A cutting element and methods of making same
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ELEMENT SIX (UK) LTD
- Filing Date
- 2026-01-29
- Publication Date
- 2026-08-06
Smart Images
Figure EP2026052396_06082026_PF_FP_ABST
Abstract
Description
[0001] [OFFICIAL]
[0002] PF1639-WO-0-ORD A CUTTING ELEMENT AND METHODS OF MAKING SAME
[0003] Field
[0004] This disclosure relates generally to a cutting element, for example formed as a cutting element for drilling in the oil and gas industry or as an insert for machine tools, and to methods for making the same.
[0005] Background
[0006] In various fields such as earth-boring, road milling, and mining tough materials such as rock, asphalt, or concrete are engaged and degraded using cutting elements that are typically coupled to a movable body such as a drill bit secured to a drill string to bring the cutting elements into contact with the material to be degraded as the body moves. For example, when exploring for or extracting subterranean oil, gas, or geothermal energy deposits, a plurality of cutting elements is typically secured to a drill bit attached to the end of a drill string and as the drill bit is rotated, the cutting elements degrade a subterranean formation forming a wellbore, which allows the drill bit to advance through the formation. In another example, when preparing an asphalt road for resurfacing, cutting elements are typically coupled to tips of picks that may be connected to a rotatable drum. As the drum is rotated, the cutting elements degrade the asphalt leaving a surface ready for application of a fresh layer.
[0007] The cutting elements used in such applications often include super-hard materials, such as polycrystalline diamond material, sintered to a substrate material such as tungsten carbide, in a high-pressure, high-temperature environment. These cutting elements typically include a cutting edge formed in the super-hard material designed to scrape against and shear away a surface. While effective in cutting
[0008]
[0009] [OFFICIAL]
[0010] PF1639-WO-0-ORD formation or other materials, such cutting elements may be susceptible to chipping, cracking, or partial fracturing when subjected to high forces.
[0011] In drilling operations, a cutting element, also termed an insert, is subjected to heavy loads and high temperatures at various stages of its useful life. In the early stages of drilling, when the sharp cutting edge of the insert contacts the subterranean formation, it is subjected to large contact pressures. This results in the possibility of a number of fracture processes such as fatigue cracking being initiated. As the cutting edge of the insert wears, the contact pressure decreases and is generally too low to cause high energy failures. However, this pressure can still propagate cracks initiated under high contact pressures and may eventually result in spallingtype failures. In the drilling industry, PCD cutter performance is determined by a cutter's ability to achieve high penetration rates in increasingly demanding environments, and still retain a good condition post-drilling (enabling re-use if desired). In any drilling application, cutters may wear through a combination of smooth, abrasive type wear and spalling / chipping type wear. Whilst a smooth, abrasive wear mode is desirable because it delivers maximum benefit from the highly wear-resistant PCD material, spalling or chipping type wear is unfavourable. Even fairly minimal fracture damage of this type can have a deleterious effect on both cutting life and performance.
[0012] Cutting efficiency may be rapidly reduced by spalling-type wear as the rate of penetration of the drill bit into the formation is slowed. Once chipping begins, the amount of damage to the diamond table continually increases, as a result of the increased normal force required to achieve a given depth of cut. Therefore, as cutter damage occurs and the rate of penetration of the drill bit decreases, the response of increasing weight on bit may quickly lead to further degradation and ultimately catastrophic failure of the chipped cutting element.
[0013]
[0014] [OFFICIAL]
[0015] PF1639-WO-0-ORD It has been appreciated that cutting elements and machine tool cutting inserts having cutting surfaces with non-planar, shaped topographies or topologies may be advantageous in various applications. In particular, the surface features and / or shape of the cutting surface may be beneficial in use to divert, for example, chips from the working surface being worked on by the cutter or machine tool, and / or in some instances to act as a chip breaker, with a view to reducing the risk of chipping, or cracking, thereby extending the working life of the cutting element.
[0016] There is a need to provide super-hard inserts such as inserts for cutting or machine tools having effective performance and enhanced resistance to chipping or spalling.
[0017] Summary
[0018] Viewed from a first aspect there is provided a cutting element comprising:
[0019] a substrate having a peripheral side edge, the peripheral side edge having an associated radius of curvature; and
[0020] a body of superhard polycrystalline material bonded to the substrate along an interface, the body of superhard polycrystalline material having a peripheral side edge and a longitudinal axis; wherein:
[0021] the body of superhard polycrystalline material comprises:
[0022] a working surface;
[0023] a plurality of spaced apart cutting edges, the cutting edges being spaced around the working surface and separated by a respective further region, the cutting edges have an associated radius of curvature, the radius of curvature of one or more of the cutting edges being less than the radius of curvature of the substrate; and
[0024] the body of superhard polycrystalline material further comprises a chamfer extending from the cutting edges to the working surface.
[0025]
[0026] [OFFICIAL]
[0027] PF1639-WO-0-ORD wherein the working surface comprises:
[0028] a central region extending about the longitudinal axis, the central region being non-planar; and
[0029] a plurality of further regions extending from the central region to a respective one of said plurality of spaced apart cutting edges, said further regions forming a plurality of lobes; and
[0030] a plurality of ridged regions extending between adjacent lobes, the plurality of ridged regions extending from an intersection region between adjacent lobes towards the peripheral side edge of the body of superhard polycrystalline material; wherein:
[0031] the working surface including the lobes comprises an undulating topology.
[0032] Viewed from a second aspect there is provided a method of making the cutting element defined above comprising:
[0033] providing a mass of particles or grains of superhard material to form a pre-sinter assembly; and
[0034] treating the pre-sinter assembly in the presence of a catalyst / solvent material for the superhard grains at an ultra-high pressure of around 5.5 GPa or greater and a temperature at which the superhard material is more thermodynamically stable than graphite to sinter together the grains of superhard material to form the cutting element.
[0035] Viewed from a yet further aspect there is provided a drill bit or a component of a drill bit for boring into the earth, comprising one or more of the above defined cutting elements.
[0036] In examples where the insert is used as a cutting element, for example for drilling in the oil and gas industry, the shape of the cutting element and any surface topography may be used to direct or divert the rock or earth away from the drill bit
[0037]
[0038] [OFFICIAL]
[0039] PF1639-WO-0-ORD to which the cutter is attached. Alternatively or additionally, for such uses or when used as an insert for a machine tool for machining a work piece, the shape and surface topography may act as a chip breaker suitable for controlling aspects of the size and shape of chips formed in use.
[0040] Brief description of the drawings
[0041] Various examples are now described with reference to the accompanying drawings in which:
[0042] Figure 1 is a schematic drawing of a conventional PCD compact comprising a PCD structure bonded to a substrate;
[0043] Figure 2 is a schematic drawing of the microstructure of a conventional body of PCD material;
[0044] Figure 3 is a schematic drawing of a conventional PCD compact comprising a PCD structure bonded to a substrate having a chamfered peripheral edge to act as a cutting edge;
[0045] Figures 4a and 4b are schematic perspective views from above and one side of a cutting element according to a first example;
[0046] Figures 5 and 5b are plan views of the cutting element of Figures 4a and 4b respectively; and
[0047]
[0048] [OFFICIAL]
[0049] PF1639-WO-0-ORD Figure 6 is a schematic cross sectional side view through the cutting element of Figures 4a-5b.
[0050] Detailed description
[0051] Referring in general to the following description and accompanying drawings, various versions of the present disclosure are described and illustrated to show its structure and method of operation. Common elements of the illustrated examples are designated by the same reference numerals.
[0052] As used herein, “drill bit” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore in subterranean formations and includes, for example, fixed cutter bits, rotary drill bits, percussion bits, core bits, eccentric bits, bi-center bits, reamers, mills, drag bits, roller cone bits, hybrid bits and other drilling bits and tools known in the art.
[0053] As used herein, a “superhard material” is a material having a Vickers hardness of at least about 28 GPa. Diamond and cubic boron nitride (cBN) material are examples of superhard materials.
[0054] As used herein, a “superhard construction” means a construction comprising a body of polycrystalline superhard material. In such a construction, a substrate may be attached thereto.
[0055] As used herein, polycrystalline diamond (PCD) is a type of polycrystalline superhard (PCS) material comprising a mass of diamond grains, a substantial portion of which are directly inter-bonded with each other and in which the content of diamond is at least about 80 volume percent of the material. In one example of PCD material, interstices between the diamond grains may be at least partly filled with a binder material comprising a catalyst for diamond. As used herein, “interstices” or
[0056]
[0057] [OFFICIAL]
[0058] PF1639-WO-0-ORD “interstitial regions” are regions between the diamond grains of PCD material. In examples of PCD material, some or all interstices or interstitial regions may be substantially or partially filled with a material other than diamond, or they may be substantially empty. PCD material may comprise at least a region from which catalyst material has been removed from the interstices, leaving interstitial voids between the diamond grains.
[0059] Cutter elements for use in drill bits in the oil and gas industry typically comprise a layer of polycrystalline diamond (PCD) bonded to a cemented carbide substrate. PCD material is typically made by subjecting an aggregated mass of diamond particles or grains to an ultra-high pressure of greater than about 5 GPa, and temperature of at least about 1200°C, typically about 1440°C, in the presence of a sintering aid, also referred to as a solvent-catalyst material for diamond. Solventcatalyst materials for diamond are understood to be materials that are capable of promoting direct inter-growth of diamond grains at a pressure and temperature condition at which diamond is thermodynamically more stable than graphite.
[0060] Examples of solvent-catalyst materials for diamond are cobalt, iron, nickel and certain alloys including alloys of any of these elements.
[0061] As used herein, PCBN (polycrystalline cubic boron nitride) material refers to a type of superhard material comprising grains of cubic boron nitride (cBN) dispersed within a matrix comprising metal or ceramic.
[0062] The term "substrate" as used herein means any substrate over which the superhard material layer is formed. For example, a "substrate" as used herein may be a transition layer formed over another substrate.
[0063]
[0064] [OFFICIAL]
[0065] PF1639-WO-0-ORD The superhard construction shown in the figures may be suitable, for example, for use as a cutter insert for a drill bit for boring into the earth. Such an earth-boring drill bit (not shown) includes a plurality of cutting elements, and typically includes a bit body which may be secured to a shank by way of a threaded connection and / or a weld extending around the earth-boring drill bit on an exterior surface thereof along an interface between the bit body and the shank. A plurality of cutting elements are attached to a face of the bit body, one or more of which may comprise a cutting element as described herein in further detail below.
[0066] Figures 1 and 2 show a conventional polycrystalline composite construction 1 , T for use as a cutter insert for a drill bit (not shown) for boring into the earth. The polycrystalline composite compact or construction 1, T comprises a body of polycrystalline super hard material 2, 2’ integrally bonded at an interface 12 to a substrate 10. The super hard material may be, for example, polycrystalline diamond (PCD) and the super hard particles or grains may be of natural or synthetic origin.
[0067] The substrate 10 may be formed of a hard material such as a cemented carbide material and may be, for example, cemented tungsten carbide. The binder metal for such carbides suitable for forming the substrate 10 may be, for example, nickel, cobalt, iron or an alloy containing one or more of these metals. Typically, this binder will be present in an amount of 10 to 20 mass %, but this may be as low as 6 mass % or less. Some of the binder metal may infiltrate the body of polycrystalline super hard material 2, 2’ during formation of the compact 1, T.
[0068] As shown in Figure 2, during formation of the polycrystalline composite construction 1, T, the interstices 24 between the grains 22 of super hard material such as diamond grains in the case of PCD, may be at least partly filled with a non-super hard phase material. This non-super hard phase material, also known as a filler
[0069]
[0070] [OFFICIAL]
[0071] PF1639-WO-0-ORD material may comprise residual catalyst / binder material, for example cobalt, nickel or iron.
[0072] The polycrystalline composite construction 1, T when used as a cutting element may be mounted in use in a bit body, such as a drag bit body (not shown).
[0073] The substrate 10 may be, for example, generally cylindrical having a peripheral surface 3, a peripheral top edge 8 and a distal free end.
[0074] The exposed surface of the super hard material 4 opposite the substrate 10 forms or comprises a working surface which also acts as a rake face in use. In some conventional cutting elements such as that shown in Figure 3, a chamfer 28 typically extends between the working surface 4 and a cutting edge 6, and at least a part of a flank or barrel 2 of the cutting element, the cutting edge 36 being defined by the edge of the chamfer 28 and the flank 2.
[0075] The working surface or Take face” 4 of the polycrystalline composite construction 1 , T is the surface or surfaces over which the chips of material being cut flow when the cutter is used to cut material from a body, the rake face 4 directing the flow of newly formed chips. This face 4 is commonly also referred to as the top face or working surface of the cutting element as the working surface 4 is the surface which, along with its edge 6, is intended to perform the cutting of a body in use. It is understood that the term “cutting edge”, as used herein, refers to the actual cutting edge, defined functionally as above, at any particular stage or at more than one stage of the cutter wear progression up to failure of the cutter, including but not limited to the cutter in a substantially unworn or unused state.
[0076] As used herein, “chips” are the pieces of a body removed from the work surface of the body being cut by the polycrystalline composite construction 1, T in use.
[0077]
[0078] [OFFICIAL]
[0079] PF1639-WO-0-ORD As used herein, the “flank” 2 of the cutter is the surface or surfaces of the cutter that passes over the surface produced on the body of material being cut by the cutter and is commonly referred to as the side or barrel of the cutter. The flank 2 may provide a clearance from the body and may comprise more than one flank face.
[0080] As used herein, a “wear scar” is a surface of a cutter formed in use by the removal of a volume of cutter material due to wear of the cutter. A flank face may comprise a wear scar. As a cutter wears in use, material may progressively be removed from proximate the cutting edge, thereby continually redefining the position and shape of the cutting edge, rake face and flank as the wear scar forms.
[0081] With reference to Figure 3, the chamfer 28 is formed in the structure adjacent the cutting edge 6 and flank or barrel surface 2.
[0082] The rake face 4 is joined to the flank 2 by the chamfer 28 which extends from the cutting edge 6 to the rake face 4, and lies in a plane at a predetermined angle to the plane perpendicular to the plane in which the longitudinal axis of the cutter extends. In some examples, this chamfer angle is up to around 45 degrees. The vertical height of the chamfer 28 may be, for example, between 350pm and 450pm, such as around 400pm.
[0083] The conventional cutting elements shown in Figure 1 to 3 are typically cylindrical in shape with a substantially planar cutting surface 4.
[0084] A cutting element 30 according to a first example is shown in Figures 4a to 6 and comprises a body of polycrystalline super hard material 39 integrally bonded at an interface 44 to a substrate 40. The super hard material 39 may be, for example, polycrystalline diamond (PCD) and the super hard particles or grains may be of natural or synthetic origin.
[0085]
[0086] [OFFICIAL]
[0087] PF1639-WO-0-ORD The substrate 40 may be formed of a hard material such as a cemented carbide material and may be, for example, cemented tungsten carbide, cemented tantalum carbide, cemented titanium carbide, cemented molybdenum carbide or mixtures thereof. The binder metal for such carbides suitable for forming the substrate 40 may be, for example, nickel, cobalt, iron or an alloy containing one or more of these metals. Typically, this binder will be present in an amount of 10 to 20 mass %, but this may be as low as 6 mass % or less.
[0088] The substrate 40 may be, for example, generally cylindrical and has a peripheral surface 48, a distal free end 41 and a peripheral top edge 44 forming an interface with a body of superhard material 39.
[0089] The body of superhard material 39 comprises a substantially cylindrical first region 42 bonded to the substrate 40 along the interface 44 and has a longitudinal axis. A further region 46 extends therefrom to an exposed surface 32 of the super hard material 39 opposite the substrate 40 which forms or comprises a working surface 32, also termed a cutting face which also acts as a rake face in use. This working surface 32 has a central region 34 extending into and from the working surface 32 around the longitudinal axis and towards the interface 44. The central region 34 is substantially non-planar and may, in some examples, be generally concave or convex, and / or have one or more regions that includes a plurality of interconnecting concave portions, or a concave portion and a convex portion, forming an undulating profile. The further region 46 may have an undulating peripheral surface which may assist in reducing drag on the lateral surface of the cutting element in use and may improve cutting efficiency by controlling chip flow over the external surfaces of the cutting element 30.
[0090]
[0091] [OFFICIAL]
[0092] PF1639-WO-0-ORD A plurality of curved cutting edges 41 are spaced from one another around the working surface 32 and are formed by the bottom of a chamfer 37 extending between the working surface 32 and further region 46 of the body of superhard material, the cutting edges 41 being defined by the edge of the chamfer 37 and the top 38 of the further region 46.
[0093] The cutting edges 41 are spaced from each other such that the cutting edges 41 form lobes 36 in the working surface 32.
[0094] In some examples, the central region 34 in the working surface 32 extends into the body of superhard material 39 but terminates above the interface 44 with the substrate 40.
[0095] In some examples, the depth of the first region 42 is between around 1 mm to around 2mm.
[0096] The cutting edges 41 are spaced around the working surface 45 and are separated by the further region 46, the cutting edges 41 having an associated radius of curvature, the radius of curvature of one or more of the cutting edges 41 being less than the radius of curvature of the substrate 40.
[0097] The chamfer 37 may be variable or non-variable in one or both of angle relative to the plane extending through the longitudinal axis of the body of superhard material 39, and length L. In some examples the chamfer is continuous. In some examples, the chamfer 37 extends at an inclined angle to the plane along which the longitudinal axis extends, the angle being between around 30 degrees to around 60 degrees, and in some examples around 45 degrees.
[0098]
[0099] [OFFICIAL]
[0100] PF1639-WO-0-ORD In the example of Figures 4a to 6, the central region 34 extends from the working surface 32 away from the interface 44 and about the longitudinal axis and does not intersect and / or does not interfere with the chamfer 37, and is tangential to the chamfer 37 at one or more points in the working surface 32 between the respective lobes 36.
[0101] In the example of Figures 4a to 6, a ridged region or portion 47 extends between adjacent lobes 36 from the intersection of adjacent lobes 43 towards the peripheral side edge 42 of the body of superhard polycrystalline material 39. The ridged regions 47 may be angled such that the apex 48 of the ridged regions 47 at the peripheral side edge of the body of superhard material is further away from the interface 44 in a plane parallel to the longitudinal axis than the intersection 43 of the ridged region 47 with adjacent lobes. The width of the ridged regions 47 may also be narrower at the intersection 43 with adjacent lobes than at the peripheral side edge, and the ridged regions 47 may have a draft angle of between around 3 to around 15 degrees, for example around 5 degrees.
[0102] As mentioned above, the super hard material 39 may be, for example, polycrystalline diamond (PCD) and the super hard particles or grains may be of natural or synthetic origin.
[0103] Also, the substrate 40 may be formed of a hard material such as a cemented carbide material and may be, for example, cemented tungsten carbide, cemented tantalum carbide, cemented titanium carbide, cemented molybdenum carbide or mixtures thereof. The binder metal for such carbides suitable for forming the substrate 60 may be, for example, nickel, cobalt, iron or an alloy containing one or more of these
[0104]
[0105] [OFFICIAL]
[0106] PF1639-WO-0-ORD metals. Typically, this binder will be present in an amount of 10 to 20 mass %, but this may be as low as 6 mass % or less.
[0107] In some examples in which the central region 34 is a recessed portion, the depth along a central longitudinal axis of the cutting element 30 of the recessed portion in the working surface may be up to around 1mm, and in some examples it may be greater than 1mm.
[0108] In the examples, the radius of curvature of the cutting edges 41 is less than the radius of curvature of the substrate 40, and, in the examples of Figures 4a to 6, less than the radius of curvature of the first region 42, which may improve the rate of penetration of the cutting element in use. As an illustration, the radius of curvature of the cutting edges 41 may, in some examples, be between around 2mm to around 16mm. By way of further example, for a cutting element 30, 70 in which substrate 40 has a diameter of around 16mm, the radius of curvature of one or more of the cutting edges 41 may be between around 4mm to around 12mm; for a cutting element in which the substrate 40 has a diameter of around 19mm, the radius of curvature of one or more of the cutting edges 41 may be between around 6mm to around 14mm; and for a cutting element in which the substrate 40 has a diameter of around 13mm, the radius of curvature of one or more of the cutting edges 41 may be between around 3mm to around 9mm.
[0109] In some examples, the depth / height of the central region 34 in the working surface 32 in a plane parallel to the longitudinal axis of the cutting element 30 measured from the highest point on the working surface 32 to the bottom of the recess or tiop of the protrusion, in the event the central region is either concave or convex respectively, may be between around 0.5mm to around 2.5mm. In the example of the central region being a recessed region, the distance along said axis from the
[0110]
[0111] [OFFICIAL]
[0112] PF1639-WO-0-ORD bottom of the recessed region 34 to the interface 44 with the substrate 40 may be between around 1 to around 2mm, and in some examples is at least around 1 ,4mm.
[0113] The wear resistance of the example cutting element 30 was tested against conventional polycrystalline diamond cutting elements having the same average grain size of diamond grains as the super hard grains in the example constructions 30, and sintered under pressure of around 6.8GPa. The tests performed included vertical boring mill tests. From the results it was seen that the wear resistance of the example constructions was better than that of the conventional PCD cutting elements bonded to a WC substrate in which the PCD layer had the same average grain size as the PCD layer of the examples and same PCD layer thickness.
[0114] An example method of preparing the cutting element of Figures 4a to 6 is as follows. A pre-sinter mixture was prepared by combining a mass of diamond particles with a non-diamond phase mixture designed to act as a solvent / catalyst for diamond, such as cobalt, and to form up to around 20 wt % in the sintered product. The presinter mixture was loaded into a cup and placed in an HP / HT reaction cell assembly together with a mass of carbide to form the substrate. The contents of the cell assembly were subjected to HP / HT processing. The HP / HT processing conditions selected were sufficient to effect inter-crystalline bonding between adjacent grains of diamond particles and the joining of sintered particles to the cemented metal carbide support to form a PCD construction comprising a PCD structure integrally formed on and bonded to the cemented tungsten carbide substrate. In one example, the processing conditions generally involved the imposition for about 3 to 120 minutes of a temperature of at least about 1200 degrees C and a super high pressure of greater than about 5 GPa. In some examples, the pre-sinter assembly may be subjected to a pressure of at least about 6 GPa, at least about 6.5 GPa, at
[0115]
[0116] [OFFICIAL]
[0117] PF1639-WO-0-ORD least about 7 GPa or even at least about 7.5 GPa or more, at a temperature of around 1440 deg C.
[0118] In some examples, both the bodies of, for example, diamond and carbide material plus sintering aid / binder / catalyst are applied as powders and sintered simultaneously in a single UHP / HT process.
[0119] In another example, the substrate may be pre-sintered in a separate process before being bonded to the superhard material in the HP / HT press during sintering of the superhard polycrystalline material.
[0120] In some examples, the cemented carbide substrate 40 may be formed of tungsten carbide particles bonded together by the binder material, the binder material comprising an alloy of any one or more of Co, Ni and Cr. The tungsten carbide particles may form at least 70 weight percent and at most 95 weight percent of the substrate.
[0121] After sintering, the PCD construction 30 was subjected to further treatment to remove the canister material.
[0122] In some examples, the canister may be shaped to create one or more of the concave or convex central region in the working surface 32, the chamfer 37, the cutting edges 41 , the central region 34 and an undulating peripheral surface 46 of the body of superhard material 39. In other examples, any one or more of the central region 34 of the working surface 32, the chamfer 37, the cutting edges 41 , and the undulating peripheral surface 46 may be created after sintering using additional processing such as laser ablation, EDM machining or another machining process to shape the construction to the desired cutting element shape and size. Additionally, laser ablation of different regions of the superhard material / working
[0123]
[0124] [OFFICIAL]
[0125] PF1639-WO-0-ORD surface 45 may be used to create regions of different surface roughness, for example by ablating using different laser parameters. This may be used, as desired, to influence chip flow across the working surface 45 during the cutting applications.
[0126] The number, depth and dimensions of the lobes 36 and discrete cutting edges 41, may be chosen to suit the desired application, and in some examples the cutting elements comprise three or more lobes to provide three or more cutting edges 41 enabling the cutting element to be spun to increase the working life of the cutting element and present a new cutting edge to the surface to be cut.
[0127] In the examples where the body of superhard material comprises PCD, the PCD material may be, for example, formed of diamond grains that are of natural and / or synthetic origin.
[0128] The cutting elements 30 of the types shown in Figures 4a to 6 may be provided along blades on the face of a drill bit body (not shown). The cutting elements may be secured to the bit body within pockets therein using, for example a conventional brazing process.
[0129] In some examples, the example constructions may be subjected to an acid leaching treatment to remove the residual catalyst from interstitial spaces between the grains of superhard material in the body 39 of superhard material.
[0130] In use, the cutting element 30 shears away the surface of the underlying formation and wear scar forms progressively in the superhard material in the region of the cutting edge 41. As used herein, a “wear scar” is a surface of the cutter formed in use by the removal of a volume of cutter material due to wear of the cutter. As a cutter wears in use, material may progressively be removed from proximate the
[0131]
[0132] [OFFICIAL]
[0133] PF1639-WO-0-ORD cutting edge, thereby continually redefining the position and shape of the cutting edge, rake face and flank as the wear scar forms.
[0134] Whilst not wishing to be bound by a particular theory, the example cutting elements are believed to assist in providing improved rock cutting efficiency over conventional PCD cutters, as the geometry of the lobes and associated cutting-edges 41 , having a smaller radius of curvature than the substrate 40 and a central region 34 that does not interfere and / or does not intersect the chamfer 37 in combination with ridged regions 47 between adjacent lobes axis, is such that the wear scar area will grow at a far slower rate than for a conventional cylindrical PCD cutter. This is believed to assist in maintaining a greater load at the cutter-rock contact point for a longer period, resulting in a slower build up of thermal loading, both of which are believed to be contributors to more efficient rock cutting and may assist in providing more efficient crushing and removal of the rock cuttings and chips in application and chip flow over the cutting element in use.
[0135] In some examples, the cutting elements may have a generally cylindrical shape. In other examples, the cutting elements be a different shape, such as conical, or ovoid.
[0136] In some examples, the body of PCD material may be formed as a standalone object, that is, a free-standing unbacked body of PCD material, and may be attached to a substrate in a subsequent step.
[0137] In some examples, the cutting elements may comprise natural or synthetic diamond material, or cBN material. Examples of diamond material include polycrystalline diamond (PCD) material, thermally stable PCD material, crystalline diamond material, diamond material made by means of a chemical vapour deposition (CVD) method or silicon carbide bonded diamond. An example of cBN material is polycrystalline cubic boron nitride (PCBN).
[0138]
[0139] [OFFICIAL]
[0140] PF1639-WO-0-ORD It will therefore be seen that various versions of the present disclosure include cutting elements and methods of forming same for earth-boring drill bits which may enhance the working life of the cutting elements by one or more of improving the abrasion resistance, thermal stability, durability, sharpness of the cutting edge, spall resistance, and fracture / impact resistance, potentially by cutting the rock more efficiently through the rock crushing action and control of chip and drilling mud flow through the shapes / topography of the cutting elements and may lead to improved drill bit stability of, for example, the earth-boring drill bit to which the cutting elements may be mounted.
[0141] Although the foregoing description contains many specifics, these are not to be construed as limiting the scope of the present disclosure, but merely as providing certain exemplary versions.
[0142]
Claims
[OFFICIAL]PF1639-WO-0-ORD Claims:
1. A cutting element comprising:a substrate having a peripheral side edge, the peripheral side edge having an associated radius of curvature; anda body of superhard polycrystalline material bonded to the substrate along an interface, the body of superhard polycrystalline material having a peripheral side edge and a longitudinal axis; wherein:the body of superhard polycrystalline material comprises:a working surface;a plurality of spaced apart cutting edges, the cutting edges being spaced around the working surface and separated by a respective further region, the cutting edges have an associated radius of curvature, the radius of curvature of one or more of the cutting edges being less than the radius of curvature of the substrate; andthe body of superhard polycrystalline material further comprises a chamfer extending from the cutting edges to the working surface.wherein the working surface comprises:a central region extending about the longitudinal axis, the central region being non-planar; anda plurality of further regions extending from the central region to a respective one of said plurality of spaced apart cutting edges, said further regions forming a plurality of lobes; anda plurality of ridged regions extending between adjacent lobes, the plurality of ridged regions extending from an intersection region between adjacent lobes towards the peripheral side edge of the body of superhard polycrystalline material; wherein:[OFFICIAL]PF1639-WO-0-ORD the working surface including the lobes comprises an undulating topology.
2. The cutting element of claim 1 , wherein the central region is tangential to the chamfer at one or more at one or more points in the working surface.
3. The cutting element of any one of the preceding claims, wherein the chamfer is non-variable in one or both of angle relative to the plane extending through the longitudinal axis, and length.
4. The cutting element of any one of the preceding claims, wherein the central region does not intersect and / or does not interfere with the chamfer.
5. The cutting element of any one of the preceding claims, wherein the central region is convex or concave.
6. The cutting element of any one of the preceding claims, wherein the plurality of cutting edges comprises an odd number of cutting edges.
7. The cutting element of any one of the preceding claims, wherein the body of superhard polycrystalline material comprises any one or more of polycrystalline diamond, diamond-like carbon, or cubic boron nitride of natural and / or synthetic origin.
8. The cutting element of any one of the preceding claims, comprising three or more cutting edges.
9. The cutting element of any one of the preceding claims, wherein the central region comprises a recessed region extending to a position between around 0.5mm to around 2mm above the interface between the body of superhard polycrystalline material and the substrate.
10. The cutting element of any one of the preceding claims, wherein the chamfer extends at an inclined angle to the plane along which the longitudinal axis extends, the angle being between around 30 degrees to around 70 degrees.[OFFICIAL]PF1639-WO-0-ORD 11. The cutting element of any one of the preceding claims, wherein the radius of curvature of one or more of the cutting edges is between around 2mm to around 16mm.
12. The cutting element of any one of claims 1 to 10, wherein the radius of curvature of one or more of the cutting edges is between around 3mm to around 9mm.
13. The cutting element of any one of claims 1 to 10, wherein the radius of curvature of one or more of the cutting edges is between around 4mm to around 12mm.
14. The cutting element of any one of claims 1 to 10, wherein the radius of curvature of one or more of the cutting edges is between around 6mm to around 14mm.
15. The cutting element of any one of the preceding claims, wherein the body of superhard polycrystalline material comprises polycrystalline diamond material having inter-bonded diamond grains with interstitial spaces between the interbonded diamond grains, at least a portion of the interstitial spaces being substantially free of metal solvent catalyst material.
16. The cutting element of any one of the preceding claims, wherein any one or more of the plurality of ridged regions extend to the peripheral side edge of the body of superhard polycrystalline material.
17. The cutting element of any one of the preceding claims, wherein the ridged regions have an associated apex, and wherein any one or more of the plurality of ridged regions are angled such that the apex of said ridged region(s) at the peripheral side edge of the body of superhard material is further away from the interface i a plane parallel to the longitudinal axis than the intersection of the ridged region(s) with adjacent lobes.
18. The cutting element of any one of the preceding claims, wherein the ridged regions have an associated width, the width of any one or more of the ridged region(s) being narrower at the intersection with adjacent lobes than at the peripheral side edge.[OFFICIAL]PF1639-WO-0-ORD 19. The cutting element of any one of the preceding claims, wherein one or more of the ridged regions comprise a draft angle of between around 3 to around 15 degrees, for example around 5 degrees.
20. The cutting element of any one of the preceding claims, wherein the recessed region comprises a central recess having a depth in a plane parallel to the longitudinal axis of the cutting element measured from the highest point on the working surface to the bottom of the recess of between around 0.5mm to around 2.5mm; and / or the distance along said axis from the bottom of the central recess to the interface with the substrate is between around 1 to around 2mm.
21. The cutting element of any one of the preceding claims, wherein the further regions between the plurality of spaced apart cutting edges extending between the working surface and the peripheral side edge of the body of superhard polycrystalline material are arcuate in a plane parallel to the longitudinal axis.
22. The cutting element of claim 21, wherein the further regions are concave in a plane parallel to the longitudinal axis.
23. An earth-boring tool, comprising:a body; andat least one cutting element according to any one of the preceding claims attached to the body.
24. A method of making the cutting element of any one of claims 1 to 22 comprising: providing a mass of particles or grains of superhard material to form a pre-sinter assembly; andtreating the pre-sinter assembly in the presence of a catalyst / solvent material for the superhard grains at an ultra-high pressure of around 5.5 GPa or greater and a temperature at which the superhard material is more thermodynamically stable than graphite to sinter together the grains of superhard material to form the cutting element.[OFFICIAL]PF1639-WO-0-ORD 25. A method according to claim 24, wherein the step of providing a mass of grains of superhard material comprises providing a mass of diamond grains to form a body of polycrystalline diamond material.
26. A method according to claim 25, wherein the step of treating comprises treating the pre-sinter assembly to a temperature and pressure such that the diamond grains exhibit inter-granular bonding and define a plurality of interstitial regions therebetween, any residual catalyst / solvent at least partially filling a plurality of the interstitial regions.
27. A method according to any one of claims 25 or 26, further comprising treating at least a portion of the body of polycrystalline diamond material to remove residual catalyst / binder from the interstitial spaces to form a region substantially free of the catalyst / binder material for the PCD material, said portion forming a thermally stable region extending a depth from the working surface of the body of polycrystalline super hard material towards the interface with the substrate.
28. A method according to any one of claims 24 to 27, wherein the step of treating the pre-sinter assembly comprises treating the pre-sinter assembly in a canister that is shaped to create any one or more of the plurality of spaced apart cutting edges, the chamfer, the topology of the working surface, and / or the topology of the peripheral side surface.
29. A method according to any one of claims 24 to 27, further comprising processing the cutting element after the step of treating the pre-sinter assembly to create any one or more of the plurality of spaced apart cutting edges, the chamfer, the topology of the working surface, or the topology of the peripheral side surface.[OFFICIAL]PF1639-WO-0-ORD 30. A method according to claim 29, wherein the step of processing comprises using any one or more of laser ablation or EDM machining.
31. A tool comprising a cutting element according to any one of claims 1 to 22, the tool being for cutting, milling, grinding, drilling, or rock drilling.
32. A tool according to claim 31 , wherein the tool comprises a rotary fixed-cutter bit for use in the oil and gas drilling industry.
33. A tool according to claim 31, wherein the tool is a rolling cone drill bit, a hole opening tool, an expandable tool, a reamer or other earth boring tools.
34. A drill bit or a component therefor comprising the cutting element according to any one of claims 1 to 22.