Devices, systems, and methods for cutting elements

Abstract

A cleaning cutting element includes a superhard layer connected to a substrate. The substrate includes a substrate bore formed at least partially through the substrate. The substrate includes a plurality of conduits that extend from the substrate bore at a junction. The conduits exit the substrate at an exit opening in a circumferential wall to direct drilling fluid to a feature of a drill bit to which the cleaning cutting element is secured.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. non-provisional application No. 18 / 492,383, filed October 23, 2024, entitled “DEVICES, SYSTEMS, AND METHODSFOR A CUTTING ELEMENT,” the disclosure of which is incorporated herein by reference. Background Technology

[0002] Wellbores can be drilled into surface locations or the seabed for various exploration or extraction purposes. For example, wellbores can be drilled to obtain fluids (such as liquid and gaseous hydrocarbons) stored in underground formations and to extract fluids from the formations. Wellbores for producing or extracting fluids can be formed in the formation using drilling tools, such as drill bits for drilling wellbores and reamers for enlarging the diameter of the wellbore. Drilling tools may include one or more cutting elements attached to the tool's blades. Typically, the tool includes one or more cutting cavity recesses on the outer surface of the tool body, and the cutting elements are fixed within these cavity recesses by brazing. Summary of the Invention

[0003] In some respects, the technology described herein relates to drill bits. The drill bit includes a body having a longitudinal axis. Fluid channels extend through the body. Multiple blades extend from the body. The multiple blades form multiple chip removal grooves between adjacent blades. A cleaning cutting element is located in the central region of the drill bit. The cleaning cutting element includes a matrix including a matrix bore extending at least partially therethrough. The matrix bore is in fluid communication with the fluid channels of the inner body. Multiple conduits are in fluid communication with the matrix bore. Each of the multiple conduits includes an outlet opening that guides drilling fluid out of the body of the drill bit. An ultrahard layer having an ultrahard material (such as polycrystalline diamond (PCD)) is attached to the upper surface of the matrix. In some embodiments, the entire cutting element has a diamond top and a matrix.

[0004] In some respects, the techniques described herein relate to cutting elements. A cutting element includes a superhard layer and a substrate attached to the superhard layer. The substrate includes a body and an upper surface of the body. The superhard layer is attached to the upper surface of the body. The superhard layer includes a bottom surface of the body and a circumferential wall of the body extending between the upper surface and the bottom surface. The body forms a substrate bore with an inlet in the bottom surface of the body. The substrate bore includes a plurality of conduits leading to a plurality of outlet openings in the circumferential wall of the body.

[0005] In some aspects, the technology described herein relates to a method for manufacturing cutting elements. The method includes forming a superhard layer on a substrate. The method includes forming a substrate bore in the substrate. The substrate bore extends from an inlet at the bottom surface of the substrate to a junction near the superhard layer. An operator forms a plurality of conduits in the substrate. The plurality of conduits extend from the junction to a circumferential wall of the substrate.

[0006] This summary is provided to introduce a series of concepts further described in the detailed description. The summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help limit the scope of the claimed subject matter. Additional features and aspects of embodiments of this disclosure will be set forth herein and will be apparent in part from the description, or may be learned by practice of such embodiments. Attached Figure Description

[0007] To describe how the above and other features of this disclosure are obtained, a more specific description will be presented by reference to the specific embodiments shown in the accompanying drawings. For better understanding, the same elements have been denoted by the same reference numerals throughout the drawings. While some in the drawings may be schematic or exaggerated representations of concepts, at least some in the drawings may be drawn to scale. It should be understood that the drawings depict some exemplary embodiments, which will be described and explained in more specific and detailed manner by means of the drawings, in which: Figure 1 An example of a drilling system for drilling surface formations to form a wellbore, according to at least one embodiment of the present disclosure, is shown; Figure 2-1 This is a perspective view of a drill bit including a cleaning cutting element according to at least one embodiment of the present disclosure; Figure 2-2 yes Figure 2-1 A top view of the drill bit; Figure 2-3 yes Figure 2-1 A side cross-sectional view of the drill bit; Figure 2-4 yes Figure 2-1 A longitudinal cross-sectional view of the drill bit; Figure 3-1 This is a side view of a clean cutting element according to at least one embodiment of the present disclosure; Figure 3-2 yes Figure 3-1 A side cross-sectional view of the clean cutting element; Figure 4 This is a cross-sectional view representing a clean cutting element according to at least one embodiment of the present disclosure; Figure 5This is a cross-sectional view representing a clean cutting element according to at least one embodiment of the present disclosure; Figure 6 This is a cross-sectional view representing a clean cutting element according to at least one embodiment of the present disclosure; Figure 7 This is a longitudinal cross-sectional view of a drill bit having a cleaning cutting element fixed to its body according to at least one embodiment of the present disclosure; and Figure 8-1 This is an exploded view of a clean cutting system according to at least one embodiment of the present disclosure; Figure 8-2 yes Figure 8-1 A cross-sectional view of the assembled clean cutting system; Figure 9 This is a flowchart of a method for forming a cutting element according to at least one embodiment of the present disclosure. Detailed Implementation

[0008] This disclosure generally relates to apparatus, systems, and methods for cutting elements having a fluid path for guiding drilling fluid from a matrix bore in the matrix to a conduit having an outlet opening in the sidewall of the matrix. Typically, a drill bit can have a limited fluid flow rate in its central region. The drill bit may include cutting elements extending into its central region for material removal. To remove drill cuttings and / or cool the drill bit, the drill bit typically includes one or more nozzles in a chip removal groove located between two blades. Nozzles can effectively guide fluid between the blades, but drilling fluid may not circulate effectively around the central region of the drill bit. Alternatively, the nose and shoulder regions may not be able to effectively utilize hydraulic energy to cool and rapidly remove drill cuttings due to the angle of conventional nozzle orientation. This can reduce the cutting removal and / or cooling efficiency of the cutting elements in the center, nose, and shoulder regions.

[0009] According to at least one embodiment of this disclosure, the cutting element can be fixed to the central region of the drill bit. Drilling fluid can pass through the body of the drill bit and enter the base bore of the cutting element. The drilling fluid can be guided out of the cutting element through one or more conduits. The conduits can guide the drilling fluid toward one or more structures on the drill bit. For example, the drilling fluid can be guided toward one or more chip flutes between two blades of the drill bit. This can help improve fluid flow in the center and nose regions of the drill bit. Improved fluid flow in the center of the drill bit can help increase the cutting efficiency of the drill bit and / or reduce the accumulation of drill cuttings and other materials in the center and nose regions of the drill bit.

[0010] Figure 1An example of a drilling system 100 for drilling through formation 101 to form a wellbore 102 is shown. The drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 that extends downward 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.

[0011] The drill string 105 may include several joints of the drill pipe 108 connected end-to-end via a tool joint 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 sub sections, pup joints, etc. The drill pipe 108 provides hydraulic channels through which drilling fluid is pumped from the surface. The drilling fluid exits through nozzles, orifices, or other orifices of selected size in the drill bit 110 to cool the drill bit 110 and its cutting structures, and to lift drill cuttings out of the wellbore when it is drilled out of the wellbore 102.

[0012] BHA 106 may include drill bit 110 or other components. Example BHA 106 may include additional or other components (e.g., connected between drill string 105 and drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, downhole reamers, casing shoes, hydraulic disconnect joints, slappers, vibration or damping tools, other components, or combinations of the foregoing. BHA 106 may also include a rotary steerable system (RSS). The RSS may include a directional drilling tool that changes the orientation of drill bit 110, thereby altering the wellbore trajectory. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame (such as gravity, magnetic north, and / or true north). Using measurements obtained through the geostationary position, the RSS can position drill bit 110, change the path of drill bit 110, and guide the directional drilling tool along a planned trajectory.

[0013] Generally, drilling system 100 may include other drilling components and accessories, such as specialized valves (e.g., kerb plugs, blowout preventers, and safety valves). Additional components included in drilling system 100 may be considered part of drilling tool assembly 104, drill string 105, or BHA 106, depending on their location within drilling system 100.

[0014] Drill bit 110 in BHA 106 can be any type of drill bit suitable for eroding downhole materials. For example, drill bit 110 can be a drill bit suitable for drilling into surface formation 101. Example drill bit types for drilling into surface formations are fixed cutting or scraper bits. In other embodiments, drill bit 110 can be a milling shoe for removing metal, composite materials, elastomers, other downhole materials, or combinations thereof. For example, drill bit 110 can be used with a directional drilling tool to mill into casing 107 fitted onto wellbore 102. Drill bit 110 can also be a flat-end milling shoe for milling away tools, plugs, cement, other materials, or combinations thereof within wellbore 102. Cuttings or other drill cuttings generated by using the milling shoe can be lifted to the surface or allowed to fall downhole.

[0015] Drill bit 110 may include a cleaning cutting element fixed to a central region of the drill bit. The cleaning cutting element may include an ultrahard layer fixed to a substrate. The substrate may include a substrate bore that is in fluid communication with fluid channels through the drill bit 110. The cleaning cutting element may include a plurality of conduits connected to the substrate bore that terminate at outlet openings on the sidewalls of the cutting element. The outlet openings may be oriented to guide drilling fluid to one or more structures on the drill bit. For example, the outlet openings may guide drilling fluid to chip flutes between the cutter wings. As discussed herein, this can help improve drilling fluid circulation in the central region, thereby increasing drilling efficiency and / or reducing or preventing the accumulation of drill cuttings and / or other materials in the central region.

[0016] Figure 2-1 This is a perspective view of a drill bit 210 according to at least one embodiment of the present disclosure. The drill bit 210 includes a body 212 and a plurality of cutter wings 214 extending from the body 212. The drill bit 210 may also include a plurality of cutting elements 216, which are fixed to one or more of the cutter wings 214. When the drill bit 210 rotates, the cutting elements 216 may engage the formation and erode at least a portion of the formation.

[0017] The drill bit 210 may also include one or more nozzles 218. Drilling fluid can pass through fluid passages in the body 212 of the drill bit 210 and can be guided out of the drill bit 210 through the nozzles 218. This helps to cool the drill bit 210 (including the cutting elements 216, blades 214, body 212, and other parts of the drill bit 210). In some cases, drilling fluid guided from one or more nozzles 218 may pass through a chip flushing groove 220 located between two adjacent blades 214. Drill cuttings or material removed by the cutting elements 216 during drilling can be flushed away from the cutting elements 216 through the chip flushing groove 220 in front of the cutting elements 216.

[0018] According to at least one embodiment of this disclosure, the drill bit 210 may include a cleaning cutting element 222. The cleaning cutting element 222 may include a superhard layer 223 attached to a substrate 225. The superhard layer 223 may be formed of a superhard material such as polycrystalline diamond (PCD) and / or polycrystalline diamond composite (PDC).

[0019] In some embodiments, the cleaning cutting element may encompass the substrate and the PCD on the top portion 251 of the cleaning cutting element 222. For example, the top portion 251 may include a tapered superhard layer 223. The substrate material 225 may extend into the tapered top portion 251 of the cleaning cutting element 222.

[0020] The superhard layer 223 can be shaped and positioned to engage the formation. For example, the superhard layer 223 can be tapered. The tapered superhard layer 223 can engage the formation to erode it. In some embodiments, the superhard layer 223 can be configured to engage the formation vertically along the longitudinal axis 228. As the drill bit 210 descends along the longitudinal axis 228 into the formation, the superhard layer 223 can contact the formation and crush it at the tip of the tapered layer. This can help improve formation erosion in the central region 226 of the drill bit 210, where rotation of the drill bit 210 may limit and / or reduce the shearing motion of the cutting elements 216 in the central region 226.

[0021] In some embodiments, the superhard layer 223 may have any other shape. For example, the superhard layer 223 may have a truncated cone shape, a cone shape with offset cone tip, a ridge shape (e.g., "axe shape"), a cone shape with two or more tips, any other shape and combination thereof.

[0022] The cleaning cutting element 222 may include a hole through the base 225. Drilling fluid guided through the body 212 may be directed into the base 225 of the cleaning cutting element 222 and directed out of the base 225 through one or more outlet openings 224.

[0023] The outlet opening 224 on the cleaning cutting element 222 can direct drilling fluid to any structure on the drill bit 210. For example, the outlet opening 224 can direct drilling fluid to one or more of the cutter wings 214. In some examples, the outlet opening 224 can direct drilling fluid to one or more of the cutting elements 216 on the cutter wings 214. In some examples, the outlet opening 224 can direct drilling fluid to the chip flue 220 between adjacent cutter wings 214.

[0024] In some embodiments, drilling fluid exiting from outlet opening 224 can cool the cleaning cutting elements 222, blades 214, body 212, and / or cutting elements 216 on drill bit 210. In some embodiments, drilling fluid exiting from outlet opening 224 can flush drill cuttings off drill bit 210. For example, drilling fluid exiting from outlet opening 224 can flush drill cuttings off cutting elements 216 on blades 214, allowing them to pass through and exit the chip flue 220 between adjacent blades 214, and / or exit the body 212 of drill bit 210. Drilling fluid exiting from outlet opening 224 can help improve cooling and / or cuttings removal of drill bit 210.

[0025] According to at least one embodiment of this disclosure, the cleaning cutting element 222 may be located in the central region 226 of the drill bit 210. The central region 226 may be the bottom region of the drill bit 210. For example, the cleaning cutting element 222 may be located at the bottom of the drill bit 210. In some examples, the cleaning cutting element 222 may be located between the blades 214 of the drill bit 210. In some examples, the cleaning cutting element 222 may be located at the longitudinal axis 228 of the drill bit 210. In some examples, the cleaning cutting element 222 may be coaxial with the longitudinal axis 228. In some examples, the cleaning cutting element 222 may be tapered, and a certain point of the tapered shape of the cleaning cutting element 222 may intersect with the longitudinal axis 228.

[0026] In some embodiments, drill bit 210 may include a cleaning cutting element 222 in any part of drill bit 210. For example, drill bit 210 may include the cleaning cutting element 222 on the cutter wings 214 of drill bit 210 or on the body 212 of drill bit 210, offset from the longitudinal axis 228 of drill bit 210. Placing the cleaning cutting element 222 in any part of drill bit 210 can help improve fluid flow throughout drill bit 210.

[0027] In some embodiments, the cleaning cutting element 222 may include an outlet opening 224 for each chip flute 220 in the drill bit 210. For example, the number of fluid conduits 236 and / or outlet openings 224 may be the same as the number of blades 214. In some embodiments, the cleaning cutting element 222 may include fewer outlet openings 224 than the chip flutes 220. For example, the number of fluid conduits 236 and / or outlet openings 224 may be less than the number of blades 214. In some examples, the cleaning cutting element 222 may include an outlet opening 224 for each main blade 214. In some examples, the cleaning cutting element 222 may include more outlet openings 224 than the blades 214 and / or chip flutes 220. For example, the number of fluid conduits 236 and / or outlet openings 224 may be greater than the number of blades 214.

[0028] In some embodiments, the outlet opening 224 may point to a specific feature of the drill bit 210. For example, the outlet opening 224 may point to the center of the chip flute 220. In some examples, the outlet opening 224 may point to the cutter wing 214. In some examples, the outlet opening 224 may point to a specific cutting element 216 and / or a group of cutting elements 216. In some examples, the outlet opening 224 may point to the leading edge of the cutter wing 214. In some examples, the outlet opening 224 may point to one or more of the nozzles 218 to facilitate and / or improve the flow of drilling fluid from the nozzles 218. In some examples, different outlet openings 224 may point to different features of the drill bit 210. For example, a first outlet opening 224 may point to the chip flute 220, and a second outlet opening 224 may point to the cutting element 216.

[0029] Figure 2-2 yes Figure 2-1 The diagram shows a top view of drill bit 210. An outlet opening 224 directs a flow of drilling fluid (collectively referred to as 230) to one or more features of drill bit 210. For example, outlet opening 224 may direct a first flow 230-1 of drilling fluid to a chip flue 220 between the two cutter wings 214. The first flow 230-1 may be directed to the center of the chip flue 220. This can help increase the fluid flow through drill bit 210, thereby helping to flush drill cuttings away from the central region 226 of 210, helping to flush drill cuttings away from the cutter wings 214, helping to flush drill cuttings out of the chip flue 220, increasing cooling of one or more structures of drill bit 210, performing any other operations, and combinations thereof.

[0030] In some embodiments, the drilling fluid flow 230 may be oriented perpendicular to the cleaning cutting element 222. The conduit at the outlet opening 224 may be oriented towards and perpendicular to the outer cylindrical surface of the substrate. This can cause the drilling fluid flow 230 to exit from the outlet opening 224 perpendicularly or substantially perpendicular to the cleaning cutting element 222. Figure 2-2 In the illustrated embodiment, the cleaning cutting element 222 is oriented in the steering direction within the body 212 to guide the first flow 230-1 of drilling fluid vertically away from the cleaning cutting element 222 toward the chip removal groove 220. In some embodiments, the cleaning cutting element 222 may be taken in the steering direction to be oriented toward any feature of the drill bit 210, such as one of the cutting elements 214 and / or the cutting element 216.

[0031] In some embodiments, the drilling fluid flow 230 may be oriented laterally to or non-perpendicular to the cleaning cutting element 222. For example, the drilling fluid flow 230 may be oriented laterally to the outer surface of the substrate. This allows the flow 230 to be oriented to specific features of the drill bit 210. For example, in Figure 2-2 In the illustrated embodiment, the second flow 230-2 of drilling fluid is oriented transversely to the cleaning cutting element 222 to guide the second flow 230-2 to the illustrated cutting element 216, and / or to guide the second flow 230-2 more closely to the leading surface 232 of the blade 214. Guiding the second flow 230-2 to the cutting element 216 and / or the leading surface 232 of the blade 214 can help improve drill bit operation by flushing away drill cuttings from the cutting element 216 and / or the leading surface 232, provide cooling to the cutting element 216 and / or the leading surface 232 of the blade 214, and otherwise improve the performance of the drill bit 210, as well as combinations thereof.

[0032] Figure 2-3 yes Figure 2-1 The diagram shows a side cross-sectional view of drill bit 210. In the cross-sectional view shown, the cleaning cutting element 222 includes six fluid conduits 236 extending from a base bore 234 in the base 225 of the cleaning cutting element 222. The base bore 234 may extend at least partially through the base 225. The fluid conduits 236 extend through 225 to six outlet openings 224 in the outer surface of the cleaning cutting element 222. The six fluid conduits 236 and outlet openings 224 shown are oriented to guide a flow 230 of drilling fluid from the base bore 234 to each of the chip removal grooves 220 between the blades 214. As discussed herein, this can help flush drill cuttings from the central region 226 of drill bit 210 and / or cool drill bit 210.

[0033] Although Figure 2-3 The illustrated embodiment shows six fluid conduits 236 guiding six flows 230 from the cleaning cutting element 222; however, it should be understood that the cleaning cutting element 222 may include any number of fluid conduits 236 guiding any number of flows 230 from the cleaning cutting element 222. Furthermore, although the illustrated embodiment shows the flows 230 extending perpendicular to the cleaning cutting element 222, it should be understood that the flows 230 may extend in any direction from the cleaning cutting element 222 and / or toward any feature of the drill bit 210.

[0034] In some embodiments, the fluid conduit 236 may extend along a radial conduit angle 272, which extends between a conduit axis 268 passing through the fluid conduit 236 and a tangent 274 tangent to the circumferential wall of the base hole 234 and / or the base 225. In some embodiments, the radial conduit angle 272 may have an upper limit, a lower limit, or both of the following values: 90°, 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°. For example, the radial conduit angle 272 may be greater than 45°. In another example, the radial conduit angle 272 may be less than 90°. In yet another example, the radial conduit angle 272 may be any value within the range of 45° and 90°. In some embodiments, a radial conduit angle 272 between 60° and 90° may be critical for specific features of guiding drilling fluid to the drill bit. In some embodiments, each of the fluid conduits 236 may have the same radial conduit angle 272. In some embodiments, different fluid conduits 236 may have different radial conduit angles 272. In some embodiments, adjacent fluid conduits 236 may have the same or different radial conduit angles 272. In some embodiments, the cleaning cutting element 222 is arranged along the drill axis 228, and one or more of the fluid conduits 236 extend radially from the drill axis 228 of the base hole 234 such that the radial conduit angle 272 is 90° (i.e., perpendicular to the drill axis 228).

[0035] Figure 2-4 This is a longitudinal cross-sectional view of the drill bit 210 shown in Figure 2-1. As shown, the main flow 238 of the drilling fluid can flow through a fluid passage 240 in the body 212 of the drill bit 210. The fluid passage 240 can be in fluid communication with a base hole 234. For example, the main flow 238 of the drilling fluid can flow from the fluid passage 240 in the body 212 and enter the base hole 234 formed in the base 225 of the cleaning cutting element 222. The main flow 238 can be diverted at the junction 242 of the cleaning cutting element 222 to a fluid conduit 236. This can cause the main flow 238 to separate into a flow 230 of drilling fluid, which is guided out of the fluid conduit 236 and directed to various features of the drill bit 210.

[0036] In the illustrated embodiment, the joint 242 is located at the upper portion of the cleaning cutting element 222. For example, the joint 242 may be positioned close to the superhard layer 223. In some examples, the joint 242 may be located close to the superhard layer 223 within the base 225 of the cleaning cutting element 222. In some embodiments, the joint 242 may be located at any portion along the length of the cleaning cutting element 222. The joint 242 may be positioned to help guide and / or divert the main stream 238 of the drilling fluid into the fluid conduit 236 and the flow 230 directed to the various features of the drill bit 210.

[0037] As discussed further in detail herein, the substrate 225 may include a deflector plate located at the junction 242 between the substrate bore 234 and the fluid conduit 236. The deflector plate may be located on the upper surface of the junction 242 to contact the drilling fluid as it flows into the junction 242. The deflector plate may help redirect the drilling fluid and reduce wear and / or erosion of the substrate 225 at the junction 242.

[0038] As shown, the base 225 of the cleaning cutting element 222 can extend above the chip flue surface 244 of the body 212. The base 225 extending above the chip flue surface 244 allows the outlet opening 224 to guide the flow 230 of drilling fluid from the fluid conduit 236 and toward a feature of the drill bit 210. In some embodiments, extending the base 225 above the chip flue surface 244 can allow the superhard layer 223 to extend further above the chip flue surface 244, thereby engaging the formation above the chip flue surface 244.

[0039] The cleaning cutting element 222 can be secured to the body 212 of the drill bit 210 at the drill chip flute surface 244. For example, the body 212 may include a cutting element cavity 245. The cutting element cavity 245 can extend from the drill chip flute surface 244 of the body 212 into the body 212. The cleaning cutting element 222 can be brazed to the drill bit 210 in the cutting element cavity 245 to secure the cleaning cutting element 222 to the body 212. In some embodiments, the cleaning cutting element 222 can be secured to the drill bit 210 at the cutting element cavity 245 in any manner, such as by welding, brazing, mechanical fasteners, shrinkage fit, press fit, interference fit, any other manner, and combinations thereof.

[0040] The cleaning cutting element 222 includes a cutting element diameter 247. In some embodiments, the cutting element diameter 247 can be within a range having an upper limit, a lower limit, or both an upper limit and a lower limit, including any of or between 0.5 inches (1.3 cm), 0.6 inches (1.5 cm), 0.7 inches (1.8 cm), 0.8 inches (2.0 cm), 0.9 inches (2.3 cm), 1.0 inch (2.5 cm), 1.1 inch (2.8 cm), 1.2 inches (3.0 cm), 1.3 inches (3.3 cm), 1.4 inches (3.6 cm), 1.5 inches (3.8 cm), and 2.0 inches (5.1 cm). For example, the cutting element diameter 247 can be greater than 0.5 inches (1.3 cm). In another example, the cutting element diameter 247 can be less than 2.0 inches (5.1 cm). In other examples, the cutting element diameter 247 can be any value in the range of 0.5 inches (1.3 cm) to 2.0 inches (5.1 cm). In some embodiments, a cutting element diameter 247 between 0.5 inches (1.3 cm) and 2.0 inches (5.1 cm) may be critical in order to allow drilling fluid to flow through the substrate 225.

[0041] Drill bit 210 includes a drill bit diameter 249. In some embodiments, the drill bit diameter 249 may have an upper limit, a lower limit, or both of the following values: 3 inches (7.6 cm), 4 inches (10.2 cm), 5 inches (12.7 cm), 6 inches (15.2 cm), 7 inches (17.8 cm), 8 inches (20.3 cm), 9 inches (22.9 cm), 10 inches (25.4 cm), 11 inches (27.9 cm), 12 inches (30.5 cm), 13 inches (33.0 cm), 14 inches (35.6 cm), 15 inches (38.1 cm), 16 inches (40.6 cm), 17 inches (43.2 cm), 18 inches (45.7 cm), and 26 inches (66.0 cm). For example, the drill bit diameter 249 may be greater than 3 inches (7.6 mm). In another example, the drill diameter 249 can be less than 26 inches (66 cm). In yet another example, the drill diameter 249 can be any value in the range between 3 inches (7.6 mm) and 26 inches (66 cm).

[0042] In some embodiments, the cleaning cutting element 222 and drill bit 210 may have a cutting element to drill bit diameter ratio. In some embodiments, the cutting element to drill bit diameter ratio may be within an upper limit, lower limit, or both, of any of or between 1:3, 1:4, 1:5, 1:6, 1:8, 1:9, 1:10, 1:11, 1:12, 1:15, 1:20. For example, the cutting element to drill bit diameter ratio may be greater than 1:3. In another example, the cutting element to drill bit diameter ratio may be less than 1:20. In other examples, the cutting element to drill bit diameter ratio may be any value within the range of 1:3 and 1:20. In some embodiments, a cutting element to drill bit diameter ratio between 1:5 and 1:12 may be critical for providing fluid flow to the central region of the drill bit.

[0043] According to at least one embodiment of this disclosure, the cleaning cutting element 522 may be located at the longitudinal axis 228 of the drill bit 210. For example, the longitudinal axis of the cleaning cutting element 222 (e.g., Figure 5 The 570 shown may be coaxial with the longitudinal axis 228 of the drill bit. In some embodiments, the longitudinal axis of the cleaning cutting element 222 may be offset relative to the longitudinal axis 228 of the drill bit 210. In some embodiments, the longitudinal axis of the cutting element 222 may be parallel to the longitudinal axis 228 of the drill bit. In some embodiments, the cleaning cutting element 222 may be non-parallel to or may be transverse to the longitudinal axis 228 of the drill bit.

[0044] Figure 3-1 This is a side view representing a cleaning cutting element 322 according to at least one embodiment of the present disclosure. The cleaning cutting element 322 may include a substrate 325 and an ultrahard layer 323 attached to the substrate 325. The substrate 325 includes a plurality of fluid conduits 336 that exit from the body of the substrate 325 at outlet openings 324.

[0045] The substrate 325 includes a bottom surface 346 and an upper surface 348 opposite to the bottom surface 346. A circumferential wall 350 may extend between the upper surface 348 and the bottom surface 346. In the illustrated embodiment, the substrate 325 may be cylindrical, with a circular bottom surface 346, a circular upper surface 348, and the circumferential wall 350 forming a cylinder between the bottom surface 346 and the upper surface 348. However, it should be understood that the substrate 325 may have other shapes, such as prisms with any cross-sectional shape, including oval, circular, triangular, square, rectangular, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, any other polygonal shape, and combinations thereof.

[0046] As discussed herein, the substrate 325 includes a substrate bore that extends at least partially through it. The substrate bore has an inlet in the bottom surface 346. The substrate bore extends through the body of the substrate 325 to a junction between the bottom surface 346 and the top surface 348. At the junction, a plurality of fluid conduits 336 can extend toward the circumferential wall 350. The fluid conduits 336 can exit the substrate 325 at an outlet opening 324 in the circumferential wall 350. In this way, drilling fluid can be guided out from the cleaning cutting element 322.

[0047] In some embodiments, the outlet openings 324 may be uniformly distributed circumferentially around the circumferential wall 350, such that the spacing between adjacent outlet openings 324 is the same. In some embodiments, the outlet openings 324 may be non-uniformly distributed circumferentially around the circumferential wall 350, such that the spacing between adjacent outlet openings 324 is different. The circumferential spacing of the outlet openings 324 may be based on the target of guiding drilling fluid from the substrate 325 through the outlet openings 324.

[0048] In some embodiments, the outlet openings 324 may be uniformly longitudinally distributed along the circumferential wall 350, such that the spacing between the outlet openings 324 and the upper surface 348 (and the bottom surface 346) may be the same. In some embodiments, the outlet openings 324 may be non-uniformly longitudinally distributed along the circumferential wall 350, such that the spacing between the outlet openings 324 and the upper surface 348 (and the bottom surface 346) may be different. The longitudinal spacing of the outlet openings 324 may be based on the target (e.g., chip flue, cutting element, cutter root) from the matrix 325 through the outlet openings 324.

[0049] Figure 3-2 yes Figure 3-1 A longitudinal cross-sectional view of the cleaning cutting element 322. The base 325 includes a base bore 334 passing through it. As discussed herein, drilling fluid can enter the base bore 334 from a fluid passage in the body of the drill bit. The base bore 334 has an inlet 352 in a bottom surface 346. Drilling fluid can enter the base 325 and the base bore 334 at the inlet 352 in the bottom surface 346. The drilling fluid can be diverted to a fluid conduit 336 at or near a junction 342 located on or near the upper surface 348 of the base 325. The drilling fluid can exit the base 325 through an outlet opening 324 in the fluid conduit 336.

[0050] In the illustrated embodiment, the inlet 352 in the bottom surface 346 has an inlet diameter 354 and an orifice diameter 356 within the body of the substrate 325. The inlet 352 may be funnel-shaped, such that the inlet diameter 354 is larger than the orifice diameter 356, to help improve hydraulic flow through the substrate orifice 334 and / or increase the pressure of the drilling fluid through the substrate orifice 334. In some embodiments, the inlet diameter 354 of the inlet 352 may be larger than the outlet diameter 358 of the outlet opening 324. This helps to increase the pressure of the drilling fluid as it exits the substrate 325 through the outlet opening 324.

[0051] In some implementations, the inlet diameter 354 can be within a range of upper limits, lower limits, or both, including any of the following values: 0.3 inches (0.8 cm), 0.4 inches (1.0 cm), 0.5 inches (1.3 cm), 0.6 inches (1.5 cm), 0.7 inches (1.8 cm), 0.8 inches (2.0 cm), 0.9 inches (2.3 cm), 1.0 inch (2.5 cm), 1.1 inch (2.8 cm), 1.2 inches (3.0 cm), and 1.3 inches (3.3 cm). For example, the inlet diameter 354 can be greater than 0.3 inches (0.8 cm). In another example, the inlet diameter 354 can be less than 1.3 inches (3.3 cm). In yet another example, the inlet diameter 354 can be any value within the range of 0.3 inches (0.8 cm) and 1.3 inches (3.3 cm). In some implementations, an inlet diameter 354 between 0.5 inches (1.3 cm) and 1.1 inches (2.8 cm) may be critical in order to maintain sufficient flow of drilling fluid through the matrix orifice 334.

[0052] In some implementations, the outlet diameter 358 can be within a range of upper limits, lower limits, or both, including any of the following values: 0.1 inch (0.3 cm), 0.2 inch (0.5 cm), 0.3 inch (0.8 cm), 0.4 inch (1.0 cm), 0.5 inch (1.3 cm), 0.5 inch (1.3 cm), 0.6 inch (1.5 cm), 0.7 inch (1.8 cm), 0.8 inch (2.0 cm), 0.9 inch (2.3 cm), 1.0 inch (2.5 cm). For example, the outlet diameter 358 can be greater than 0.1 inch (0.3 cm). In another example, the outlet diameter 358 can be less than 1.0 inch (2.5 cm). In yet another example, the outlet diameter 358 can be any value within the range of 0.1 inch (0.3 cm) and 1.0 inch (2.5 cm). In some implementations, an outlet diameter 358 between 0.3 inches (0.8 cm) and 0.8 inches (2.0 cm) may be critical in order to maintain the flow rate and pressure of the flow exiting the fluid conduit 336.

[0053] The inlet diameter 354 and outlet diameter 358 may have an inlet-to-outlet ratio. In some embodiments, the inlet-to-outlet ratio may have an upper limit, a lower limit, or both an upper limit and a lower limit, including any of 1:1, 5:4, 4:3, 3:2, 2:1, 3:1, 4:1, 5:1, or any value between them. For example, the inlet-to-outlet ratio may be greater than 1:1. In another example, the inlet-to-outlet ratio may be less than 5:1. In yet another example, the inlet-to-outlet ratio may be any value between 1:1 and 5:1. In some embodiments, an inlet-to-outlet ratio between 4:3 and 2:1 may be critical in order to maintain the desired drilling fluid pressure at outlet 324. In some embodiments, each outlet opening 324 may have the same inlet-to-outlet ratio. In some embodiments, different outlet openings may have different inlet-to-outlet ratios.

[0054] As discussed herein, the superhard layer 323 may be attached to the substrate 325 at the upper surface 348 of the substrate 325. In some embodiments, the superhard layer 323 may be formed directly on the substrate 325. For example, when the superhard layer 323 is formed using a high pressure high temperature (HPHT) technique, the superhard layer 323 may be formed on the substrate 325.

[0055] In some embodiments, the superhard layer 323 may be attached to the upper portion 360 of the substrate 325. After the superhard layer 323 is formed on the upper portion 360 of the substrate 325, a lower portion 362 of the substrate may be formed. For example, the lower portion 362 may be additively manufactured based on the upper portion 360. Additive manufacturing may include forming the substrate 325 layer by layer on the upper portion 360. According to at least one embodiment of the present disclosure, at least a portion of the additively manufactured substrate may allow the formation of substrate holes 334 and fluid conduits 336 in the substrate 325. This may help reduce manufacturing time, including the time spent milling, grinding, and otherwise processing the substrate 325. In some embodiments, at least a portion of the additively manufactured substrate 325 may allow the substrate 325 to include complex geometries of substrate holes 334 and / or fluid conduits 336, which may not be formed by milling and / or grinding. For example, additive manufacturing of the substrate 325 can allow the substrate hole 334 and / or fluid conduit 336 to include curved portions, thereby guiding the fluid conduit 336 and the outlet opening 324 to specific features of the drill bit.

[0056] In some embodiments, the substrate 325 can be formed as a single monolithic block, such as by casting, infiltration, sintering, etc. After the substrate 325 is formed, substrate holes 334 and / or fluid conduits 336 can be formed in the substrate 325. For example, the substrate holes 334 and / or fluid conduits 336 can be machined into the body of the substrate 325 by drilling, milling, and / or grinding. This can help simplify the manufacture of the cleaning cutting element 322 and / or the substrate 325.

[0057] Figure 4 This is a cross-sectional view representing a cleaning cutting element 422 according to at least one embodiment of the present disclosure; the cleaning cutting element 422 may include a substrate 425 and an ultrahard layer 423 connected to the substrate 425. The substrate 425 includes a substrate bore 434 that at least partially passes through it. As discussed herein, drilling fluid may enter the substrate bore 434 through an inlet 452 in fluid communication with a fluid passage in the body of the drill bit. The drilling fluid may be diverted to a fluid conduit 436 at or near a junction 442 located on or near the upper surface 448 of the substrate 425. The drilling fluid may flow out of the substrate 425 through an outlet opening 424 of the fluid conduit 436, which exits from a circumferential wall 450 extending between the bottom surface 446 and the upper surface 448.

[0058] According to at least one embodiment of this disclosure, the cleaning cutting element 422 may include a deflector 464. The deflector 464 may be located at the junction 442 between the base bore 434 and the fluid conduit 436. The deflector 464 may be positioned to withstand the impact of drilling fluid at the junction 442. The drilling fluid may impact the deflector 464 and then be deflected into the fluid conduit 436. The deflector 464 may reduce the direct interaction of the drilling fluid with the matrix material of the base 425 at the junction 442. This may help reduce or prevent damage to the base 425 caused by the drilling fluid interacting with the matrix material of the base 425 at the junction 442. This may help extend the service life of the cleaning cutting element 422.

[0059] In some implementations, the deflector 464 may be formed of a corrosion-resistant and / or wear-resistant material. For example, the deflector 464 may be formed of PCD, PDC, or thermally stabilized polycrystalline diamond (TSP). Forming the deflector 464 with a corrosion-resistant and / or wear-resistant material can help reduce the wear of the drilling fluid on the deflector 464 and / or clean other parts of the cutting element 422.

[0060] In the illustrated embodiment, the deflector 464 has a conical shape. The conical shape can help redirect the flow of drilling fluid into the fluid conduit 436. The deflector 464 can have any shape. For example, the deflector 464 can be dome-shaped, pyramidal, truncated cone-shaped, any other shape, or combinations thereof.

[0061] In some embodiments, the deflector 464 may be formed together with the substrate 425 when the superhard layer 423 is formed on the substrate 425. In some embodiments, the deflector 464 may be formed separately from the substrate 425 and subsequently fixed to the substrate 425 in the upper surface of the joint 442. The deflector 464 may be press-fitted, brazed, sintered, or mechanically fixed to the upper surface of the joint 442.

[0062] Figure 5 This is a cross-sectional view representing a cleaning cutting element 522 according to at least one embodiment of the present disclosure. The cleaning cutting element 522 may include a substrate 525 and an ultrahard layer 523 connected to the substrate 525. The substrate 525 includes a substrate bore 534 at least partially passing through it. As discussed herein, drilling fluid may enter the substrate bore 534 through an inlet 552 in fluid communication with a fluid passage in the body of the drill bit. The drilling fluid may be diverted to a fluid conduit 536 at or near a junction 542 located on or near the upper surface 548 of the substrate 525. The drilling fluid may flow out of the substrate 525 through an outlet opening 524 of the fluid conduit 536, which exits from a circumferential wall 550 extending between the bottom surface 546 and the upper surface 548.

[0063] In the illustrated embodiment, the fluid conduit 536 may be oriented such that a longitudinal conduit angle 566 is formed between the conduit axis 568 of the fluid conduit 536 and the longitudinal axis 570 of the cleaning cutting element 522. The longitudinal conduit angle 566 can be any angle. In some embodiments, the longitudinal conduit angle 566 may have an upper limit, a lower limit, or both an upper limit and a lower limit having values ​​including any of 150°, 120°, 110°, 100°, 90°, 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°. For example, the longitudinal conduit angle 566 may be greater than 45°. In another example, the longitudinal conduit angle 566 may be less than 90°. In yet another example, the longitudinal conduit angle 566 may be any value within the range of 45° and 90°. In some embodiments, a longitudinal conduit angle between 90° and 150° may be critical for specific features of guiding drilling fluid to the drill bit. The longitudinal conduit angle 566 of each fluid conduit 536 can be based on a corresponding target for the fluid conduit 536 (e.g., chip flute, cutting element, blade root). In some embodiments, each of the fluid conduits 536 may have the same longitudinal conduit angle 566. In some embodiments, different fluid conduits 536 may have different conduit angles 566.

[0064] Figure 6 This is a cross-sectional view representing a cleaning cutting element 622 according to at least one embodiment of the present disclosure. The cleaning cutting element 622 may include a substrate 625 and an ultrahard layer connected to the substrate 625. The substrate 625 includes a substrate bore 634 at least partially passing through it. As discussed herein, drilling fluid may enter the substrate bore 634 through an inlet in fluid communication with a fluid passage in the body of the drill bit. The drilling fluid may be diverted to the fluid conduit 636 at a junction 642 between the substrate bore 634 and the fluid conduit 636. The drilling fluid may flow out of the substrate 625 through an outlet opening 624 of the fluid conduit 636, which exits from a circumferential wall 650 of the substrate 625.

[0065] According to at least one embodiment of this disclosure, the cleaning cutting element 622 may include one or more non-linear fluid conduits 636. For example, such as Figure 6As shown, the cleaning cutting element 622 may include a fluid conduit 636 that is curved between the base bore 634 and the circumferential wall 650. In other words, the fluid conduit 636 may have a curved profile. The curved fluid conduit 636 may help orient drilling fluid exiting from the outlet 624 to guide it to specific features of the drill bit. In some embodiments, additive manufacturing can facilitate the formation of the curved fluid conduit 636 in the base 625 by forming the base 625 layer by layer. According to at least one embodiment of this disclosure, at least a portion of the additively manufactured base may allow the formation of the base bore 634 and the fluid conduit 636 in the base 325. This can help reduce manufacturing time, including the time spent milling, grinding, and otherwise processing the base 325.

[0066] Figure 7 This is a longitudinal cross-sectional view of a drill bit 710 having a cleaning cutting element 722 fixed to its body 712 according to at least one embodiment of the present disclosure. The cleaning cutting element 722 may include a base hole 734 formed in a base 725 and extending at least partially through the base. The base hole 734 may be in fluid communication with a fluid passage 740 through the body 712. The base hole 734 may guide drilling fluid to one or more fluid conduits 736. The fluid conduits 736 may guide drilling fluid to one or more features of the drill bit 710.

[0067] The body 712 may include a cutting element cavity 745 formed in the downhole surface 744 of the body 712. According to at least one embodiment of this disclosure, a cleaning cutting element 722 may be secured to the body 712 via a sleeve 776. For example, the cleaning cutting element 722 may be brazed to the sleeve 776. The sleeve 776 may be secured to the body 712 at the cutting element cavity 745. For example, the sleeve 776 may be secured to the body 712 by welding, interference fit, press fit, mechanical fasteners, any other connection mechanism, or combinations thereof. In some embodiments, the sleeve 776 may be made of the same material as the base of the cleaning element. In some embodiments, the sleeve 776 may be formed of any other material, such as hardened tool steel. In some embodiments, the sleeve 776 may be formed of a sacrificial component that will be replaced during servicing of the drill bit 710.

[0068] In some embodiments, the materials of the body 712 and the base 725 of the drill bit 710 can have different coefficients of thermal expansion. This can cause the expansion rate of the body 712 and the cutting element cavity 745 within the body 712 to differ from the expansion rate of the base 725. When the body 712 and the base 725 cool, the shape change rate of the cutting element cavity 745 can be faster or slower than that of the base 725, thereby preventing the connection between the base 725 and the body 712. For example, if the coefficient of thermal expansion of the body 712 is greater than that of the base 725, the cutting element cavity 745 can shrink and damage the base 725 during the brazing and / or cooling process. In some examples, if the coefficient of thermal expansion of the body 712 is less than that of the base 725, the connection between the base 725 and the cutting element cavity 745 may loosen after the base 725 and the body 712 have cooled.

[0069] To improve the connection between the base 725 and the body 712, the base 725 can be fixed to the sleeve 776. The sleeve 776 can be independently fixed to the cutting element cavity 745 of the body 712. This can help reduce the mismatch in the coefficients of thermal expansion, thereby improving the connection between the base 725 and the body 712.

[0070] Figure 8-1 This is an exploded perspective view of a cleaning cutting system 886 according to at least one embodiment of the present disclosure. The cleaning cutting system 886 includes a cleaning base 888 and a cutting element 889. The cutting element 889 may include an ultrahard layer 890 bonded to a substrate 891. In some embodiments, the cutting element 889 may be made entirely of an ultrahard material (such as PCD) or thermally stabilized polycrystalline diamond (TSP). The cleaning base 888 may include a cutting element cavity 892. The cutting element 889 may be secured to the cleaning base 888 in the cavity 892, such as by brazing, welding, or other fixing mechanisms. The cleaning base 888 may also include one or more fluid conduits 836 that exit the cleaning base 888 at an outlet opening 824.

[0071] According to at least one embodiment of this disclosure, the cleaning base 888 can be fixed to the cutting element cavity (e.g., in the central region of the drill bit (e.g., drill bit 210)). Figure 2-4The cutting element 889 can be fixed to the cleaning base 888 at the cutting element cavity 892 (cutting element cavity 245). Using separate cutting elements 889 and cleaning base 888 can help improve the drill bit's flexibility and / or versatility. For example, the cleaning base 888 can be formed separately from the cutting element 889. This allows the cleaning base 888 to include different and / or more complex internal geometries of one or more fluid conduits 836 than possible in the matrix of the cutting element 889. In some embodiments, utilizing separate cutting elements 889 and cleaning base 888 can allow drill bit manufacturers to utilize cutting elements 889 that are already in stock or readily available.

[0072] Figure 8-2 yes Figure 8-2 The cleaning cutting system 886 is shown in a cross-sectional view of its assembled configuration. In the illustrated embodiment, a cutting element 889 is secured to a cleaning base 888 at a cutting element recess 892. For example, the cutting element 889 may be connected to the cleaning base 888 at the cutting element recess 892 by brazing, welding, or other means. In the illustrated embodiment, the cleaning base 888 includes a base bore 894 that is in fluid communication with the fluid passages of the drill bit. Drilling fluid from the fluid passages of the drill bit can enter the base bore 894, be diverted to one or more fluid conduits 836, and exit from the cleaning base 888 through an outlet opening 824. As discussed herein, the cleaning base 888 can improve the flexibility of the drill bit, including the flexibility in the placement and / or orientation of one or more fluid conduits 836 and / or outlet opening 824 in the cleaning base 888.

[0073] Figure 9 This is a representation of a method 978 for forming a cutting element according to at least one embodiment of the present disclosure. The method may include forming a superhard layer on a substrate at 980. As discussed herein, forming a superhard layer on a substrate may include forming a superhard material layer directly on a matrix material forming the substrate, such as by a high-temperature, high-pressure (HTHP) process.

[0074] The operator can form a matrix bore in the substrate at point 982. The matrix bore can extend from an inlet at the bottom surface of the substrate to a junction near the superhard layer. The operator can form multiple conduits in the substrate at point 984. The conduits can extend from the junction to the circumferential wall of the substrate body. In some embodiments, forming the matrix bore and multiple conduits after forming the superhard layer on the substrate at point 980 is critical.

[0075] In some embodiments, forming the matrix bore and forming the conduit involves additively manufacturing the matrix layer by layer around the matrix bore and the conduit. In some embodiments, an operator can fix a deflector at the junction between the matrix bore and the conduit.

[0076] Implementations of the clean cutting element have been described primarily with reference to wellbore drilling operations; the clean cutting element described herein can be used in applications other than wellbore drilling. In other embodiments, the clean cutting element according to this disclosure can be used externally in wellbores or other downhole environments used for exploring or producing natural resources. For example, the clean cutting element of this disclosure can be used in boreholes used for laying utility pipelines. Therefore, the terms “wellbore,” “borehole,” etc., should not be construed as limiting the tools, systems, assemblies, or methods of this disclosure to any particular industry, field, or environment.

[0077] This document describes one or more specific embodiments of the present disclosure. These described embodiments are examples of the currently disclosed technology. Additionally, in order to provide a brief description of these embodiments, not all features of an actual embodiment may be described in this specification. It should be understood that when developing any such actual implementation in any engineering or design project, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which may vary from embodiment to embodiment. Furthermore, it should be understood that such development work may be complex and time-consuming, but will still be a routine task in design, fabrication, and manufacturing for those skilled in the art who benefit from this disclosure.

[0078] Additionally, it should be understood that references to “one embodiment” or “implementation” in this disclosure are not intended to be construed as excluding the existence of additional embodiments that also incorporate the described features. For example, any element described with respect to an embodiment herein may be combined with any element of any other embodiment described herein. As will be appreciated by one of ordinary skill in the art as covered by embodiments of this disclosure, the figures, percentages, ratios, or other values ​​stated herein are intended to include, and also include, other values ​​that are “about” or “approximately” as said values. Therefore, the values ​​should be interpreted broadly enough to cover values ​​that are at least close enough to say the value to perform the desired function or achieve the desired result. The values ​​include at least the variations expected in a suitable manufacturing or production process and may include values ​​within 5%, 1%, 0.1%, or 0.01% of said value.

[0079] In view of this disclosure, those skilled in the art will recognize that equivalent constructions do not depart from the spirit and scope of this disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of this disclosure. Equivalent constructions (including the functional “apparatus plus function” clause) are intended to cover structures described herein as performing said functions, including structural equivalents operating in the same manner and equivalent structures providing the same function. The applicant’s explicit intent is not to invoke apparatus plus function or other functional requirements in any claim, except for those claims where the phrase “apparatus for…” appears with the associated function. Every addition, deletion, and modification to the embodiments falling within the meaning and scope of the claims will be included in the claims.

[0080] As used herein, the terms “approximately,” “about,” and “substantially” mean a quantity close to the stated amount, which is within standard manufacturing or process tolerances or still performs the desired function or achieves the desired result. For example, the terms “approximately,” “about,” and “substantially” can refer to a quantity less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount. Furthermore, it should be understood that any direction or frame of reference in the foregoing description is only relative direction or movement. For example, any reference to “up” and “down,” or “above” or “below”, describes only the relative position or movement of the relevant element.

[0081] This disclosure may be embodied in other specific forms without departing from the spirit or characteristics thereof. The described embodiments should be considered illustrative rather than restrictive. Therefore, the scope of this disclosure is indicated by the appended claims rather than by the foregoing description. Variations in the meaning and scope of equivalent forms of the claims are to be included within the scope of the claims.

Claims

1. A drill bit comprising: A body having a longitudinal axis, through which a fluid channel extends; Multiple blades extending from the main body, the multiple blades forming multiple chip removal grooves between adjacent blades; as well as A cleaning cutting element, located in the central region of the drill bit, comprising: A matrix, the matrix including at least partially extending therethrough matrix holes, the matrix holes being in fluid communication with the fluid channels of the body; A plurality of conduits in fluid communication with the matrix pores, each of the plurality of conduits including an outlet opening that guides drilling fluid out of the body of the drill bit; and An ultrahard layer is attached to the upper surface of the substrate.

2. The drill bit of claim 1, further comprising a deflector located at the junction between the base hole and the plurality of guide tubes.

3. The drill bit of claim 2, wherein the deflector is formed of an ultrahard material.

4. The drill bit according to claim 1, wherein the longitudinal axis of the cleaning cutting element is coaxial with the longitudinal axis of the body.

5. The drill bit according to claim 4, wherein the superhard layer has a conical shape.

6. The drill bit of claim 1, wherein the outlet opening of at least one of the plurality of conduits is oriented to guide fluid to a chip removal groove in the plurality of chip removal grooves.

7. The drill bit of claim 1, wherein the base hole is oriented substantially parallel to the longitudinal axis of the body.

8. The drill bit of claim 1, wherein the plurality of guide tubes are oriented transversely to the base hole.

9. The drill bit according to claim 1, wherein the number of the plurality of guide tubes is the same as the number of the plurality of cutting wings.

10. The drill bit of claim 1, wherein the ratio of the diameter of the cleaning cutting element to the diameter of the drill bit is between 1:6 and 1:

12.

11. A cutting element comprising: Ultra-hard layer; as well as A substrate, the substrate being connected to the superhard layer, the substrate comprising: main body; The superhard layer is fixed to the upper surface of the main body; The bottom surface of the main body; and The circumferential wall of the body extends between the upper surface and the bottom surface, the body forms a base hole, the base hole has an inlet in the bottom surface of the body, the base hole includes a plurality of conduits leading to a plurality of outlet openings in the circumferential wall of the body.

12. The cutting element according to claim 11, wherein the base hole is oriented along the longitudinal axis of the body.

13. The cutting element of claim 11, wherein the diameter of the superhard layer and the substrate is between 0.75 inches (1.9 cm) and 1.25 inches (3.2 cm).

14. The cutting element of claim 11, wherein at least one of the plurality of conduits has a curved profile between the base hole and the circumferential wall.

15. The cutting element of claim 11, wherein the substrate includes a cleaning base, the cleaning base including a cutting element cavity in the upper surface, and wherein the superhard layer is connected to a cutting element body fixed to the cutting element cavity.

16. The cutting element of claim 11, further comprising a deflection plate located at the junction between the base hole and the plurality of conduits.

17. The cutting element of claim 16, wherein the deflection plate is formed of an ultrahard material.

18. A method for manufacturing a cutting element, the method comprising: A super-hard layer is formed on the substrate; A matrix hole is formed in the matrix, the matrix hole extending from an inlet at the bottom surface of the matrix to a junction near the superhard layer; as well as A plurality of conduits are formed in the substrate, the plurality of conduits extending from the joint to the circumferential wall of the substrate.

19. The method of claim 18, wherein forming the substrate pores and forming the plurality of conduits comprises additively manufacturing the substrate layer by layer around the substrate pores and the plurality of conduits.

20. The method of claim 18, further comprising fixing a deflector at the junction between the base hole and the plurality of conduits.

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