EP0119620A2 - Improved tooth design using cylindrical diamond cutting elements - Google Patents
Improved tooth design using cylindrical diamond cutting elements Download PDFInfo
- Publication number
- EP0119620A2 EP0119620A2 EP84102985A EP84102985A EP0119620A2 EP 0119620 A2 EP0119620 A2 EP 0119620A2 EP 84102985 A EP84102985 A EP 84102985A EP 84102985 A EP84102985 A EP 84102985A EP 0119620 A2 EP0119620 A2 EP 0119620A2
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- EP
- European Patent Office
- Prior art keywords
- cutting element
- bit
- diamond cutting
- improvement
- teeth
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000010432 diamond Substances 0.000 title claims abstract description 110
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 83
- 238000005520 cutting process Methods 0.000 title claims abstract description 64
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- 230000006872 improvement Effects 0.000 claims description 23
- 238000004140 cleaning Methods 0.000 abstract description 2
- 238000001816 cooling Methods 0.000 abstract description 2
- 238000005553 drilling Methods 0.000 description 26
- 239000011159 matrix material Substances 0.000 description 26
- 238000005755 formation reaction Methods 0.000 description 13
- 230000015572 biosynthetic process Effects 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
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- 230000008901 benefit Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
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- 238000005219 brazing Methods 0.000 description 2
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- 239000003208 petroleum Substances 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
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- 230000002787 reinforcement Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
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- 230000008646 thermal stress Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
- E21B10/56—Button-type inserts
- E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
Definitions
- the present invention relates to the field of earth boring tools and in particular to rotating bits incorporating diamond elements.
- the PCD products are fabricated from synthetic and/or appropriately sized natural diamond crystals under heat and pressure and in the presence of a solvent/catalyst to form the polycrystalline structure.
- the polycrystalline structures includes sintering aid material distributed essentially in the interstices where adjacent crystals have not bonded together.
- the resulting diamond sintered product is porous, porosity being achieved by dissolving out the nondiamond material or at least a portion thereof, as disclosed for example, in U. S. 3,745,623; 4,104,344 and 4,224,380.
- a material may b ⁇ described as a porous PCD, as referenced in U.S. 4,224,380.
- Polycrystalline diamonds have been used in drilling products either as individual compact elements or as relatively thin PCD tables supported on a cemented tungsten carbide (WC) support backings.
- the PCD compact is supported on a cylindrical slug about 13.3 mm in diameter and about 3 mm long, with a PCD table of about 0.5 to 0.6 mm in cross section on the face of the cutter.
- a stud cutter the PCD table also is supported by a cylindrical substrate of tungsten carbide of about 3 mm by 13.3 mm in diameter by 26mm in overall length.
- These cylindrical PCD table faced cutters have been used in drilling products intended to be used in soft to medium-hard formations.
- the natural diamond could be either surface-set in a predetermined orientation, or impregnated, i.e., diamond is distributed throughout the matrix in grit or fine particle form.
- porous PCD compacts and those said to be temperature stable up to about 1200°C are available in a variety of shapes, e.g., cylindrical and triangular.
- the triangular material typically is about 0.3 carats in weight, measures 4mm on a side and is about 2.6mm thick. It is suggested by the prior art that the triangular porous PCD compact be surface-set on the face with a minimal point exposure, i.e., less than 0.5mm above the adjacent metal matrix face for rock drills.
- the difficulties with such placements are several.
- the difficulties may be understood by considering the dynamics of the drilling operation.
- a fluid such as water, air or drilling mud is pumped through the center of the tool, radially outwardly across the tool face, radially around the outer surface (gage) and then back up the bore.
- the drilling fluid clears the tool face of cuttings and to some extent cools the cutter face.
- the cuttings may not be cleared from the face, especially where the formation is soft or brittle.
- the clearance between the cutting surface-formation interface and the tool body face is relatively small and if no provision is made for chip clearance, there may be bit clearing problems.
- the weight on the drill bit normally the weight of the drill string and principally the weight of the drill collar, and the effect of th 4 fluid which tends to lift the bit off the bottom. It has been reported, for example, that the pressure beneath a diamond bit may be as much as 1000 psi greater than the pressure above the bit, resulting in a hydraulic lift, and in some cases the hydraulic lift force exceeds 50% of the applied load while drilling.
- Run-in in diamond bits is required to break off the tip or point of the triangular cutter before efficient cutting can begin.
- the amount of tip loss is approximately equal to the total exposure of natural diamonds. Therefore, an extremely large initial exposure is required for synthetic diamonds as compared to natural diamonds. Therefore, to accommodate expected wearing during drilling, to allow for tip removal during run-in, and to provide flow clearance necessary, substantial initial clearance is needed.
- Still another advantage is the provision of a drilling tool in which thermally stable PCD elements of a defined predetermined geometry are so positioned and supported in a metal matrix as to be effectively locked into the matrix in order to provide reasonably long life of the tooling by preventing loss of PCD elements other than by normal wear.
- the present invention is an improvement in a rotating bit having a bit face wherein the improvement comprises a plurality of teeth disposed on the bit and wherein each tooth includes a diamond cutting element.
- the diamond cutting element is particularly characterized by having the shape of a segment of a cylinder.
- the segment includes at least one planar surface and the planar surface forms, at least in part, a leading surface of the tooth.
- the cylindrical segment is a split half cylinder or a split quarter cylinder.
- the diamond cutting element is characterized by having a longitudinal axis lying along the length of the cylinder and wherein the cylindrical shape is a half cylinder shape, the planar surface is a planar surface lying along a diameter of the cylindrical shape.
- the cylindrical segment is a quarter segment of a full cylinder
- the quarter segment includes an apical edge which lies along the longitudinal axis of the cylinder.
- the apical edge of the quarter cylinder and the planar surface of the half cylinder diamond cutting element serves as an exposed leading surface of the tooth and is disposed adjacent to a fluid channel thereby forming in whole or in part one edge or wall of the fluid channel.
- the present invention is an improvement in a tooth design used in rotating bits, particularly rotary bits, wherein the tooth includes a diamond cutting element and in particular a diamond cutting element derived from cylindrical polycrystalline synthetic diamond (PCD).
- PCD cylindrical polycrystalline synthetic diamond
- full cylindrical elements are generally commercially available but not in segment form.
- Such synthetic diamond is formed in the shape of a full circular cylinder having one planar end perpendicular to the longitudinal axis of the cylindrical shape and an opposing domed end, generally formed in the shape of a circular cone.
- Such elements are typically available in a variety of sizes with the above described shape.
- the full cylindrical diamond element is segmented to form a cylindrical segment wherein the segment is then axially disposed within a bit tooth.
- segmented or split cylindrical elements thus provide a cutting element with improved cutting efficiency with less use o diamond material and less tendency to dull or polish.
- Figure 1 is a cross-sectional view of a first embodimen of the present invention showing a tooth, generally denoted by reference numeral 10, incorporating a diamond cutting element, generally denoted by reference numeral 12.
- Element 12 is axiall disposed within the tungsten-carbide matrix material 14 of the rotating bit.
- longitudinal axis 16 of element 1 is orientedT to be approximately perpendicular to bit surface 18 at the location of tooth 10.
- Bit surface 18 may be bit face of crown of a rotating bit or may be the superior surface of a raised land or pad disposed upon a bit crown. In either case, bit surface 18 is taken in the present description as the basal surface upon which tooth 10 is disposed.
- element 12 is approximately a quarter section or 90 degrees of the full cylindrical shape of the PCD element normally available.
- Element 12 is cut using a conventional laser cutter. For example, deep cuts are made every 90 degrees parallel to the longitudinal axis 16 of a full cylindrical diamond element.
- the laser could be used t completely cut through the diamond element, it has been found possible that with deep scoring, the diamond can then be fractured with propagation of the fracture lying approximately along the continuation of the plane of the laser cut.
- the laser may cut a millimeter or less into and along the length of the full cylindrical diamond element.
- a diametrically opposed cut of equal depth is also provided on the cylinder. Thereafter, the cylinder may be split in half and then later quartered on another laser cut by fracturing the diamond element using an impulsive force and chisel.
- Diamond element 12 is disposed within tooth 10 as isshown in Figure 2 so that the apical edge 20 of diamond 12 formed by the cleavage planes or laser cuts which have formed radial surfaces 22, is oriented in the leading or forward direction of tooth 10 as defined by the rotation of the bit upon which tooth 10 is disposed.
- a portion of element 12 is fully exposed above bit surface 18 and in particular, that apical edge 20 forms the foremost portion of diamond element 12 as the tooth moves forwardly in the plane of the figure.
- Surfaces 22 define a dihedral angle and the tangential direction of movement of tooth 10 during normal cutting operation is generally along the direction of the bisector of the dihedral angle.
- a channel 24 is defined immediately in front of apical edge 20 to serve as a waterway or collector as appropriate.
- leading surfaces 22 and edge 20 can be placed virtually in channel 24 or immediately next thereto, forming as shown in Figure 1, one wall of channel 24 or a portion thereof, whereby hydraulic fluid supplied to and flowing through channel 24 during normal drilling operations will serve to cool and clean the cutting face of tooth 10 and in particular the leading edge and surfaces of diamond element 12.
- tooth 10 is shown as having a trailing support 26 of matrix material integrally formed with matrix material 14 of the bit and extending above bit surface 18 to the trailing surface of diamond element 12.
- the slope of trailing support 26 is chosen so as to substantially match the slope of the top conical surface 28 of element 12 with the opposing end of element 12, which is a right circular plane, being embedded within matrix material 14.
- the exact shape and placement of trailing support 26 can be varied without departing from the spirit and scope of the present invention.
- trailing support 26 may be even more substantial than that shown in- Figure 1 and may assume a slope different from surface 28 of element 12 to thereby provide additional matrix reinforcing material behind and on top of conical surface 28 and leading surfaces 22.
- Figure 2 illustrates in plan view the tooth of Figure 1 in a double row or triad configuration.
- a first row of teeth including teeth 10a and 10b is succeeded by a trailing tooth or second row of teeth including tooth 10c, wherein tooth 10c is placed halfway between the spacing of teeth 10a and 10b. Therefore, it can be appreciated that as the teeth 10a-c move forward during cutting of a rock formation, the diamond cutting elements incorporated within each of the teeth effectively overlap and provide a uniform annular swath cut into the rock formation as the bit rotates.
- Figure 4 which shows in plan view a coring bit incorporating the teeth of Figures 1 and 2 illustrates the disposition of such a double row of configured teeth, collectively denoted by reference numeral 32, on pad 30.
- Bit 34 also includes an inner gage 44 wherein the inner and outer gage are connected by waterways 31.
- Each pad 30 begins at or near inner gage 44 and is disposed across the bit face in a generally radial direction as seen in Figure 4 and splits into two pads which then extend to outer gage 36.
- the bifurcated pads are separated by a collector 33 which communicates with a gage collector 35 or junk slot 37 as may be appropriate.
- a gage collector 35 or junk slot 37 as may be appropriate.
- other types of coring bits and petroleum bits could have been illustrated to show the use of the teeth of Figures 1-3 other than the particular bit illustrated in Figure 4. Therefore, the invention is not to be limited to any particular bit style or in fact, even to rotating bits.
- FIG. 3 a cross-sectional view of the shoulder-to-gage transition utilizing the teeth of Figures 1 and 2 is illustrated.
- the bit generally denoted by reference numeral 34, is characterized by having a vertical cylindrical section or gage 36 which serves to define and maintain the diameter of the bore drilled by bit 34. Below gage 36, bit 34 will slope inwardly along a designed curve toward the center of the bit.
- a half profile is shown in Figure 5 and is a simple elliptical cross section characterized by an outer shoulder 38, nose 40 and inner shoulder 42. Inner diameter of the core is then defined by inner gage 44.
- outer gage 36 is shown as incorporating a half cylindrical segment 46, which is surface set and embedded into gage 36 so that the rounded cylindrical surface 48 is exposed above bit surface 50 of gage 36 with the flat longitudinal face 52 of the half cylindrical segment embedded within matrix material 54 of bit 34.
- Half cylindrical diamond crystalline element 46 is more clearly depicted in cross-sectional view in Figure 4 on gage 36.
- teeth 32 as shown in Figure 4 include quarter cylindrical segments, shown in rear view in Figure 3 as exemplified by diamond elements 56 and 58.
- Each element 56 is disposed within bit 34 so as to extend therefrom in a perpendicular direction as defined by the normal to bit surface at each point where such element is located.
- each element 56 and 58 is exposed by a uniform amount, namely, 2.7 mm (0.105") above the bit face.
- Element 56 which is the diamond element closest to gage 36 is placed upon shoulder 38 at such a position next to the beginning of gage 36 so that its outermost radially extending point, namely, apex 60, extends radially from the longitudinal axis of rotation of bit 34 by an amount equal to the radial distance from the longitudinal axis of bit 34 by the gage diamonds, in particular diamond 46.
- gage diamond 46 extends above bit surface 50 by 0.64 mm (0.025").
- gage diamonds 46a are disposed at and slightly below gage level 62 on ⁇ type I gage column corresponding to a type I pad 30 shown in plai view in Figure 4.
- Gage diamonds 46b are thus placed adjacent to a pad of type II and gage diamonds 46c placed on a gage section correspondingg to a type III pad.
- Gage diamonds 46a-c thus form a staggered pattern as best illustrated in Figure 6 which effectively presents a high cutting element density as the bit rotates.
- Above gage diamonds 46a-46b are conventional natural diamonds surface set in broaches, namely, kickers which are typical of the order of 6 per carat in size.
- the adjacent row of teeth on the next adjacent gage section begins at a quarter spacing displaced from the corresponding row of gage diamonds on the adjacent pad.
- type I pad corresponds to gage diamonds 46a having two rows with each row offset by half a space between each other
- pad II corresponds to gage diamonds 46b which are similarly offset with respect to each other and are spaced down the gage one quarter of a spacing as compared to gage diamonds 46a on pad type I.
- a tooth generally denoted by reference numeral 66, incorporates a half cylindrical segment diamond element 68 extending from and embedded in matrix material 14 in much the same manner as illustrated in connection with the first embodiment of Figures 1 and 2.
- PCD element 68 is- characterized by a half cylindrical surface 70 and a planar leading surface 72, which is formed as described above by cleaving a full cylinder along the diameter.
- diamond element 68 also includes a conical or domed upper surface 74 forming the apical point 76 of element 68.
- a trailing support 78 of integrally formed matrix material is smoothly fared from surface 74 to bit face 18 to provide tangential reinforcement and support for diamond element 68 against the cutting forces to which element 68 is subjected.
- trailing supports 78 are tapered to a point 80 on bit face 18 thereby forming a teardrop shaped plan outline for tooth 66.
- diamond element 68 is placed immediately adjacent to and forms one side of a channel 80 formed into matrix material 14 which channel 80 serves as a conventional waterway or collector as may be appropriate with the same advantages-as described in connection with the first embodiment of Figure 1.
- the second embodiment of Figure 8 similarly consists of two rows of teeth 66a and 66b followed by a second row represented by tooth 66c. Tooth 66c is located halfway between the spacing between tooth 66a and 66b as defined with respect to the direction of tangential movement during normal drilling operations.
- the double row of teeth are disposed on a petroleum or coring bit in the same manner as illustrated in connection with the first embodiment of the invention in Figure 4. Teeth 66 are thus disposed within matrix material 14 and used on a bit in the same
- teeth 66 as shown in Figure 8 clearly provide a broader cutting surface and a diamond element 68 containing twice the diamond material and structural bulk as compared to diamond elements 12 of the first embodiment. Therefore, in those applications where a larger cutting bite is required or where greater structural strength is needed in the diamond element, the half cylindrical split elements 68 of the second embodiment may be more advantageously used than the quarter split diamond elements of the first embodiment.
- split cylindrical segment has been shown as perpendicularly embedded into the matrix material, it is clearly contemplated that it may be either forwardly or rearwardly raked if required by design objectives. Therefore, the illustrated embodiment must be understood as presented only as an example of the invention and should not be taken as limiting the invention as set forth in the following claim.
Abstract
Description
- The present invention relates to the field of earth boring tools and in particular to rotating bits incorporating diamond elements.
- The use of diamonds in drilling products is well known. More recently synthetic diamonds both single crystal diamonds (SCD) and polycrystalline diamonds (PCD) have become commercially available from various sources and have been used in such products, with recognized advantages. For example, natural diamond bits effect drilling with a plowing action in comparison to crushing in thecase of a roller cone bit, whereas synthetic diamonds tend to cut by a shearing action. In the case of rock formations, for example, it is believed that less energy is required to fail the rock in shear than in compression.
- More recently, a variety of synthetic diamond products has become available commercially some of which are available as polycrystalline products. Crystalline diamonds preferentially fractures on (lll), (110) and (100) planes whereas PCD tends to be isotropic and exhibits this same cleavage but on a microscale and therefore resists catastrophic large scale cleavage failure. The result is a retained sharpness which appears to resist polishing and aids in cutting. Such products are described, for example, in U.S. Patents 3,913,280; 3,745,623; 3,816,085; 4,104,344 and 4,224,380.
- In general, the PCD products are fabricated from synthetic and/or appropriately sized natural diamond crystals under heat and pressure and in the presence of a solvent/catalyst to form the polycrystalline structure. In one form of product, the polycrystalline structures includes sintering aid material distributed essentially in the interstices where adjacent crystals have not bonded together.
- In another form, as described for example in U. S. Patents 3,745,623; 3,816,085; 3,913,280; 4,104,223 and 4,224,380 the resulting diamond sintered product is porous, porosity being achieved by dissolving out the nondiamond material or at least a portion thereof, as disclosed for example, in U. S. 3,745,623; 4,104,344 and 4,224,380. For convenience, such a material may bε described as a porous PCD, as referenced in U.S. 4,224,380.
- Polycrystalline diamonds have been used in drilling products either as individual compact elements or as relatively thin PCD tables supported on a cemented tungsten carbide (WC) support backings. In one form, the PCD compact is supported on a cylindrical slug about 13.3 mm in diameter and about 3 mm long, with a PCD table of about 0.5 to 0.6 mm in cross section on the face of the cutter. In another version, a stud cutter, the PCD table also is supported by a cylindrical substrate of tungsten carbide of about 3 mm by 13.3 mm in diameter by 26mm in overall length. These cylindrical PCD table faced cutters have been used in drilling products intended to be used in soft to medium-hard formations.
- Individual PCD elements of various geometrical shapes have been used as substitutes for natural diamonds in certain applications on drilling products. However, certain problems arose with PCD elements used as individual pieces of a given carat size or weight. In general, natural diamond, available in a wide variety of shapes and grades, was placed in predefined locations in a mold, and production of the tool was completed by various conventional techniques. The result is the formation of a metal carbide matrix which holds the diamond in place, this matrix sometimes being referred to as a crown, the latter attached to a steel blank by a metallurgical and mechanical bond formed during the process of forming the metal matrix. Natural diamond is sufficiently thermally stable to withstand the heating process in metal matrix formation.
- In this procedure above described, the natural diamond could be either surface-set in a predetermined orientation, or impregnated, i.e., diamond is distributed throughout the matrix in grit or fine particle form.
- With early PCD elements, problems arose in the production of drilling products because PCD elements especially PCD tables on carbide backing tended to be thermally unstable at the temperature used in the furnacing of the metal matrix bit crown, resulting in catastrophic failure of the PCD elements if the same procedures as were used with natural diamonds were used with them. It was believed that the catastrophic failure was due to thermal stress cracks from the expansion of residual metal or metal alloy used as the sintering aid in the formation of the PCD element.
- Brazing techniques were used to fix the cylindrical PCD table faced cutter into the matrix using temperature unstable PCD products. Brazing materials and procedures were used to assure that temperatures were not reached which would cause catastrophic failure of the PCD element during the manufacture of the drilling tool. The result was that sometimes the PCD components separated from the metal matrix, thus adversely affecting performance of the drilling tool.
- With the advent of thermally stable PCD elements, typically porous PCD material, it was believed that such elements could be surface-set into the metal matrix much in the same fashion as natural diamonds, thus simplifying the manufacturing process of the drill tool, and providing better performance due to the fact that PCD elements were believed to have advantages of less tendency to polish, and lack of inherently weak cleavage planes as compared to natural diamond.
- Significantly, the current literature relating to porous PCD compacts suggests that the element be surface-set. The porous PCD compacts, and those said to be temperature stable up to about 1200°C are available in a variety of shapes, e.g., cylindrical and triangular. The triangular material typically is about 0.3 carats in weight, measures 4mm on a side and is about 2.6mm thick. It is suggested by the prior art that the triangular porous PCD compact be surface-set on the face with a minimal point exposure, i.e., less than 0.5mm above the adjacent metal matrix face for rock drills. Larger one per carat synthetic triangular diamonds have also become available, measuring 6 mm on a side and 3.7 mm thick, but no recommendation has been made as to the degree of exposure for such a diamond. In the case of abrasive rock, it is suggested by the prior art that the triangular element be set completely below the metal matrix. For soft nonabrasive rock, it is suggested by the prior art that the triangular element be set in a radial orientation with the base at about the level of the metal matrix. The degree of exposure recommended thus depended on the type of rock formation to be cut.
- The difficulties with such placements are several. The difficulties may be understood by considering the dynamics of the drilling operation. In the usual drilling operation, be it mining, coring, or oil well drilling, a fluid such as water, air or drilling mud is pumped through the center of the tool, radially outwardly across the tool face, radially around the outer surface (gage) and then back up the bore. The drilling fluid clears the tool face of cuttings and to some extent cools the cutter face. Where there is insufficient clearance between the formation cut and the bit body, the cuttings may not be cleared from the face, especially where the formation is soft or brittle. Thus, if the clearance between the cutting surface-formation interface and the tool body face is relatively small and if no provision is made for chip clearance, there may be bit clearing problems.
- Other factors to be considered are the weight on the drill bit, normally the weight of the drill string and principally the weight of the drill collar, and the effect of th4 fluid which tends to lift the bit off the bottom. It has been reported, for example, that the pressure beneath a diamond bit may be as much as 1000 psi greater than the pressure above the bit, resulting in a hydraulic lift, and in some cases the hydraulic lift force exceeds 50% of the applied load while drilling.
- One surprising observation made in drill bits having surface-set thermally stable PCD elements is that even after sufficient exposure of the cutting face has been achieved, Dy running the bit in the hole and after a fracion of the surface of the metal matrix was abraded away, the rate of penetration often decreases. Examination of the bit indicates unexpected polishing of the PCD elements. Usually ROP can be increased by adding weight to the drill string or replacing the bit. Adding weight to the drill string is generally objectionable because it increases stress and wear on the drill rig. Further, tripping or replacing the bit is expensive since the economics of drilling in normal cases are expressed in cost per foot of penetration. The cost calculation takes into account the bit cost plus the rig cost including trip time and drilling time divided by the footage drilled.
- Clearly, it is desirable to provide a drilling tool having thermally stable PCD elements and which can be manufactured at reasonable costs and which will perform well in terms of length of bit life and rate of penetration.
- It is also desirable to provide a drilling tool having thermally stable PCD elements so located and positioned in the face of the tool as to provide cutting without a long run-in period, and one which provides a sufficient clearance between the cutting elements and the formation for effective flow of drilling fluid and for clearance of cuttings.
- Run-in in diamond bits is required to break off the tip or point of the triangular cutter before efficient cutting can begin. The amount of tip loss is approximately equal to the total exposure of natural diamonds. Therefore, an extremely large initial exposure is required for synthetic diamonds as compared to natural diamonds. Therefore, to accommodate expected wearing during drilling, to allow for tip removal during run-in, and to provide flow clearance necessary, substantial initial clearance is needed.
- Still another advantage is the provision of a drilling tool in which thermally stable PCD elements of a defined predetermined geometry are so positioned and supported in a metal matrix as to be effectively locked into the matrix in order to provide reasonably long life of the tooling by preventing loss of PCD elements other than by normal wear.
- It is also desirable to provide a drilling tool having thermally stable PCD elements so affixed in the tool that it is usable in specific formations without the necessity of significantly increased drill string weight, bit torque, or significant increases in drilling fluid flow or pressure, and which will drill at a higher ROP_than conventional fits under the same drilling conditions.
- The present invention is an improvement in a rotating bit having a bit face wherein the improvement comprises a plurality of teeth disposed on the bit and wherein each tooth includes a diamond cutting element. The diamond cutting element is particularly characterized by having the shape of a segment of a cylinder. The segment includes at least one planar surface and the planar surface forms, at least in part, a leading surface of the tooth.
- More specifically, the cylindrical segment is a split half cylinder or a split quarter cylinder. The diamond cutting element is characterized by having a longitudinal axis lying along the length of the cylinder and wherein the cylindrical shape is a half cylinder shape, the planar surface is a planar surface lying along a diameter of the cylindrical shape. In the case where the cylindrical segment is a quarter segment of a full cylinder,-the quarter segment includes an apical edge which lies along the longitudinal axis of the cylinder. In each case, the apical edge of the quarter cylinder and the planar surface of the half cylinder diamond cutting element serves as an exposed leading surface of the tooth and is disposed adjacent to a fluid channel thereby forming in whole or in part one edge or wall of the fluid channel. As a result of these improvements a cutting tooth is provided using cylindrical elements characterized by improved cutting efficiency, cleaning and cooling efficiency, and less tendency to dull or polish than is the case with prior art fully cylindrical elements used in rotating bits.
- The present invention and its various embodiments are better understood by first considering the following drawings wherein like elements are referenced by like numerals.
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- Figure 1 is a cross-sectional view of a tooth incorporating a cylindrical diamond segment according to the present invention.
- Figure 2 is a plan view of three teeth of the type show! in Figure 1.
- Figure 3 is a cross-sectional view through a rotating bit showing the area of a gage-to-shoulder transition incorporating the teeth of Figure 1.
- Figure 4 is a plan view in reduced scale showing a coring bit incorporating the teeth of Figures 1 and 2.
- Figure 5 is a half profile view of the coring bit of Figure 4.
- Figure 6 is a plan view of the gage-to-shoulder transition of the coring bit in Figure 4 in conformity with the teaching of Figure 3.
- Figure 7 is a cross-sectional view in enlarged scale of a tooth incorporating a second embodiment of the present invention.
- Figure 8 is a plan view of three teeth devised according to the second embodiment shown in Figure 7.
- The present invention and its various embodiments may be better understood by viewing the above figures in light of the following detailed description.
- The present invention is an improvement in a tooth design used in rotating bits, particularly rotary bits, wherein the tooth includes a diamond cutting element and in particular a diamond cutting element derived from cylindrical polycrystalline synthetic diamond (PCD). Such full cylindrical elements are generally commercially available but not in segment form. Such synthetic diamond is formed in the shape of a full circular cylinder having one planar end perpendicular to the longitudinal axis of the cylindrical shape and an opposing domed end, generally formed in the shape of a circular cone. Such elements are typically available in a variety of sizes with the above described shape.
- According to the present invention, the full cylindrical diamond element is segmented to form a cylindrical segment wherein the segment is then axially disposed within a bit tooth. Such segmented or split cylindrical elements thus provide a cutting element with improved cutting efficiency with less use o diamond material and less tendency to dull or polish. The present invention and its various embodiments may be better understood by now turning to Figure 1.
- Figure 1 is a cross-sectional view of a first embodimen of the present invention showing a tooth, generally denoted by
reference numeral 10, incorporating a diamond cutting element, generally denoted by reference numeral 12. Element 12 is axiall disposed within the tungsten-carbide matrix material 14 of the rotating bit. In other words, longitudinal axis 16 of element 1 is orientedT to be approximately perpendicular to bit surface 18 at the location oftooth 10.Bit surface 18 may be bit face of crown of a rotating bit or may be the superior surface of a raised land or pad disposed upon a bit crown. In either case, bit surface 18 is taken in the present description as the basal surface upon whichtooth 10 is disposed. - As better seen in Figure 2, element 12 is approximately a quarter section or 90 degrees of the full cylindrical shape of the PCD element normally available. Element 12 is cut using a conventional laser cutter. For example, deep cuts are made every 90 degrees parallel to the longitudinal axis 16 of a full cylindrical diamond element. Although the laser could be used t completely cut through the diamond element, it has been found possible that with deep scoring, the diamond can then be fractured with propagation of the fracture lying approximately along the continuation of the plane of the laser cut. For example, the laser may cut a millimeter or less into and along the length of the full cylindrical diamond element. A diametrically opposed cut of equal depth is also provided on the cylinder. Thereafter, the cylinder may be split in half and then later quartered on another laser cut by fracturing the diamond element using an impulsive force and chisel.
- Diamond element 12 is disposed within
tooth 10 as isshown in Figure 2 so that theapical edge 20 of diamond 12 formed by the cleavage planes or laser cuts which have formedradial surfaces 22, is oriented in the leading or forward direction oftooth 10 as defined by the rotation of the bit upon whichtooth 10 is disposed. - Turning again to Figure 1, it can be seen that a portion of element 12 is fully exposed above
bit surface 18 and in particular, thatapical edge 20 forms the foremost portion of diamond element 12 as the tooth moves forwardly in the plane of the figure.Surfaces 22 define a dihedral angle and the tangential direction of movement oftooth 10 during normal cutting operation is generally along the direction of the bisector of the dihedral angle. In the illustrated embodiment achannel 24 is defined immediately in front ofapical edge 20 to serve as a waterway or collector as appropriate. Thus, leadingsurfaces 22 andedge 20 can be placed virtually inchannel 24 or immediately next thereto, forming as shown in Figure 1, one wall ofchannel 24 or a portion thereof, whereby hydraulic fluid supplied to and flowing throughchannel 24 during normal drilling operations will serve to cool and clean the cutting face oftooth 10 and in particular the leading edge and surfaces of diamond element 12. - Further, in the illustrated embodiment,
tooth 10 is shown as having a trailingsupport 26 of matrix material integrally formed withmatrix material 14 of the bit and extending above bit surface 18 to the trailing surface of diamond element 12. The slope of trailingsupport 26 is chosen so as to substantially match the slope of the topconical surface 28 of element 12 with the opposing end of element 12, which is a right circular plane, being embedded withinmatrix material 14. However, it must be understood that the exact shape and placement of trailingsupport 26 can be varied without departing from the spirit and scope of the present invention. For example, with larger diameter elements 12, cut from large diameter synthetic cylinders, no trailingsupport 26 may be provided at all and element 12 may be totally free standing above bit surface 18 like an embedded stud. In the cases of thinner cylindrical elements 12, trailingsupport 26 may be even more substantial than that shown in-Figure 1 and may assume a slope different fromsurface 28 of element 12 to thereby provide additional matrix reinforcing material behind and on top ofconical surface 28 and leadingsurfaces 22. - Figure 2 illustrates in plan view the tooth of Figure 1 in a double row or triad configuration. In other words, a first row of teeth including teeth 10a and 10b is succeeded by a trailing tooth or second row of teeth including tooth 10c, wherein tooth 10c is placed halfway between the spacing of teeth 10a and 10b. Therefore, it can be appreciated that as the teeth 10a-c move forward during cutting of a rock formation, the diamond cutting elements incorporated within each of the teeth effectively overlap and provide a uniform annular swath cut into the rock formation as the bit rotates. Figure 4, which shows in plan view a coring bit incorporating the teeth of Figures 1 and 2 illustrates the disposition of such a double row of configured teeth, collectively denoted by
reference numeral 32, onpad 30. -
Bit 34 also includes aninner gage 44 wherein the inner and outer gage are connected bywaterways 31. Eachpad 30 begins at or nearinner gage 44 and is disposed across the bit face in a generally radial direction as seen in Figure 4 and splits into two pads which then extend toouter gage 36. The bifurcated pads are separated by acollector 33 which communicates with agage collector 35 or junk slot 37 as may be appropriate. Clearly, other types of coring bits and petroleum bits could have been illustrated to show the use of the teeth of Figures 1-3 other than the particular bit illustrated in Figure 4. Therefore, the invention is not to be limited to any particular bit style or in fact, even to rotating bits. - Turning now to Figure 3, a cross-sectional view of the shoulder-to-gage transition utilizing the teeth of Figures 1 and 2 is illustrated. The bit, generally denoted by
reference numeral 34, is characterized by having a vertical cylindrical section orgage 36 which serves to define and maintain the diameter of the bore drilled bybit 34. Belowgage 36,bit 34 will slope inwardly along a designed curve toward the center of the bit. In the example of coring bit of Figure 4, a half profile is shown in Figure 5 and is a simple elliptical cross section characterized by anouter shoulder 38,nose 40 andinner shoulder 42. Inner diameter of the core is then defined byinner gage 44. Turning again to Figure 3,outer gage 36 is shown as incorporating a halfcylindrical segment 46, which is surface set and embedded intogage 36 so that the roundedcylindrical surface 48 is exposed above bit surface 50 ofgage 36 with the flatlongitudinal face 52 of the half cylindrical segment embedded withinmatrix material 54 ofbit 34. Half cylindricaldiamond crystalline element 46 is more clearly depicted in cross-sectional view in Figure 4 ongage 36. - Moving from
gage 36 toouter shoulder 38,teeth 32 as shown in Figure 4 include quarter cylindrical segments, shown in rear view in Figure 3 as exemplified by diamond elements 56 and 58. Each element 56 is disposed withinbit 34 so as to extend therefrom in a perpendicular direction as defined by the normal to bit surface at each point where such element is located. - In the preferred embodiment each element 56 and 58 is exposed by a uniform amount, namely, 2.7 mm (0.105") above the bit face. Element 56 which is the diamond element closest to
gage 36 is placed uponshoulder 38 at such a position next to the beginning ofgage 36 so that its outermost radially extending point, namely, apex 60, extends radially from the longitudinal axis of rotation ofbit 34 by an amount equal to the radial distance from the longitudinal axis ofbit 34 by the gage diamonds, inparticular diamond 46. For example, in the preferred embodiment,gage diamond 46 extends above bit surface 50 by 0.64 mm (0.025"). While element 56 extends above bit face 50 by 2.7 mm (0.105") it is placed as the first tooth on the bit face at such a distance from thegage 36 that the radially outermost exposed portion of diamond element 56 will equal the radial distance of thegage diamonds 46 from the axis of rotatior ofbit 34. - Thus, as illustrated in Figure 6, which shows a plan view of the gage of the bit of Figure 4, a double row of
gage diamonds 46a is disposed at and slightly belowgage level 62 on < type I gage column corresponding to atype I pad 30 shown in plai view in Figure 4. Gage diamonds 46b are thus placed adjacent to a pad of type II and gage diamonds 46c placed on a gage section correspondingg to a type III pad.Gage diamonds 46a-c thus form a staggered pattern as best illustrated in Figure 6 which effectively presents a high cutting element density as the bit rotates. Abovegage diamonds 46a-46b are conventional natural diamonds surface set in broaches, namely, kickers which are typical of the order of 6 per carat in size. Whereas the double row of diamonds within one gage section are offset from each other by approximately half a unit spacing, a unit spacing being defined as the length of agage diamond 46, the adjacent row of teeth on the next adjacent gage section begins at a quarter spacing displaced from the corresponding row of gage diamonds on the adjacent pad. In other words, while type I pad corresponds togage diamonds 46a having two rows with each row offset by half a space between each other, pad II corresponds to gage diamonds 46b which are similarly offset with respect to each other and are spaced down the gage one quarter of a spacing as compared togage diamonds 46a on pad type I. - Turning now to Figure 7, a second embodiment of the present invention is illustrated wherein a tooth, generally denoted by
reference numeral 66, incorporates a half cylindricalsegment diamond element 68 extending from and embedded inmatrix material 14 in much the same manner as illustrated in connection with the first embodiment of Figures 1 and 2. As better seen in plan view of Figure 8,PCD element 68 is- characterized by a halfcylindrical surface 70 and a planar leadingsurface 72, which is formed as described above by cleaving a full cylinder along the diameter. - Turning again to Figure 7,
diamond element 68 also includes a conical or domedupper surface 74 forming the apical point 76 ofelement 68. A trailingsupport 78 of integrally formed matrix material is smoothly fared fromsurface 74 to bit face 18 to provide tangential reinforcement and support fordiamond element 68 against the cutting forces to whichelement 68 is subjected. As better seen in plan view in Figure 8, trailingsupports 78 are tapered to apoint 80 on bit face 18 thereby forming a teardrop shaped plan outline fortooth 66. - As shown in Figure 7,
diamond element 68 is placed immediately adjacent to and forms one side of achannel 80 formed intomatrix material 14 whichchannel 80 serves as a conventional waterway or collector as may be appropriate with the same advantages-as described in connection with the first embodiment of Figure 1. - As described in connection with Figure 2, the second embodiment of Figure 8 similarly consists of two rows of
teeth 66a and 66b followed by a second row represented by tooth 66c. Tooth 66c is located halfway between the spacing betweentooth 66a and 66b as defined with respect to the direction of tangential movement during normal drilling operations. The double row of teeth are disposed on a petroleum or coring bit in the same manner as illustrated in connection with the first embodiment of the invention in Figure 4.Teeth 66 are thus disposed withinmatrix material 14 and used on a bit in the same - manner as are
teeth 10 of Figures 1 and 2. However,teeth 66 as shown in Figure 8, clearly provide a broader cutting surface and adiamond element 68 containing twice the diamond material and structural bulk as compared to diamond elements 12 of the first embodiment. Therefore, in those applications where a larger cutting bite is required or where greater structural strength is needed in the diamond element, the halfcylindrical split elements 68 of the second embodiment may be more advantageously used than the quarter split diamond elements of the first embodiment. - Many alterations and modifications may be made to the present invention without departing from its spirit and scope. For example, although the split cylindrical segment has been shown as perpendicularly embedded into the matrix material, it is clearly contemplated that it may be either forwardly or rearwardly raked if required by design objectives. Therefore, the illustrated embodiment must be understood as presented only as an example of the invention and should not be taken as limiting the invention as set forth in the following claim.
Claims (19)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US477068 | 1974-06-05 | ||
US47706883A | 1983-03-21 | 1983-03-21 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0119620A2 true EP0119620A2 (en) | 1984-09-26 |
EP0119620A3 EP0119620A3 (en) | 1986-02-12 |
EP0119620B1 EP0119620B1 (en) | 1990-02-28 |
Family
ID=23894393
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP84102985A Expired - Lifetime EP0119620B1 (en) | 1983-03-21 | 1984-03-19 | Improved tooth design using cylindrical diamond cutting elements |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP0119620B1 (en) |
JP (1) | JPS6016692A (en) |
AU (1) | AU2568884A (en) |
BR (1) | BR8401280A (en) |
CA (1) | CA1218355A (en) |
DE (1) | DE3481435D1 (en) |
ZA (1) | ZA842109B (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0189212A1 (en) * | 1985-01-25 | 1986-07-30 | Eastman Christensen Company | An improved kerfing drag bit |
EP0285678A1 (en) * | 1985-08-02 | 1988-10-12 | Eastman Teleco Company | Earth boring bit for soft to hard formations |
US4926950A (en) * | 1986-03-27 | 1990-05-22 | Shell Oil Company | Method for monitoring the wear of a rotary type drill bit |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
PE20090909A1 (en) | 2007-09-05 | 2009-07-02 | Groupe Fordia Inc | DRILL HOLE |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4351401A (en) * | 1978-06-08 | 1982-09-28 | Christensen, Inc. | Earth-boring drill bits |
GB2096669A (en) * | 1981-04-11 | 1982-10-20 | Christensen Inc | Cutting member for rotary drill bits |
US4373593A (en) * | 1979-03-16 | 1983-02-15 | Christensen, Inc. | Drill bit |
EP0117506A2 (en) * | 1983-02-24 | 1984-09-05 | Eastman Christensen Company | A cutting tooth and a rotating bit having a fully exposed polycrystalline diamond element |
-
1984
- 1984-03-16 AU AU25688/84A patent/AU2568884A/en not_active Abandoned
- 1984-03-19 JP JP59051265A patent/JPS6016692A/en active Pending
- 1984-03-19 EP EP84102985A patent/EP0119620B1/en not_active Expired - Lifetime
- 1984-03-19 DE DE8484102985T patent/DE3481435D1/en not_active Expired - Lifetime
- 1984-03-20 BR BR8401280A patent/BR8401280A/en unknown
- 1984-03-20 CA CA000450039A patent/CA1218355A/en not_active Expired
- 1984-03-21 ZA ZA842109A patent/ZA842109B/en unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4351401A (en) * | 1978-06-08 | 1982-09-28 | Christensen, Inc. | Earth-boring drill bits |
US4373593A (en) * | 1979-03-16 | 1983-02-15 | Christensen, Inc. | Drill bit |
GB2096669A (en) * | 1981-04-11 | 1982-10-20 | Christensen Inc | Cutting member for rotary drill bits |
EP0117506A2 (en) * | 1983-02-24 | 1984-09-05 | Eastman Christensen Company | A cutting tooth and a rotating bit having a fully exposed polycrystalline diamond element |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0189212A1 (en) * | 1985-01-25 | 1986-07-30 | Eastman Christensen Company | An improved kerfing drag bit |
EP0285678A1 (en) * | 1985-08-02 | 1988-10-12 | Eastman Teleco Company | Earth boring bit for soft to hard formations |
US4926950A (en) * | 1986-03-27 | 1990-05-22 | Shell Oil Company | Method for monitoring the wear of a rotary type drill bit |
Also Published As
Publication number | Publication date |
---|---|
EP0119620A3 (en) | 1986-02-12 |
AU2568884A (en) | 1984-09-27 |
EP0119620B1 (en) | 1990-02-28 |
BR8401280A (en) | 1984-10-30 |
CA1218355A (en) | 1987-02-24 |
DE3481435D1 (en) | 1990-04-05 |
JPS6016692A (en) | 1985-01-28 |
ZA842109B (en) | 1984-11-28 |
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