Direct Metal Deposition for Earth-Boring Tool Repair
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Solution Overview
Problem
Conventional methods for forming and repairing earth-boring tools are inefficient, particularly in creating complex geometries and extending tool longevity in abrasive environments, as they often result in material waste and limited customization.
Innovation Solution
The use of direct metal deposition and subtractive manufacturing processes, where a computer system generates tool paths for both additive and subtractive tools to form and repair earth-boring tools, allowing for layer-by-layer metal application and precise removal of material to achieve desired geometries and wear-resistant features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional machining methods are used to form complex geometries of earth-boring tools, then manufacturing capability is achieved, but material waste increases and manufacturing efficiency decreases
Solution Approach 1:
The patent applies preliminary action by using additive manufacturing to pre-form complex geometries and internal structures of earth-boring tools before final machining operations. This allows the bulk of material to be deposited in the desired shape, reducing subsequent material removal and waste while improving manufacturing efficiency
Solution Approach 2:
The patent employs parameter changes by transitioning from purely subtractive machining to a hybrid approach combining additive manufacturing and selective machining. This fundamental change in manufacturing methodology reduces material waste while maintaining or improving productivity
2Duration of action of stationary object
If wear-resistant materials are applied to high-wear areas of bit body, then tool longevity is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by depositing wear-resistant materials selectively only on high-wear areas such as blade surfaces, gage surfaces, and areas adjacent to cutter pockets, rather than coating the entire bit body. This targeted approach extends tool longevity while minimizing manufacturing complexity and material costs
Solution Approach 2:
The patent uses copying by creating precise digital models of the earth-boring tool geometry to guide the additive manufacturing process and wear-resistant material deposition. This ensures accurate replication of complex geometries and precise application of wear-resistant coatings, simplifying the manufacturing process
3Manufacturing precision
If direct metal deposition is used to form geometric features, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing conventional multi-step machining processes with direct metal deposition technology. This enables direct formation of complex geometric features with high precision, eliminating the need for multiple machining operations and reducing overall process complexity despite the advanced technology involved
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
This approach reduces material waste, achieves smaller manufacturing tolerances, and enables cost-effective production of earth-boring tools from high-cost materials, while extending tool longevity through customized wear-resistant coatings.
Implementation Method 1
The direct metal deposition tool is operated along the first tool path to deposit metal on an earth-boring tool component coupled to the multi-axis positioning system to at least partially form the at least one geometric feature of the earth-boring tool
Implementation Method 2
The material removal tool is operated along the second tool path to remove at least a portion of the deposited metal from the at least one geometric feature of the at least a component of the earth-boring tool
Data Source
AI summary
A method of forming at least a portion of an earth-boring tool includes entering an electronic representation of at least one geometric feature of at least a component of an earth-boring tool in a computer system including memory and a processor, the computer system operatively connected to a multi-axis positioning system, a direct metal deposition tool, and a material removal tool. The processor generates a tool path for the direct metal deposition tool. The tool path is based at least in part on the electronic representation of the at least one geometric feature of the at least a component of the earth-boring tool. The direct metal deposition tool is operated along the tool path to deposit metal on an earth-boring tool component coupled to the multi-axis positioning system to at least partially form the at least one geometric feature of the earth-boring tool. Methods also include methods of repairing earth-boring tools.