Method of hardfacing milled teeth formed on a cutter cone of a milled tooth rotary cone rock bit.

Abstract: A milled tooth rotary cone rock bit comprises chisel crested milled teeth with generously radiused corners at the ends of the crest of each chisel shaped tooth. A concave depression is formed in the crest between the radiused ends. A layer of hardfacing material formed over each tooth is thicker at the corners and in the concave depressions in the crest to provide a means for inhibiting wear of the hardfacing as the bit works in a borehole.

Description: Background of the Invention This invention relates to a method of hardfacing a milled tooth rotary cone rock bits. More particularly, this invention relates to a methode of manufacturing a milled tooth rotary cone rock bits with hardfacing material metallurgically bonded to the cutting edges of the teeth. A milled tooth rock bit is a type of bit for drilling wells or the like with a plurality of rotatable steel cones mounted on a rock bit body. Each cone has a plurality of teeth milled into the surface for cutting rock formations as the cone rotates. It is known to hardface steel teeth milled into rotary cones to enhance the cutting action of the teeth and to inhibit erosion and fracture of the teeth as the milled toothed bit works in an earthen rock formation. U.S. Patent Number 4,836,307 (according to the precharacterizing part of claim 1) entitled "Hard Facing For Milled Tooth Rock Bits" assigned to the same assignee as the present invention describes a hardfacing to reduce erosion and abrasion associated with drilling in earthen formations. Such hardfacing for teeth on a milled tooth rock bit comprises at least 65% by weight of a mixture of tungsten carbide particles and a balance of steel bonding the carbide particles together and to the cutter cone of the rock bit. The tungsten carbide particle mixture comprises from 35% to 80%, and preferably from 65% to 80%, by weight 20 to 30 mesh cemented tungsten carbide, and from 20% to 65%, and preferably from 20% to 35% by weight 40 to 89 mesh single crystal mono-tungsten carbide. Experience has shown however that, where hardfacing is applied around sharp corners retention of the hardfacing at the corners is difficult. For example, a milled tooth formed in a chisel shape is hardfaced over the apex from the side or flank of a tooth, across the crest of the tooth and down the opposite flank, the thickness of the material is less around the sharp corners. The hardfacing being thin in the corners tends to wear rapidly and flake off, exposing the relatively softer steel forming the base of the tooth. The present invention provides a means for enhancing retention of the hardfacing material on the milled teeth, especially around the vulnerable corners of the tooth adjacent the chisel type crest of the tooth. These corners are made with a radius instead of a sharp intersection and the hardfacing is applied over the radius. Premature wear and flaking of the hardfacing from the milled teet is minimized. In addition, the edges formed at the flank and end faces of each milled tooth is rounded to enhance retention of the hardfacing to the tooth. Moreover, the present invention also provides a means for enhancing the durability of the chisel crest of the milled tooth between the opposite radiused corners of the tooth. Brief Summary of the Invention Each of the corners of the chisel crest of each tooth on a milled tooth rock bit is provided with a generous radius such that the hardfacing material is layered over the radiused surface with a thickness sufficient to retard wear during operation of the bit in a borehole. In addition, each edge along each side of the milled teeth is radiused to enhance adherence of the hardfacing material to each tooth. Hardfacing material is applied over at least one chisel shaped milled tooth on a rock bit. The corner at each end of the chisel crest has a radius. A portion of the crest of the tooth between the radiused corners is provided with a concave area. These features minimize premature hardfacing failure at the corners, edges and along the concave crest during operation of the milled tooth rotary cone rock bit in a borehole. A shoulder may be formed at the base of each tooth to form a uniform barrier for the termination of the hardfacing material covering each chisel type milled tooth. Brief Description of the Drawings FIG. 1 is a perspective view of a milled tooth rotary cone rock bit with hardfacing material on each tooth; FIG. 2 is a cross-sectional prior art view of a worn tooth illustrating destructive voids in the hardfacing and base metal material at the corners of the crest of the tooth; FIG. 3 is a cross-sectional view of an improved hardfaced chisel crested milled tooth; FIG. 4 is a diagrammatic cross-section of a tooth of a 7-7/8" milled tooth rotary cone rock bit; FIG. 5 is a cross-sectional view of another configuration of an improved hardfaced milled tooth; FIG. 6 is a cross-sectional view of yet another embodiment of the invention; FIG. 7 is a cross-sectional view of still another embodiment of the invention; and FIG. 8 is a perspective view of a single chisel crested milled tooth with hardfacing in a thicker layer around rounded corners of the tooth adjacent the flank and end faces of the tooth. Detailed Description FIG. 1 illustrates a milled tooth rotary cone rock bit generally designated as 10. The bit 10 comprises a bit body 12 threaded at its pin end 14 and having a cutting end generally designated as 16. Each leg 13 of the body supports a rotary cone 18 rotatably retained on a journal cantilevered from each of the legs in a conventional manner. The milled teeth generally designated as 20 extending from each of the cones 18 are typically milled from steel. Each of the chisel crested teeth has a crest 24, a base 22, two flanks 27, and tooth ends 29. As indicated before, hardfacing material is generally applied on each of the teeth. In some cases the hardfacing material is applied only to the cutting side of the tooth as opposed to the other flanks and ends of the tooth. The rock bit further includes a fluid passage through the pin end that communicates with a plenum chamber inside the body. Typically one or more nozzles 15 are secured within the body. The nozzles direct fluid from the plenum chamber towards a borehole bottom. The upper portion of each of the legs may have a lubricant reservoir 19 to supply a lubricant to each of the rotary cones 18. Turning now to the prior art of FIG. 2, conventional hardfaced chisel crested teeth generally designated as 40, when they operate in a borehole for a period of time, wear on the corners 44 of the teeth. The prior art tooth comprises a crown or crest 41 having hardfacing material 42 across the crest and down the flanks 43, terminating near the base 45 of the tooth. As heretofore stated the hardfacing material transitioning from the crest 41 towards the flanks 43 is very thin at the corners of the conventional teeth. Consequently, as the tooth wears, the hardfacing, since it is very thin, wears out quickly thus exposing the underlying steel 47 of the tooth. Consequently, erosion voids 46 easily invade the base metal since it is much softer than hardfacing material. Turning now to the preferred embodiment of FIG. 3, the chisel tooth generally designated as 20 comprises, for example, a steel foundation 21, having flanks 27, ends 29 and a crest 24. Between the rounded corners 26 is a concave portion 25 formed in the crest of the tooth. The concave portion enables the hardfacing material to form a thicker portion at the middle of the crest, therefore providing a more robust cutting crest. Preferably, the thickness of the hardfacing in the center of such a concave depression is up to twice as thick as the hardfacing on the corners and other areas of the tooth. A preferred hardfacing material is described in U.S. Patent No. 4,836,307. Each of the corners 26 at the ends of the crest of the tooth has a sufficient radius that the thickness of the hardfacing material is assured as it transitions from the crest towards the ends 29 and the flanks 27 of the tooth. Preferably, the radius at the corners is at least as great as the thickness of the hardfacing material. For example, if the thickness of the hardfacing desired is 1.5 mm, the radius of the corner should be at least 1.5 mm. When the radius at the corner is less than the thickness of the hardfacing material, cracking and premature failure at the corners may occur. The hardfacing material terminates in a groove or shoulder 23 formed at the base 22 at each of the teeth. The shoulder or groove provides a termination point for the hardfacing material 32 as it is applied over the crest, ends and flanks of each of the teeth. By providing a concave portion or depression 25 and rounded corners 26 at the end of the crested tooth, the hardfacing material may be applied more generously in the center of the crest and at a sufficient thickness around the rounded corners to resist premature failure. The large radius at the corners assures a thick hardfacing material at a vulnerable area of the tooth. Referring now to the cross-sectional example of FIG. 4, a typical tooth formed on a cone of a conventional 7-7/8 inch (20 cm.) diameter milled tooth rotary cone rock bit would, for example, have a tooth height "A" 18.3 mm and a width "B" 16 mm across the chisel crown of the tooth. The radius 23 at the base groove may be between 1.5 mm and 3.3 mm. The radius at the corners 26 may be between 0.5 mm and 5 mm with a preferred radius of 1.5 mm. The concave radius 25 may be between 3.8 mm and 10 mm with a preferred radius of 8.9 mm. The depth "C" of the concave radius may be up to 1.5 mm with a preferred depth of 1 mm. Clearly, the crest of the tooth may be flat between radiused corners, so that the tooth has a constant hardfacing thickness between radiused corners. The hardfacing 32 having a thickness along the ends 29, flanks 27 and corners 26 between 1 and 2 mm with a preferred thickness of 1.5 mm. The thickness of the hardfacing at depth "D" is between 2 mm and 3 mm with a preferred depth of 2.5 mm with respect to the example of FIG. 3. FIG. 5 is an alternative embodiment of the present invention wherein the chisel crest tooth generally designated as 120 has a crest 124 that transitions into ends 129 and flanks 127. The ends of the crest have a generous radius. The crest 124 has a depression 125 between the ends 126 that allows a thicker hardfacing material at the center of the crest. The hardfacing material 132 maintains a relatively thick layer across the angled ends 126 and down the ends and flanks 129 and 127 towards a groove or shoulder 123. Again the object is to provide a robust or thick hardfacing material over the corners, across the flanks and ends such that the tooth, as it operates in a borehole, retains its integrity and sharpness. FIG. 6 is yet another alternative embodiment illustrating a tooth generally designated as 220, the chisel crested tooth having a crest 224, a depression at the center of the crest 225 and rounded corners 226 much as is shown in FIGs. 3 and 4. However, the ends 229 have a depression or concave portion 228 whereby the hardfacing material 232 is thicker at the concave portion 228, thus providing a thicker area along the ends 229. It would be obvious to provide the same concave portion on each of the flanks 227. Again hardfacing terminates along a shoulder 223 at the base 222 at each of the milled teeth 220. FIG. 7 is still another alternative embodiment illustrating a chisel crested tooth generally designated as 320. The tooth 320 has a pair of concave portions 325 along the crest 324, the ends 326 of the crest being rounded in much the same manner as FIGs. 3, 4, 5 and 6, thus assuring a robust thickness at the corners of the tooth 320. The ends of the tooth 329 may have a concave portion 335 or the flanks and end may have a series of depressions 333 to assure a robust layer of hardfacing 332 over the corners and along the crest, ends and flanks, thereby assuring that the hardfacing material 332 is retained on the tooth. Preferably, the thickness of the hardfacing in the center of such a concave depression is up to twice as thick as the hardfacing on the corners and other areas of the tooth. Again the hardfacing material terminates on a groove or shoulder or recess 323 at base 322 of the tooth 320. FIG. 8 illustrates a perspective view of one of the chisel crested teeth 320 wherein the corners 330 of the tooth are rounded, again for the purpose of assuring that a minimum thickness of hardfacing material is over the corners which form the junction between the end 329 and flanks 327 for the purpose of assuring a thickness over the entire tooth, thereby improving the integrity and durability of the hardfacing material 332 on the tooth 320. It is apparent that would be possible to hardface a milled tooth with a straight chisel crest converging at both radiused ends without departing from the scope of this invention as stated before. The thickness of the hardfacing would remain constant across the crest in keeping with the parameters of the specific example of FIG. 4. Moreover, it would be possible to hardface a spherical or semi-spherical surface of a milled tooth as long as the radiuses are equal to or greater than the parameters as set forth in FIG. 4 thereby assuring a minimum thickness of hardfacing and the enhanced durability of the tooth as it works in a borehole. Each tooth, after the hardfacing is applied, will appear outwardly with substantially straight crest, ends and flanks, the hardfacing having a uniform termination point adjacent the shoulder 323 formed at the base 322 of the milled tooth 320. It will of course be realized that various modifications can be made in the design and operation of the present invention within the scope of the appended claims. Thus, while the principal preferred construction and mode of operation of the invention have been explained in what is now considered to represent its best embodiments, it should be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically illustrated and described.

Claims: A method of hardfacing milled teeth formed on a cutter cone of a milled tooth rotary cone rock bit (10) comprising the steps of: shaping at least one of the milled teeth (20;120;220; 320) to have a chisel crest (24;124;224;324) ; and applying hardfacing material (32;132;232;332) over the chisel shaped tooth (20;120;220;320) characterized by the steps of: forming a radius on each corner (26;126;226;326) at the ends of said chisel crest (24;124;224;324); and applying said hardfacing material (32;132;232;332) over the radiused corners (26;126;226;326) and adjacent areas of the tooth (20;120;220;320) to minimize premature hardfacing failures at said corners (26;126;226;326) during operation of the milled tooth rotary cone rock bit (10) in a bore hole; shaping the crest (24;124;224;324) of such a chisel shaped milled tooth (20;120;220;320) with one or more concave depressions (25;125;225;325;) between opposite corners (26,26;126,126;225,226;326,326) of the crest (24;124;224;324) ; and applying hardfacing material (32;132;232;332) thicker in the concave crest areas than over the corners (26;126;226;326). A method as set forth in claim 1 comprising forming the radius at the corners (26;126;226;326) at least as great as the thickness of the hardfacing material (32;132;232;332). The method as set forth in any of the preceding claims further comprising the step of: forming a hardface limiting shoulder (23;123;223;323) substantially around a base (22;122;222;322) of each of such a chisel shaped milled tooth (20;120;220;320) for providing a uniform termination point for a layer of hardfacing material (32;132;232;332) from the shoulder (23;123;223;323) across flanks (27;127;227;327) and ends (29;129;229;329) of the tooth (20;120;220;320) around the radiused corner (26;126;226;326) and across the concave crest (24;124;224;324) of the chisel cutter. The method as set forth in either of claims 2 or 3 comprising forming a single concave depression (25;125;225;) between the radiused ends (26;126;226) of the crest (24,124,224) of the milled teeth (20;120;220). The method as set forth in either of claims 2 or 3 comprising the step of forming multiple concave depressions (325) between radiused ends (326) of the chisel crested milled teeth (320). The method as set forth in any of the preceding claims further comprising the step of forming one or more concave depressions (228;333,335) in the ends (229,329) and a hardface limiting shoulder (223;323) formed at the base (222;322) of the tooth (220;320). The method as set forth in claim 6 wherein a single concave depression (228;335) is formed in each end (229;325) of the milled tooth (220;320) between the crest (224;324) and a hardface limiting shoulder (223;323) formed at the base (222,322) of the tooth (220;320). The method as set forth in claim 6, wherein a single concave depression (228;335) is formed in each flank (227;327) of the milled tooth (220;320) between the crest (224;324) and a hardface limiting shoulder (223;323) formed at the base (222;322) of the tooth (220;320). The method as set forth in any of the preceding claims further comprising the step of applying hardfacing material (32;123;232;332) over the chisel shaped tooth (20;120;220;320) with a sufficient thickness to cover the tooth (20;120;220;320) around the radiused corners (26;126;226;326) and across the concave flanks (27;127;227;327), ends (29;129;229;329) and crest (24;124;224;324), an outward appearance of the hardfaced teeth (20;120;220;320) after the hardfacing application having substantially flat surfaces at the ends (29;129;229;329), flanks (27;127;227;327) and crest (24,124;224;324) of the teeth (20;120;220;320). The method as set forth in any of the preceding claims wherein the hardfacing material in such a concave depression (25;125;225;325;228;333;335) is up to twice as thick at the center of the depression (25;125; 225;325;228;333;335) formed in the crest (24;124;224;324) of the tooth (20;120;220;320) as the thickness of the hardfacing over the corners of the tooth (20;120;220;320).

Inventors: KESHAVAN MADAPUSI K, MCDONOUGH SCOTT D, SLAUGHTER ROBERT H JR, KESHAVAN, MADAPUSI K., MCDONOUGH, SCOTT D., SLAUGHTER, ROBERT H., JR.
Applicants: SMITH INTERNATIONAL, SMITH INTERNATIONAL, INC.
Application year: 1992
Main classification: E21B10
IPC codes: E21B10