connected to the attachment mechanism 744.

[0066] In some embodiments, the drill insert 712 can be connected to both the attachment mechanism 744 and the drill bit body 714. For example, the drill insert 712 can be brazed to both the attachment mechanism 744 and the drill bit body 714. In some embodiments, the drill insert 712 can be threaded into the attachment mechanism 744 and brazed to the drill bit body 714. In some embodiments, the attachment mechanism 744 and the drill insert 712 can be brazed to the drill bit body 714 at the same time. In some embodiments, the attachment mechanism 744 can be brazed to the drill bit body 714 first, and then the drill insert 712 can be brazed to the attachment mechanism 744 and the drill bit body 714.

[0067] According to at least one embodiment of the present disclosure, different attachment mechanisms 744 can have different features. For example, different attachment mechanisms 744 can have different lengths, which can change the exposed portion 748 of the drill insert 712. Longer attachment mechanisms 744 can result in a higher exposed portion 748. Shorter attachment mechanisms 744 can result in a lower exposed portion 748.

[0068] In some embodiments, the attachment mechanism 744 may include one or more internal openings to allow drilling fluid from the hole 732 to flow through to clean and / or cool the cutting elements on the insert 712. In some embodiments, a sealing element may be placed between the drill insert 712 and the drill bit body. This may help prevent hydraulic leaks. In some embodiments, the sealing element may include any type of sealing element, such as an O-ring, etc.

[0069] Figure 8-1 and Figure 8-2 is a representation of a drill insert 812 having interlocking features to engage with an attachment mechanism (e.g., Figure 7 The attachment mechanism 744) is engaged. Figure 8-1 , the first drill insert 812-1 has a first insert body 834-1 connected to a first insert shaft 836-1. A first interlocking feature 840-1 is connected to the first insert shaft 836-1. Figure 8-1The first interlocking feature 840-1 can be a full thread, or a thread that is continuous over the entire length of the thread. The full thread can increase the engagement of the first interlocking feature 840-1 with the attachment mechanism, thereby increasing the connection strength of the first drill insert 812-1 with the drill body.

[0070] exist Figure 8-2 , the second drill insert 812-2 has a second insert body 834-2 connected to the second insert shaft 836-2. The second interlocking feature 840-2 is connected to the second insert shaft 836-2. The second interlocking feature 840-2 is shown as a partial thread, including knobs or protrusions radially and longitudinally spaced around the second insert shaft 836-2. The knobs or protrusions of the second interlocking feature 840-2 can be spaced along the thread path instead of being continuous between two separate protrusions.

[0071] According to at least one embodiment of the present disclosure, the protrusion of the second interlocking feature 840-2 may not be continuous to improve ease of manufacturing. A separate protrusion may be easier to manufacture than a continuous thread around the outer surface of the second insert shaft 836-2. In some embodiments, a separate protrusion used as a threaded or threaded attachment mechanism or an interlocking groove in a drill body may have a lower manufacturing tolerance. This may reduce post-processing of the second drill insert 812-2, thereby reducing manufacturing costs and / or improving ease of installation. In some embodiments, a sealing element (such as an O-ring or other sealing element) may be located between the second drill insert 812-2 and the attachment mechanism.

[0072] Fig. 9 9 is a cross-sectional view of a portion of a drill bit 910 having an insert 912 inserted into an insert cavity 918 in accordance with at least one embodiment of the present disclosure. In the illustrated embodiment, the insert cavity 918 has a cavity profile including a cavity shoulder 952. The insert 912 has an insert profile including an insert shoulder 954. As discussed herein, the cavity profile and the insert profile can be complementary. In this manner, the insert shoulder 954 can engage the cavity shoulder 952, thereby increasing the strength of the connection or support of the insert 912 to the drill bit body 914. In some embodiments, a seal can be located between the drill bit insert 912 and the cavity shoulder 952.

[0073] The insert 912 includes an insert shaft 936 having a primary hydraulic path 928 that can extend into the insert body 934. A connection mechanism 944 can secure or at least partially secure the insert 912 to the drill bit body 914. In the illustrated embodiment, an inner surface of the insert shaft 936 (e.g., in the primary hydraulic path 928) can have a threaded connection, including internal threads. The connection mechanism 944 can have a threaded outer surface, and the connection mechanism 944 can be threaded into the internal threaded connection of the insert shaft 936. By threading the connection mechanism 944 into the insert shaft 936, the connection mechanism 944 can secure the insert 912 to the drill bit body 914.

[0074] In some embodiments, the threaded connection connection mechanism 944 can place 912 and 944 in tension, thereby placing the drill bit body 914 in compression between the insert 912 and the hole 932. The connection mechanism 944 can be inserted into the insert cavity 918 through the hole 932 and threaded into the insert 912. In some embodiments, the insert 912 can rotate relative to the connection mechanism 944. In some embodiments, the connection mechanism 944 can rotate relative to the insert 912. In some embodiments, the insert 912 can include one or more interlocking features that can prevent the insert 912 from rotating within the insert cavity 918. In order to secure the insert 912 to the drill bit body 914, the connection mechanism 944 can be threaded into the insert 912 and rotated relative to the drill bit body 914. In some embodiments, the connection mechanism 944 may be difficult to access during assembly of the drill bit 910. To facilitate assembly, the connection mechanism 944 can be keyed into the insert cavity 918, and the insert 912 can be rotated to thread the insert 912 and the connection mechanism 944 together.

[0075] In accordance with at least one embodiment of the present disclosure, insert 912 may be brazed to drill bit body 914 and secured to connection mechanism 944. In some embodiments, insert 912 may be brazed to drill bit body 914, while connection mechanism 944 is secured to drill bit body 914 by being threaded into insert 912. In some embodiments, insert 912 may be brazed to drill bit body 914 before connection mechanism 944 is threaded into insert 912.

[0076] Fig.10is a flow chart of a method 1056 for manufacturing a drill bit according to at least one embodiment of the present disclosure. The method 1056 includes preparing a drill bit body at 1058. The drill bit body defines an insert cavity. The insert cavity has a cavity profile. The method 1056 also includes preparing a drill bit insert at 1060. The drill bit insert has an insert profile. The insert profile is complementary to the cavity profile. The drill bit insert includes an insert cutting element. In some embodiments, preparing the drill bit insert may include preparing the drill bit insert in any manner. For example, preparing the drill bit insert may include additively manufacturing the drill bit insert. In some examples, preparing the drill bit insert may include casting the drill bit insert. In some examples, preparing the drill bit insert may include machining or subtractively manufacturing the drill bit insert.

[0077] At 1062, a drill insert may be inserted into the insert cavity. In some embodiments, the drill insert may be secured to the insert cavity at 1064. In some embodiments, the drill insert may be secured to the insert cavity in any manner described herein. For example, the drill insert may be secured to the insert cavity by brazing. In some examples, the drill insert may be secured to the insert cavity by a connecting mechanism. In some embodiments, the drill insert may be secured to the insert cavity by both brazing and a connecting mechanism. In some embodiments, securing the drill insert to the insert cavity may include threading the connecting mechanism into the drill insert.

[0078] According to at least one embodiment of the present disclosure, a drill bit may include a kit for a drill bit. The kit for a drill bit may include one or more components or parts. Each component or part may be interchangeable. For example, a drill bit may include a drill bit body. The drill bit body may include an insert cavity. The kit may include a plurality of drill bit inserts. Each drill bit insert may have an insert profile that is complementary to the cavity profile of the insert cavity. In this way, the drill bit inserts may be interchangeable. This may allow a drilling operator to adjust the configuration of the drill bit by replacing the drill bit inserts. In some embodiments, the kit may allow a drilling operator to repair a broken or damaged portion of a drill bit insert without replacing the drill bit.

[0079] In some embodiments, method 1056 may include removing a drill insert. For example, method 1056 may include removing a damaged insert. The damaged drill insert may be removed by raising the temperature of the drill bit and the drill insert to a temperature above the brazing temperature so that the brazing melts and the drill insert can be removed. In some embodiments, the drill insert may be removed by unscrewing the associated connection mechanism. In some embodiments, after removing the drill insert, method 1056 may include replacing the removed drill insert with a new drill insert, or method 1056 may be repeated.

[0080] Embodiments of the drill bit insert have been described primarily with reference to wellbore drilling operations; the drill bit inserts described herein may be used in applications other than drilling wellbores. In other embodiments, drill bit inserts according to the present disclosure may be used outside of a wellbore or other downhole environment for exploring or producing natural resources. For example, the drill bit inserts of the present disclosure may be used in a borehole for placing utility lines. 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.

[0081] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of currently disclosed technologies. 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 embodiments, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the specific goals of the developer, 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, it is still a routine task of design, production and manufacturing.

[0082] 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 include the features described. For example, any element described in the embodiments herein can be combined with any element of any other embodiment described herein. The numerals, percentages, ratios or other values ​​described herein are intended to include the value, as well as other values ​​of "about" or "approximately" the value, as will be understood by those of ordinary skill in the art covered by the embodiments of the present disclosure. Therefore, the value should be interpreted broadly enough to cover values ​​that are at least close enough to the value 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%, 1%, 0.1% or 0.01% of the value.

[0083] In view of the present disclosure, it should be recognized by those skilled in the art that equivalent constructions do not depart from the spirit and scope of the present 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 present disclosure. Equivalent constructions including functional "means plus function" clauses are intended to cover structures described herein as performing the functions, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. Except for those claims in which the words "means for..." appear together with the associated functions, it is the express intention of the applicant not to invoke means plus function or other functional claims for any claim. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims will be covered by the claims.

[0084] As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount, that is within standard manufacturing or process tolerances, or 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%, less than 1%, less than 0.1%, and less than 0.01% of a stated amount. Furthermore, it should be understood that any directions or reference frames in the foregoing descriptions are merely relative directions or movements. For example, any reference to "up" and "down," or "above," or "below," is merely a description of the relative position or movement of the associated elements.

[0085] Without departing from the spirit or characteristics of the present disclosure, the present disclosure may be implemented in other specific forms. The described embodiments are considered to be illustrative rather than restrictive. Therefore, the scope of the present disclosure is indicated by the appended claims rather than the preceding description. Changes within the meaning and scope of the equivalents of the claims will be included within the scope of the claims.

Claims

1. A drill bit, comprising: a body comprising a plurality of blades, an aperture, and an insert cavity, wherein each blade of the plurality of blades comprises a plurality of blade cutting elements, and wherein the aperture is hydraulically connected to the insert cavity; a drill insert secured to and inserted into the insert cavity; and An insert cutting element is connected to the drill insert in the cone region of the body.

2. The drill bit of claim 1, wherein the drill insert is rotationally fixed in the insert cavity.

3. The drill bit of claim 1, wherein the drill insert is located at an axis of rotation of the body.

4. The drill bit of claim 1, wherein the drill insert includes an interlocking connection with the insert cavity.

5. The drill bit of claim 4, wherein the interlocking connection comprises a threaded connection between the drill insert and the body.

6. The drill bit of claim 1, wherein the drill insert is brazed to the insert cavity.

7. The drill bit of claim 1, wherein the drill insert includes a nozzle hydraulically connected to the bore.

8. The drill bit of claim 1, wherein the drill bit insert includes an insert shoulder that engages a body shoulder at the insert cavity.

9. The drill bit of claim 1, wherein the drill insert defines an insert cavity, and wherein the insert cavity includes internal threads, and further comprising an attachment mechanism threaded into the internal threads of the insert cavity to secure the drill insert to the body.

10. The drill bit of claim 1, wherein a drill insert is formed of a different material than the drill bit body.

11. The drill bit of claim 1, wherein the insert cutting element comprises a plurality of cutting elements.

12. The drill bit of claim 1, wherein the insert cutting element is offset from an axis of rotation of the body.

13. A kit for a drill, comprising: a body including an insert cavity, a hole connected to the insert cavity, and a plurality of blades, each blade of the plurality of blades including a plurality of blade cutting elements; and A plurality of drill inserts, each of the plurality of drill inserts being configured to be inserted into and secured to the insert cavity, each drill insert including an insert cutting element coupled to the drill insert.

14. The kit of claim 13, wherein each drill insert of the plurality of drill inserts includes a different arrangement of the insert cutting elements.

15. The kit of claim 13, wherein each drill insert of the plurality of drill inserts has a different exposed portion.

16. The kit of claim 13, wherein each drill insert has an identical shape to fit within the insert cavity.

17. A method for manufacturing a drill bit, comprising: preparing a drill bit body defining an insert cavity hydraulically connected to a bore of the drill bit body, the insert cavity being located in a cone region of the drill bit body, the insert cavity having a cavity profile; preparing a drill insert having an insert profile that is complementary to the cavity profile, the drill insert including an insert cutting element; Insert the drill insert into the insert cavity; and The drill insert is secured to the insert cavity.

18. The method of claim 17, wherein preparing the drill insert comprises additive manufacturing the drill insert.

19. The method of claim 17, wherein securing the drill insert to the insert cavity comprises brazing the drill insert to the insert cavity.

20. The method of claim 17, wherein securing the drill insert to the insert cavity comprises threading a connection mechanism into the drill insert.

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