Drill bit with composite cutting members

Abstract: Drill bits may include cutting members which have cutting faces formed of segments of differing cutting materials. The faces of the cutting members may include two or more segments, with the segments formed from at least two different materials. For example, a first segment could be formed of a polycrystalline diamond compact surface while a second segment could be formed of a thermally stable diamond product material.

Description: The present invention relates to a rotary drill bit for drilling subterranean formations as characterized in the pre-characterizing portion of claim 1. Drill bits presently known to the industry which utilize stationary cutting members typically use either natural or synthetic diamonds as cutting elements, and are conventionally known as "diamond bits". References herein to "diamond bits" or "diamond drill bits" refer to all bits, for either drilling or coring, having primarily stationary cutting members. Conventional diamond drill bits may have a variety of different types of cutting surfaces, such as, for example polycrystalline diamond compact (PDC) cutters, thermally stable diamond product (TSP) cutters, mosaic-type cutters and diamond impregnated stud cutters. Mosaic cutters are typically formed of a plurality of geometrically-shaped thermally stable diamond elements cooperatively arranged and bonded in a desired shape, to form a unitary cutting surface (EP-A-0 157 278). On conventional bits, the diamond cutting surface is typically bonded to a supporting member, which is then secured to a carrier member which facilitates attachment to the drill bit. The cutting surface layer is preferably connected to the supporting member such as through use of brazing or sintering. Preferably, the supporting member and the carrier member will both be formed of a suitable hard or sintered metal, such as, for example, tungsten carbide. The supporting member can be soldered or otherwise connected, such as by form sintering or hot isostatic pressing, to the carrier member (US-A- 4,498,549). Additionally, drill bits may include more than one type of cutting member on a single bit. Some types of cutting surfaces are better adapted to cut specific formations than are others. For example, while large PDC-type cutters are extremely efficient at cutting shales and other similarly soft formations, they are quickly broken or abraded in hard formations. Other cutting surfaces, however, such as mosaic surfaces, will cut through the harder formations satisfactorily. Accordingly, some relatively recent diamond drill bit designs have included dual sets of cutting members, with each set composed of cutting members having different types of cutting surfaces. With bits of that type, for example, a first set of cutters is arranged on the bit to provide essentially full face coverage across the face of the bit, and a second set of cutters, of a different type, is arranged to provide coverage across at least a portion of the bit face. Such bits with dual cutter sets, while performing exceptionally well in some applications, may not be feasible for use with all types of bits. For example, with bits having cutting members with large cutting surfaces, such as 2,5 centimeter (one inch) or greater in diameter, it may not be feasible to include two sets of cutters on a single bit. Additionally, even if the additional cutter set could be included on a single bit, the extra surface area could interfere with chip removal, or could raise the total bottom hole surface area contacting the formation to a level which would require an unacceptably high weight-on-bit to cut the formation. Accordingly, the present invention provides a drill bit as claimed in claim 1 including composite cutting surfaces on a single drill bit, whereby the exposed face of the cutting member may be maintained at a desired size, but whereby that face can be composed of different cutting surfaces adapted to perform differently in the earth formations. Figure 1 depicts a diamond drill bit having cutting members in accordance with the present invention. Figure 2 depicts that an isolated cutting member of the drill bit of Figure 1. Figures 3A-F depict exemplary alternative cutting faces for a cutting member in accordance with the present invention. Referring now to the drawings in more detail, and particularly to Figure 1, therein is depicted an exemplary embodiment of a drill bit 10 in accordance with the present invention. Drill bit 10 includes a body section 12 which carries a plurality of cutting members 16. Body 12 is preferably a molded component fabricated through conventional metal matrix infiltration technology. Body section 12 is coupled to a shank 18 which includes a threaded portion 20. Shank 18 and body 12 are preferably formed to be functionally integral with one another. Drill bit 10 includes an internal recess (not illustrated), through which hydraulic fluid will flow. A plurality of nozzles 22 are placed in body 12 to distribute hydraulic flow proximate the faces of cutting members 16. Referring now also to Figure 2, therein is depicted an exemplary cutting member 16 in greater detail. The cutting face 24 of cutting member 16 includes two segments, 26 and 28. Cutting face segments 26 and 28 will each be formed of a layer of a cutting material, but will be formed of different types of cutting material. For example, segment 26 may be a PDC cutting layer, while segment 28 may be a TSP cutting layer. Cutting face 24 of cutting member 16 may be formed of segments arranged in any of a variety of conformities, and such face segments may be formed of any of a variety suitable materials. The segment faces preferably lie in generally parallel planes, and most preferably will be coplanar as depicted in the drawing. Referring now to Figures 3A-F, therein are depicted exemplary alternative configurations and constructions for the cutting face of a cutting member 16 as depicted in Figures 1 and 2. Figure 3A depicts a cutting face 30 having a PDC face segment 32 and a mosaic face segment 34. The two segments 32 and 34 are symmetrically arranged relative to a vertical axis. Figure 3B depicts a face segment 36 having three generally vertically extending faces 38, 40 and 42, symmetrically arranged about a central vertical diameter. In the depicted embodiment, outer face segments 38 and 42 are of a first type of cutting surface, while central face segment 40 is of a second type of cutting surface. Figure 3C depicts a cutting face 44, which is similar in construction to cutting face 36 of Figure 3B, with the exception that the face segments 46, 48 and 50 are symmetrically disposed about a nonvertical diameter. Figure 3D depicts a two segment cutting face 52, with face segments distributed on either side of a horizontal diameter. Here again, upper segment 54 may be of a material such as a PDC layer, while lower segment 56 may be of a different material, such as a TSP or mosaic material. Figure 3E depicts an exemplary embodiment where the cutting face 58 is divided into a plurality of quadrant face segments 60, 62, 64 and 66. These face segments 60, 62, 64 and 66 can be formed, for example, of two alternating cutting layer materials or could all be formed of different cutting layer materials. Figure 3F depicts an embodiment similar to that of Figures 3B and 3C, with the exception that the three face segments of cutting face 68 are disposed symmetrically relative to a horizontal diametrical axis.

Claims: A rotary drill bit (10) for drilling subterranean formations including a body member (12) secured to a shank (18) for rotating said bit (10) about a longitudinal axis, a plurality of cutting members (16) disposed on said body member (12), said cutting members (16) each including a cutting face (24,30,36,58) facing primarily toward the direction of bit rotation and said cutting face (24,30,36,58) having a cutting edge, characterized in that said cutting face (24,30,36,58) includes at least two different laterally adjacent cutting surfaces (32,34,38,40,42,46,50,60,62) adapted to perform differently in said subterranean formations, one of said at least two laterally adjacent cutting surfaces being essentially formed of a polycrystalline diamond material selected from the group comprising: polycrystalline diamond compact material, thermally stable diamond material, and mosaic diamond material; and at least one other of said at least two laterally adjacent cutting surfaces being formed of another, different material selected from said group, said cutting surfaces being oriented on said body member (12) so that said cutting edge includes sectors of at least two of said different, selected materials. The rotary drill bit (10) of claim 1, wherein said laterally adjacent cutting face segments (32, 34, 38, 40, 42, 46, 48, 50, 60, 62) of said cutting member (10) lie in generally parallel planes. The rotary drill bit (10) of claim 1, wherein said laterally adjacent cutting face segments (32, 34, 38, 40, 42, 46, 48, 50, 60, 62) of each cutting member (16) are generally coplanar.

Inventors: JUERGENS RAINER DR, JUERGENS, RAINER DR., Jürgens, Rainer Dr.
Applicants: BAKER HUGHES INC, BAKER-HUGHES INCORPORATED
Application year: 1989
Main classification: E21B10
IPC codes: E21B10