Cutting member for rotary drill bits

A cutting member for rotary drill bits consists of a carrier member with a supporting face which consists of two component supporting faces adjoining one another in wedge-shape forming a front edge, and applied to each of the two component supporting faces is a supporting member together with a cutting layer which occupies the whole area. The cutting member which is wedge-shaped in its contours develops high drilling performances particularly in comparatively soft ground formations and is considerably cheaper than known wedge-shaped cutting members and renders possible an extensive variability in the formation of the supporting members together with the cutting layers and their arrangement on the carrier member.

The invention relates to a cutting member for rotary drill bits for 
deep-well drilling and to rotary drill bits incorporating such cutting 
members. 
In cutting members of this kind found commercially (U.S.-PS No. 4,006,788), 
the supporting member together with its cutting layer consists of a 
circular small plate or a flat cylinder, and the polycrystalline synthetic 
diamond material forming the cutting layer is applied to the supporting 
member by a sintering or hot infiltration process and forms a rigid unit 
with this. The expensive diamond material causes by far the greatest 
proportion of the production costs of such diamond cutting plates. It is 
true that such cutting members have a number of possibilities of use on 
rotary drill bits for deep-well drilling, and display satisfactory 
drilling capacities, but the drill bits equipped with diamond cutting 
members in this manner are very expensive because of the high price of the 
diamond material. In particular, however, such cutting members have only 
limited suitability in comparatively soft ground formations. 
Furthermore, rotary drill bits for deep-well drilling in rock and the like 
ground formations have been proposed (DE-OS No. 2910347), the cutting 
members of which each consist of a carrier portion or supporting member of 
hard metal or the like and a cutting portion particularly of 
polycrystalline synthetic diamond material disposed on this, and are 
formed from a sector of a sintered body surrounding the cutting portion in 
the form of a core with its carrier portion at least at the periphery as a 
sheath. In this case, the cutting members have the shape of wedge-shaped 
sectors which are preferably cut out of a cylinder or a polygonal straight 
prism with suitable wedge angles of 45.degree., 60.degree. or 90.degree. 
for example. 
In this proposed construction, in contrast to the cutting members in the 
form of small plates with a diamond covering mentioned at the beginning, 
the cutting portion is not formed from a thin surface layer but from a 
corner region of augmented diamond composition. A preferred field of use 
for these cutting members is formed by rotary drill bits for deep-well 
drilling in comparatively soft ground formations, the cutting members 
being inserted in a base member of the drill bit in such a manner that 
they engage in the formation with a leading end cutting edge and detach a 
chip from the formation in the manner of a plough. 
It is true that particularly satisfactory drilling results can be achieved 
in soft ground formations with cutting members constructed in this manner, 
but the production of the cutting members requires a high proportion of 
the expensive diamond material accumulated in the corner region in the 
finished cutting member. 
It is the object of the present invention to provide an improved cutting 
member for rotary drill bits. 
The present invention is a cutting member for rotary drill bits comprising 
a carrier member having a supporting face consisting of two component 
supporting faces adjoining one another in a wedge-shape to form a front 
edge, each of the two component supporting faces mounting a supporting 
member occupying its full area and having on its front face a cutting 
layer. 
The present invention is also a rotary drill bit incorporating cutting 
members as defined in the last preceding paragraph. 
In a preferred embodiment, a supporting member together with a cutting 
layer is disposed on each of the component supporting faces of the carrier 
member mating in wedge-shape, so that a cutting member which is 
wedge-shaped in its contours is formed which can develop a plough effect 
in drilling operation when working the ground formation and therefore can 
achieve high drilling performances particularly in comparatively soft 
ground formations. At the same time, the cutting member according to the 
preferred embodiment is considerably cheaper than the known wedge-shaped 
cutting members because the supporting member and cutting layer used 
according to the invention can be formed from the cutting members in the 
form of small plates or circular cylindrical shaped bodies which have long 
been known and are found commercially and out of which they are cut 
preferably in contours corresponding to the component supporting faces of 
the carrier member. Fundamentally, production of the supporting member 
together with the cutting layer is also possible as a shaped body 
corresponding to a predetermined component supporting face of the carrier 
member but the preparation from sectors from a circular cylindrical shaped 
body according to the component supporting faces of the carrier member 
offers the advantage that ordinary commercial diamond cutting plates can 
be used and rationally employed. In particular, an accumulation of 
expensive diamond material in the corner region of the cutting members is 
avoided and a far-reaching variability in the formation of the supporting 
members together with the cutting layer and their arrangement on the 
carrier member is ensured. In this manner, the cutting members according 
to the invention can be produced with a maximum of economy, to which not 
least the fact contributes that even unused residues of circular diamond 
cutting plates which have already been used can be used economically for 
the production of cutting members according to the invention.

The cutting members illustrated in the figures comprise a carrier member 1 
which is formed from a hard-metal or the like hard-material pin and can be 
inserted by one end in a base member 2, for example a matrix binding-agent 
composition, of a drill bit. In the embodiments shown in FIGS. 1 and 2, 
the carrier member 1 has, in its main portion, the cross-sectional shape 
which can be seen from these figures and which is composed of 
asemicircular area 3 and a triangular area 4. Machined in the lateral 
faces 5 and 6 bounding the triangular area 4 of the carrier member 1 is a 
supporting face 7 which consists of two component supporting faces 8. The 
two component supporting faces 8 meet in a wedge shape, in the example 
illustrated at an angle of 90.degree., and at their transition form a 
front edge 9 of the supporting face 7. 
Applied to each of the two component supporting faces 8, at its back, is a 
supporting member 10 together with a cutting layer 11, which occupies the 
whole area. The supporting members 10 consist of a suitable hard metal or 
sintered metal or the like hard material, for example tungsten carbide, 
while the cutting layer 11 consists of suitable diamond material, 
particularly polycrystalline synthetic diamond material and is rigidly 
connected to the supporting member 10 by a hot infiltration process by 
methods known per se. The supporting member 10 together with its cutting 
layer 11 is cut, for example by spark erosion, out of a circular 
cylindrical shaped body comprising the cutting layer at one surface, which 
can be formed by production methods known per se. In the embodiment shown 
in FIG. 1a, the adjacent edges 12 of the supporting member 10 and cutting 
layer 11 are mitre-cut, mate flush with one another in front of the front 
edge 9 of the supporting face 7 and together form an end cutting edge 13, 
while in the modification shown in FIG. 1b the supporting member 10 and 
cutting layer 11 are cut at right angles forming marginal faces 12' and 
are secured to the carrier member overlapping in the manner shown. 
The embodiment according to FIG. 2 differs from that of FIG. 1a in that the 
adjacent marginal faces 12' of the supporting member 10 together with the 
cutting layer 11 extend at right angles to their front and their back and 
a separate insert 14 of hard material is disposed in the gusset remaining 
between them. The insert 14 of hard material is formed from a shaped body 
in the form of a square rod, the lateral dimensions of which correspond 
substantially to the width of the supporting member 10 together with the 
cutting layer 11, that is to say their marginal faces 12', and the height 
of which corresponds substantially to that of the front edge 9 of the 
supporting face 7. The outer faces 15 of the insert 14 of hard material 
are in alignment with the cutting layer 11 of the particular adjoining 
supporting member 10, while its front edge 16 forms an end cutting edge 
corresponding to the end cutting edge 13 of the embodiment shown in FIG. 
1. 
The insert 14 of hard material may consist of a hard metal or, as 
illustrated in the enlarged detail shown in FIG. 3, or a matrix 
composition which is impregnated with diamonds or comprises diamonds set 
in the surface. Above all, diamonds 17, preferably natural ones, are 
inserted in the region of the end cutting edge 16 of the insert 14. 
As can further be seen from FIGS. 1 and 2, the component supporting faces 8 
of the carrier member 1 are provided with marginal faces 18 which are 
stepped outwards and against which the supporting members 10 together with 
their cutting layer 11 are supported at the edge side in regions of their 
marginal faces 12 and 12' remote from one another. Remaining in a lateral 
extension of the supporting members 10 are regions of the lateral faces 5 
and 6 of the carrier member 1 which continue the cutting layer 11 of the 
supporting members 10 in a direction facing away from the end cutting edge 
13 or 16 and are in alignment with these in the embodiment illustrated. 
These face regions form rakes to remove the formation chips drilled out. 
In FIGS. 4 to 10, the pin-shaped carrier member 1 is shown in its installed 
state in a drill bit, in which case it is inserted by one of its ends in 
the base member 2 of the drill bit and carries the two supporting members 
10 together with the cutting layer 11 in its region projecting beyond the 
base member 2. It can be seen that the supporting members 10 together with 
the cutting layer 11 each have the shape of a segment or a sector of a 
circle, the component supporting faces 8 being constructed in the form of 
a divided circle accordingly. The supporting members 10 border, with a 
front marginal edge, which can be formed during an operation of cutting 
the supporting member 10 together with the cutting layer 11 out of a 
circular cylindrical shaped body, against the front edge 9 of the 
supporting face 7, while the edges 19 remote from one another of the 
supporting members 10 together with the cutting layer 11 are either 
engaged over and supported by the marginal faces 18 of the component 
supporting faces 8 which are bent outwards at an angle or form outer 
cutting edges 20 supplementing the end cutting edge 13 or 16 which is 
disposed in the plane of the front edge 9 of the supporting face 7 of the 
carrier member 1. 
In the embodiment shown in FIG. 4, the two supporting members 10 together 
with the cutting layer 11 each have the form of a semicircle in plan view, 
the straight edge forming the end cutting edge 13 while the arcuate edges 
19 are mainly engaged over by the marginal face 18 of the component 
supporting faces 8 and only their lower end region forms an additional 
outer cutting edge 20. 
Instead of a semicircle, other supporting members 10 together with cutting 
layers 11 in the form of segments of a circle may be used in arrangements 
corresponding to FIG. 4. 
Apart from this, in the embodiment shown in FIG. 4, as in the further 
embodiments shown in FIGS. 5 to 8, the pin-shaped carrier member 1 is 
provided with an outer, free, backward end region 21 which is rounded in 
arcuate shape towards the front edge 9 of the supporting face 7 or towards 
the end cutting edge 13 or 16. 
In the embodiment shown in FIG. 5, the two supporting members 10 together 
with the cutting layers 11 each have the basic shape of a sector of a 
circle in plan view, one straight edge forming the end cutting edge 13 and 
the other sector edge kept free of support by the carrier member 1 is in 
turn rounded in continuation of the arcuately rounded region 21 of the 
carrier member 1 towards the end cutting edge 13. The arcuate edge of the 
two supporting members 10 together with the cutting layers 11 is engaged 
over and supported by the angled marginal faces 18 of the component 
supporting faces 8. 
The embodiment shown in FIG. 6 differs from that of FIG. 5 essentially in 
that the outer cutting edge 20 of the supporting members together with the 
cutting layers 11, which are also in the form of a sector of a circle 
here, extends straight and at right angles to the end cutting edge 13. 
In the embodiment shown in FIG. 7, in which the two supporting members 10 
together with the cutting layers 11, as in the case of the embodiment 
shown in FIG. 6, are each formed from a sector of a circle in the form of 
a quadrant, a modification is made in such a manner that the one straight 
sector edge forms the end cutting edge 13 and the arcuate marginal edge 
forms the additional outer cutting edge 20, while the other straight 
sector edge is engaged over and supported by one of the angled marginal 
faces 18 of the two component supporting faces 7. The rear, rounded outer 
region 21 of the carrier member 1 extends congruent with the outer cutting 
edge 20 of the supporting member 10 together with the cutting layer 11. 
In the embodiment shown in FIG. 8, the two supporting members 10 together 
with the cutting layers 11 are provided in the form of acute-angled 
sectors of a circle in an arrangement corresponding to FIG. 7. While the 
one straight sector edge again forms the end cutting edge 13 and the 
arcuate edge forms the additional outer cutting edge 20, the other 
straight marginal edge, engaged over by one of the angled marginal faces 
18 of the component support faces 8, extends obliquely to the end cutting 
edge 13 according to the angle selected. The rear, rounded outer region 21 
of the carrier member 1 assumes a course corresponding to the example 
shown in FIG. 7. 
In the embodiments of FIGS. 9 and 10, the supporting members 10 together 
with the cutting layers 11 are not formed by sectors of a circle but only 
have straight boundary edges. In these cases, the supporting members 10 
together with the cutting layers 11 may likewise be formed by being cut 
out of appropriate shaped bodies or may be constructed in the form of 
shaped bodies preshaped in their final form. 
In the embodiments shown in FIGS. 9 and 10, the arrangement and mounting of 
the supporting members 10 together with the cutting layers 11 on the 
carrier member is effected as in the examples described above. Thus in the 
embodiment shown in FIG. 9 there is a lower outer cutting edge 20 
corresponding to FIG. 6, which extends straight and at right angles to the 
end cutting edge 13. The straight marginal edge situated opposite to the 
outer cutting edge 20 and extending parallel to this is engaged over and 
supported by an angled marginal face 18 of the associated component 
supporting face. Between these two marginal edges, a straight marginal 
edge of the supporting member 10 together with the cutting layer 11, which 
edge is kept free of support, extends obliquely to the base member 2. 
In the embodiment shown in FIG. 10, a lower outer cutting edge 20 which 
extends straight and at right angles to the end cutting edge 13 is 
likewise provided, and the straight marginal edges engaged over by the 
angled marginal faces 18 of the component supporting faces 8 extend at 
first at right angles to the lower outer cutting edge 20 and then extend 
obliquely to the outer cutting edge 13 and to the base member 2. 
Lateral face regions 5 and 6 in an extension of the cutting layers 11 of 
the two supporting members 10 are omitted in the embodiments shown in 
FIGS. 7, 8 and 9. 
The rigid connection of the two supporting members 10 to the carrier member 
1 can be effected by a soldered connection 22, as illustrated 
diagrammatically in FIGS. 1 to 3. In the case of the embodiment shown in 
FIGS. 2 and 3, the connection of the insert 14 of hard material to the 
supporting members 10 can also be effected by the soldered connection 22. 
Instead of a soldered connection, the two supporting members 10 can be 
connected to the carrier member 1 and possibly the insert 14 of hard 
material may be connected to the two supporting members 10 by form 
sintering or hot isostatic pressing. 
The examples illustrated in the drawings are only a selection from a large 
number of possible forms of the cutting members and their mounting on the 
drill bit, and various setting angles may be selected with regard to the 
ground formation to be worked, so that the cutting members can act on the 
formation not only with a ploughing action with a leading end cutting edge 
13 or 16, but also with a scratching or scraping action.