Recessed Impregnated Cutting Structures for Drill Bit Wear

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Solution Overview

Problem

Conventional impregnated drag bits face issues with cutting structure wear and loss, leading to reduced efficiency in drilling hard and abrasive rock formations, as the matrix and diamond particles wear down, causing exposure of new cutting particles that may not be optimally positioned for effective cutting.

Innovation Solution

The development of cutting structures with superabrasive particles dispersed within a matrix material, where the cutting structures are recessed from the outer surface, allowing them to engage the formation material only after the matrix material has worn down, providing a more durable and efficient drilling process by exposing uniformly or variably sized abrasive particles as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional impregnated drag bits with superabrasive particles dispersed in matrix material are used, then the bit can drill hard and abrasive rock formations, but the matrix and diamond particles wear down causing cutting particles to be lost and new particles exposed that may not be optimally positioned for effective cutting

Engineering Contradiction:

Improvedurability of cutting structuresVSAvoidcutting efficiency

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The cutting structures are segmented into discrete recessed elements rather than a continuous impregnated matrix. Each recessed cutting structure contains superabrasive particles that are exposed in a controlled manner, allowing individual cutting elements to maintain optimal positioning while the overall structure provides durability through the recessed design that protects particles until needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The superabrasive particles are pre-positioned within the recessed cutting structures before drilling begins. This preliminary positioning ensures that when the cutting structures engage the formation, the particles are already in optimal positions for effective cutting, eliminating the problem of randomly exposed particles that occur in conventional impregnated bits where particles are exposed only after matrix wear.

Inventive Principle:

Principle #10Preliminary action

2Duration of action of moving object

If superabrasive particles are dispersed within matrix material, then the bit can maintain cutting ability through particle exposure as matrix wears, but the newly exposed particles may not be optimally positioned for effective cutting

Engineering Contradiction:

Improveservice life of bitVSAvoidrate of penetration

Core Design Contradiction:

Duration of action of moving objectVSProductivity

Solution Approach 1:

The cutting surface is segmented into multiple recessed cutting structures rather than a continuous impregnated layer. This segmentation allows controlled exposure of superabrasive particles from each recessed structure, ensuring that particles are revealed in optimal cutting positions while maintaining extended service life through the protective recessed design that prevents premature particle loss.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cutting surface have different local qualities - the recessed cutting structures provide protected particle reservoirs that expose particles at optimal positions, while the surrounding matrix material provides structural support and gradual wear characteristics. This local differentiation ensures both durability and high rate of penetration by maintaining optimally positioned cutting particles throughout the bit's service life.

Inventive Principle:

Principle #3Local quality

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 design enhances the durability and performance of the cutting structures, allowing for increased exposure of abrasive particles during drilling, leading to improved rate of penetration and reduced wear of the matrix material, thus maintaining efficiency in drilling through both hard and abrasive formations.

Implementation Method 1

superabrasive cutting particles, such as natural or synthetic diamond grit, dispersed within and metallurgically and mechanically bonded to a matrix of wear-resistant material

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

the matrix and embedded diamond particles wear, cutting particles are lost as the matrix wears and new cutting particles are exposed

Methodology Applied

Scientific EffectWear: Wear

Data Source

PatentEP3348781B1Earth-boring tools having impregnated cutting structures and methods of forming and using the same

Publication Date: 2022.08.31 BAKER HUGHES CO

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AI summary

A tool for drilling subterranean formations includes a tool body having a face surface, a blade extending radially outward on the face surface toward a gage surface, and a plurality of cutting structures disposed in the blade. Each of the plurality of cutting structures comprises a substantially spherical body of particulate impregnated matrix material. A method of forming the tool includes forming a tool body having the plurality of cutting structures dispersed therein. A method of using the tool includes rotating the earth-boring tool within the wellbore and engaging a formation material of the earth formation with an outer surface of the blade and wearing the outer surface of the blade to expose the spherical cutting structure. After wearing the outer surface of the blade, the method includes engaging the earth formation with the spherical cutting structure.