Composite Milling Tool With Interspersed Cutting Elements

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cutting and milling tools in the drilling and completion industry lack optimal cutting efficiency and longevity due to inconsistent cutting element shapes and sizes, leading to premature dulling and increased manufacturing costs.

Innovation Solution

A composite cutting/milling tool design featuring two or more pluralities of consistently shaped and sized cutting elements, with varying hardness and size configurations, interspersed at the cutting end, attached using a bonding material like copper nickel braze, to enhance cutting efficiency and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If crushed carbide cutting elements are used, then cutting effectiveness is achieved, but cutting efficiency and longevity are suboptimal due to inconsistent shapes and sizes

Engineering Contradiction:

Improvecutting efficiencyVSAvoidcutting element shape and size consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The cutting elements are segmented into distinct geometric shapes (triangular, rectangular, square, trapezoidal) with consistent dimensions within each shape category. This segmentation allows for standardized manufacturing processes that ensure shape and size consistency, directly addressing the precision issue while maintaining cutting effectiveness through varied geometries optimized for different cutting functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different geometric shapes are assigned to specific positions around the peripheral surface of the tool body. Each shape is selected for its optimal cutting characteristics in that particular location, creating local quality variations that enhance overall cutting efficiency while each individual shape maintains consistent dimensions for manufacturing precision.

Inventive Principle:

Principle #3Local quality

2Productivity

If varied cutting element shapes are used, then cutting performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecutting performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention varies geometric parameters (shape type, orientation, position) of cutting elements rather than their fundamental dimensions. Each cutting element maintains consistent width and length parameters, while only the geometric configuration changes. This approach improves cutting performance through shape variation while keeping manufacturing complexity manageable by standardizing critical dimensional parameters.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If crushed carbide cutting elements are used, then tool longevity is reduced due to premature dulling, but manufacturing costs are increased

Engineering Contradiction:

Improvetool longevityVSAvoidmanufacturing cost

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

Cutting elements are pre-formed with specific geometric shapes and consistent dimensions before attachment to the tool body. This preliminary shaping action ensures that each element starts with optimal geometry for its designated position, preventing premature dulling and extending tool longevity. The standardized pre-forming process controls manufacturing costs through efficiency and material optimization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses carbide material with consistent compositional properties formed into different geometric shapes. The composite nature of carbide (hard particles in a binder matrix) provides both the durability needed for extended tool life and the manufacturability required for cost-effective production through standardized forming processes.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution improves cutting performance, extends tool longevity, and reduces manufacturing costs by ensuring precise and repeatable tool dimensions, while maintaining consistent shape and size within each plurality, thereby optimizing wear characteristics and attachment material usage.

Implementation Method 1

attaching each plurality of cutting elements to a cutting end of the tool

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS8534392B2Composite cutting/milling tool having differing cutting elements and method for making the same

Publication Date: 2013.09.17 BAKER HUGHES CO

AI summary

A cutting/milling tool includes a tool body, a cutting end of the tool body, a first plurality of cutting elements having a substantially identical shape disposed at the cutting end of the tool body, and a second plurality of cutting elements having a different shape than the first plurality of cutting elements. The second plurality of cutting elements are substantially identical in shape to each other, and the second plurality of cutting elements are interspersed with the first plurality of cutting elements at the cutting end of the tool body. Also included is a method for making a cutting/milling tool.