Source: http://www.google.com/patents/US7740090?dq=oakley+D523,461
Timestamp: 2014-04-21 04:19:13
Document Index: 357188864

Matched Legal Cases: ['application No. 2', 'Application No. 0604699', 'Application No. 2', 'Application No. 2', 'application No. 0606575', 'application No. 11', 'application No. 0606575', 'Application No. 2', 'application No. 2', 'Application No. 2', 'Application No. 2', 'Application No. 0604699']

Patent US7740090 - Stress relief feature on PDC cutter - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA cutter having a base portion, an ultrahard layer disposed on the base portion, and at least one relief groove formed on an outer surface of the cutter. The at least one relief groove is configured to form a relief gap between the ultrahard layer and an inside surface of a cutter pocket....http://www.google.com/patents/US7740090?utm_source=gb-gplus-sharePatent US7740090 - Stress relief feature on PDC cutterAdvanced Patent SearchPublication numberUS7740090 B2Publication typeGrantApplication numberUS 11/372,614Publication dateJun 22, 2010Filing dateMar 10, 2006Priority dateApr 4, 2005Fee statusPaidAlso published asCA2541267A1, CA2541267C, US20060219439Publication number11372614, 372614, US 7740090 B2, US 7740090B2, US-B2-7740090, US7740090 B2, US7740090B2InventorsYuelin Shen, John Youhe ZhangOriginal AssigneeSmith International, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (32), Non-Patent Citations (22), Referenced by (1), Classifications (5), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetStress relief feature on PDC cutterUS 7740090 B2Abstract A cutter having a base portion, an ultrahard layer disposed on the base portion, and at least one relief groove formed on an outer surface of the cutter. The at least one relief groove is configured to form a relief gap between the ultrahard layer and an inside surface of a cutter pocket.
a bit body having at least one cutter pocket;
at least one cutter disposed in the at least pocket, the at least one cutter comprising a base portion, an ultrahard layer disposed on said base portion, and at least one relief groove formed on an outer surface of the ultrahard layer of the cutter, wherein the at least one relief groove extends backward from a cutting face a selected distance past an interface of the ultrahard layer and the base portion, and
a relief gap formed between the at least one relief groove and an inside surface of the at least one cutter pocket.
2. The drill bit of claim 1, wherein the ultrahard layer comprises thermally stable polycrystalline diamond.
3. The drill bit of claim 1, wherein the at least one relief groove comprises a full cut around the circumference of the cutter.
4. The drill bit of claim 1, wherein the at least one relief groove comprises at least one notch.
5. The drill bit of claim 1, wherein the at least one relief groove comprises at least one radiused edge.
6. The drill bit of claim 1, wherein said base portion is substantially cylindrical in shape and has an end face upon which the ultrahard layer is disposed.
7. A method of drilling, comprising:
contacting a formation with a drill bit, wherein the drill bit comprises a bit body having at least one cutter pocket; and at least one cutter disposed in the at least one cutter pocket, the at least one cutter comprising a base portion, an ultrahard layer disposed on said base portion, and at least one relief groove formed on an outer surface of the ultrahard layer of the cutter, wherein the at least one relief groove extends backward from a cutting face a selected distance past an interface of the ultrahard layer and the base portion, and a relief gap formed between the at least one relief groove and an inside surface of the at least one cutter pocket of a blade.
8. A method of forming a relief gap in a cutter pocket of a drill bit, the method comprising:
forming a cutter comprising:
an ultrahard layer disposed on the base portion; and
at least one relief groove formed on an outer surface of the ultrahard layer of the cutter, wherein the at least one relief groove extends backward from a cutting face a selected distance past an interface of the ultrahard layer and the base portion; and
inserting the cutter in the cutter pocket, wherein the at least one relief groove is disposed within the cutter pocket.
at least one cutter disposed in the at least one cutter pocket, the at least one cutter comprising a base portion, a diamond table sintered to said base portion, and at least one relief groove subsequently formed on an outer surface of the diamond table of the cutter, wherein the at least one relief groove extends backward from a cutting face a selected distance past an interface of the diamond table and the base portion, and
10. The drill bit of claim 9, wherein the base portion is substantially cylindrical in shape and the diamond table is sintered to an end face of said base portion. Description
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims benefit under 35 U.S.C. � 119 to U.S. Provisional Application Ser. No. 60/667,978, filed on Apr. 4, 2005. This provisional application is hereby incorporated by reference in its entirety.
The invention relates generally to the field of fixed cutter bits used to drill wellbores through earth formations.
Rotary drill bits with no moving elements on them are typically referred to as �drag� bits. Drag bits are often used to drill a variety of rock formations. Drag bits include those having cutters (sometimes referred to as cutter elements, cutting elements or inserts) attached to the bit body. For example, the cutters may be formed having a substrate or support stud made of carbide, for example tungsten carbide, and an ultra hard cutting surface layer or �table� made of a polycrystalline diamond material or a polycrystalline boron nitride material deposited onto or otherwise bonded to the substrate at an interface surface.
A typical cutter 18 is shown in FIG. 2. The typical cutter 18 has a cylindrical cemented carbide substrate body 38 having an end face or upper surface 54 referred to herein as the �interface surface� 54. An ultrahard material layer (cutting layer) 44, such as polycrystalline diamond or polycrystalline cubic boron nitride layer, forms the working surface 20 and the cutting edge 22. A bottom surface 52 of the ultrahard material layer 44 is bonded on to the upper surface 54 of the substrate 38. The bottom surface 52 and the upper surface 54 are herein collectively referred to as the interface 46. The top exposed surface or working surface 20 of the cutting layer 44 is opposite the bottom surface 52. The cutting layer 44 typically has a flat or planar working surface 20, but may also have a curved exposed surface, that meets the side surface 21 at a cutting edge 22.
Generally speaking, the process for making a cutter 18 employs a body of tungsten carbide as the substrate 38. The carbide body is placed adjacent to a layer of ultra hard material particles such as diamond or cubic boron nitride particles and the combination is subjected to high temperature at a pressure where the ultra hard material particles are thermodynamically stable. This results in recrystallization and formation of a polycrystalline ultra hard material layer, such as a polycrystalline diamond or polycrystalline cubic boron nitride layer, directly onto the upper surface 54 of the cemented tungsten carbide substrate 38.
It has been found by applicants that many cutters develop cracking, spalling, chipping and partial fracturing of the ultra hard material cutting layer at a region of cutting layer subjected to the highest loading during drilling. This region is referred to herein as the �critical region� 56. The critical region 56 encompasses the portion of the ultrahard material layer 44 that makes contact with the earth formations during drilling. The critical region 56 is subjected to high magnitude stresses from dynamic normal loading, and shear loadings imposed on the ultrahard material layer 44 during drilling. Because the cutters are typically inserted into a drag bit at a rake angle, the critical region includes a portion of the ultrahard material layer near and including a portion of the layer's circumferential edge 22 that makes contact with the earth formations during drilling.
In addition to bit bodies being formed by infiltrating powered tungsten carbide with, a binder alloy in a suitable mold, a bit body can also be made from steel or other alloys which can be machined or otherwise cut and finished formed using conventional machining and/or grinding equipment. For example, a bit body �blank� may be rough formed, such as by casting or forging, and is finished machined to include at least one blade having mounting pads for cutting elements. The mounting pads may be formed by grinding or machining to include a relief groove.
PDC bits known in the art have been subject to fracture failure of the diamond table, and/or separation of the diamond table from the substrate during drilling operations. One reason for such failures is compressive contact between the exterior of the diamond table and the proximate surface of the bit body under drilling loading conditions. One solution to this problem known in the art is to mount the cutting elements so that substantially all of the thickness of the diamond table is projected outward past the surface of the bit body. While this solution does reduce the incidence of diamond table failure, having the diamond tables extend outwardly past the bit body can cause erratic or turbulent flow of drilling fluid past the cutting elements on the bit. This turbulent flow has been known to cause the cutter mounting to erode, and to cause the bonding between the cutters and the bit body to fail, among other deficiencies in this type of PDC bit configuration.
Other PDC bits known in the art have reduced the turbulent flow caused by the outwardly projected diamond table by including a relief groove formed in the cutter pocket of the bit body. The relief groove reduces the amount of compressive contact between the exterior of the diamond table and the proximate surface of the bit body under drilling loading conditions, thereby reducing the risk of fracture failure of the diamond table, and/or separation of the diamond table from the substrate during drilling operations. Additionally, the PDC cutter may be mounted so that it is substantially flush with the outer surface of the mounting position of the bit body, thereby reducing the amount of turbulent flow created by and outwardly projected diamond table. Thus, relief grooves often reduce diamond table failure, while retaining the benefits of flush mounting of the cutters on the bit body. However, the geometry and dimensions of a cutter pocket with a relief groove are often difficult to control. Additionally, cleaning a pocket with a relief groove requires more work and time.
Displacements are known in the art for forming relief grooves in the cutter pocket of a matrix bit body. U.S. Pat. No. 6,823,952 issued to Mensa-Wilmot, et al. discloses such a conventional displacement configured to form a relief groove in the cutter pocket on the PDC matrix bit body. This patent is incorporated by reference in its entirety. A conventional displacement 102 is shown in FIG. 4. The displacement 102 is a substantially cylindrical body having a selected length indicated by L, a diameter indicated by D and on one end, and a projection 104 having a selected width W. The length L and the diameter D are selected to provide a mounting pad (106 in FIG. 5) on the finished bit body having dimensions suitable to mount a selected cutting element. Typically, the cutting element affixed to the mounting pad (106 in FIG. 5) will be a polycrystalline diamond compact insert. The projection 104 has a substantially cylindrical shape and extends laterally past the exterior surface 102A of the main body of the displacement 102 by about 0.025 inches (0.63 mm). The displacement is affixed to the mold so that the mounting pad is formed to have a recess or relief groove positioned under a diamond table forming part of the cutting element affixed to the mounting pad.
FIG. 5 shows a blade portion of a bit body formed using a displacement, such as shown in FIG. 4. A blade 110 includes thereon a mounting pad 106, having the shape of a displacement. The radius of the mounting pad 106 is determined by the diameter of the displacement. Typically, this radius is selected to match the radius of the cutting element mounted thereon. A relief groove 108 is formed in the mounting pad 106 by having placed the displacement in the mold so that the projection was positioned outward and downward with respect to the blade 110. Shown mounted in the moutning pad 106 is a cutting element 112 consisting of a diamond table 114 affixed to a substrate 116. Typically, the substrate 116 is formed from tungsten carbide or similar hard material. The diamond table 114 can be formed in any manner known in the art for making diamond cutting surfaces for fixed cutter drill bits. The cutting element is typically bonded to the blade 110 by brazing the substrate 116 to the blade 110.
The diamond table 114 extends longitudinally past the surface of the blade 110 by an amount shown at E. The diamond table 114 has a thickness Z which is selected based on the diameter of the cutting element and the expected use of the particular drill bit, among other factors. Diamond table breakage may be reduced efficiently when the depth X of the relief groove 108 is selected so that the relief groove 108 extends back from the surface of the blade 110 at least about 40 percent of that portion (Z-E) of the thickness Z of the diamond table which does not extend past the edge of the blade 110.
While conventional PDC bit bodies have been designed to reduce diamond table failure, the accuracy of designing the cutter pocket has become more difficult, as has cleaning and preparing the pocket.
What is still needed, therefore, is a structure for a PDC bit body which reduces diamond table failure and increases accuracy of designing the cutter pocket.
SUMMARY OF INVENTION In one aspect, the invention provides an improved cutter. In one aspect, the cutter comprises a base portion, an ultrahard layer disposed on the base portion, and at least one relief groove formed on an outer surface of the cutter. The at least one relief groove is configured to form a relief gap between at least a portion of the ultrahard layer and an inside surface of a cutter pocket.
In another aspect, the invention provides a drill bit comprising a bit body, having at least one cutter pocket, and at least one cutter disposed in the at least one cutter pocket. The at least one cutter comprises a base portion, an ultrahard layer disposed on the base portion, and at least one groove formed on an outer surface of the cutter. The at least one relief groove is configure to form a relief gap between at least a portion of the ultrahard layer and an inside surface of the at least one cutter pocket.
In another aspect, the invention provides a method of drilling comprising contacting a formation with a drill bit, wherein the drill bit comprises a bit body having at least one cutter pocket, and at least one cutter disposed in the at least one cutter pocket. The at least one cutter comprises a base portion, an ultrahard layer disposed on the base portion, and at least one relief groove formed on an out surface of the cutter. The at least one relief groove is configure to form a relief gap between at least a portion of the ultrahard layer and an inside surface of the at least one cutter pocket.
FIG. 4 shows a side view of one example of a prior art displacement;
FIG. 5 shows a cross section of a drill bit body having a prior art cutting element mounted on a pad;
FIG. 6 shows a cutter in accordance with an embodiment of the invention;
FIG. 7 shows a cutter in accordance with an embodiment of the invention;
FIG. 8 shows a cutter in accordance with an embodiment of the invention;
FIG. 9 shows a cutter in accordance with an embodiment of the invention mounted in a cutter pocket of a blade.
DETAILED DESCRIPTION The present invention relates to shaped cutters that provide advantages when compared to prior art cutters. In particular, embodiments of the present invention relate to cutters that have structural modifications to the cutting edge in order to improve cutter performance. As a result of the modifications, embodiments of the present invention may provide improved cooling, higher cutting efficiency, improved cutter durability, and longer lasting cutters when compared with prior art cutters. Embodiments of the present invention may shift thermal stress induced during brazing and thermal mechanical stress from drilling away from the cutter interface and onto the cutter substrate. Additionally, embodiments of the present invention may reduce the impact damages to the cutter that may occur from localized diamond-matrix contact.
Embodiments of the present invention relate to cutters having a substrate or support stud, which in some embodiments may be made of carbide, for example tungsten carbide, and an ultra hard cutting surface layer or �table� made of a polycrystalline diamond material or a polycrystalline boron nitride material deposited onto or otherwise bonded to the substrate at an interface surface. Also, in selected embodiments, the ultra-hard layer may comprise a �thermally stable� layer. One type of thermally stable layer that may be used in embodiments of the present invention is leached polycrystalline diamond.
A typical polycrystalline diamond layer includes individual diamond �crystals� that are interconnected. The individual diamond crystals thus form a lattice structure. A metal catalyst, such as cobalt, may be used to promote recrystallization of the diamond particles and formation of the lattice structure. Thus, cobalt particles are typically found within the interstitial spaces in the diamond lattice structure. Cobalt has a significantly different coefficient of thermal expansion as compared to diamond. Therefore, upon heating of a diamond table, the cobalt and the diamond lattice will expand at different rates, causing cracks to form in the lattice structure and resulting in deterioration of the diamond table.
Removing cobalt causes the diamond table to become more heat resistant, but also causes the diamond table to be more brittle. Accordingly, in certain cases, only a select portion (measured either in depth or width) of a diamond table is leached, in order to gain thermal stability without losing impact resistance. As used herein, thermally stable polycrystalline diamond compacts include both of the above (i.e., partially and completely leached) compounds. In one embodiment of the invention, only a portion of the polycrystalline diamond compact layer is leached. For example, a polycrystalline diamond compact layer having a thickness of 0.01 inch may be leached to a depth of 0.006 inches. In other embodiments of the invention, the entire polycrystalline diamond compact layer may be leached. A number of leaching depths may be used, depending on the particular application and depending on the thickness of the PDC layer, for example, in one embodiment the leaching depth may be 0.05 in.
FIG. 8 shows a cutter formed in accordance with an embodiment of the present invention. In FIG. 8, a cutter 300 comprises a substrate or �base portion,� 302, on which an ultrahard layer 304 is disposed. In this embodiment, the ultrahard layer 304 comprises a polycrystalline diamond layer. As explained above, when a polycrystalline diamond layer is used, the layer may further be partially or completely leached. Further, at least one relief groove 308 is formed on an outer surface of the cutter 300 and extends back from the cutting face 310 of the ultrahard layer 304. In one embodiment, the relief groove 308 extends back a selected distance past the interface 306 of the ultrahard layer 304 and the substrate 302. In one embodiment, the relief groove 308 comprises a notch, or groove. In one embodiment, the relief groove 308 may comprise beveled edges 312. Multiple relief grooves may be placed around the circumference of the cutter 300 so that the cutter 300 may be removed and reoriented for multiple uses. While the relief groove 308 appears to be rectangular in shape, one of ordinary skill in the art will appreciate that other shapes and sizes of recessed regions may be used without departing from the scope of the invention.
Modified cutters, as described herein, may be modeled using computer programs. In one embodiment, a modified cutter maybe be modeled and simulated during drilling using, for example, a finite element analysis (FEA) program. In this embodiment, the geometrical shape and material properties of the cutter may be entered into the FEA program. The modified cutter may then be simulated contacting an earth formation during drilling. The simulation of the modified cutter displays the forces acting on the modified cutter, for example, the stress induced on the cutter may be displayed, and the bottomhole geometry data. The positioning of the modified cutter in the cutter pocket and on the bit maybe be evaluated, as well as the geometrical dimensions of the modified cutter itself. The position of the modified cutter and geometrical dimensions of the modified cutter may be adjusted, and the simulation repeated, until the design of the modified cutter is optimized. The design of the modified cutter may be adjusted to reduce the stress induced on the modified cutter in specific regions of the modified cutter to reduce the risk of damage, failure, or breakage of the modified cutter.
In another embodiment of the present invention, shown in FIG. 6, a relief groove is achieved by forming a full groove around the circumference of a cutter 200. The relief groove 208 is formed on an outer surface of the cutter 200 and extends back a selected distance from the cutting face 210 of the cutter 200. In one embodiment, the relief groove 208 extends back to the interface 206 of the ultrahard layer 204 and the substrate 202. In one embodiment, the relief groove 208 may comprise a radiused edge 212 at the interface 206.
FIG. 7 shows a cutter 220 in accordance with an embodiment of the invention with a relief groove 228 achieved by forming a full cut around the circumference of the cutter 220. The relief groove 228 is formed on an outer surface of the cutter 220 and extends back a selected distance from the cutting face 230 of the cutter 220. In one embodiment, the relief groove 228 extends back a selected distance past the interface 226 of the ultrahard layer 224 and the substrate 222. In one embodiment, the relief groove may comprise a radiused edge 232.
A cutter in accordance with embodiments of the invention has a relief groove formed proximate the cutting face of the cutter. When the cutter is inserted in the blade, the relief groove provides a relief gap between the ultrahard layer of the cutter and the inside surface of the cutter pocket of the blade. The relief groove reduces the impact damages on the cutter induced by the localized diamond-matrix contact of the ultrahard layer and the blade. By forming the relief groove on the cutter, the dimensions and geometry of the relief gap formed between the cutter and the cutter pocket are easier to control, and therefore more accurate and precise. The relief gap allows the thermal stress induced by brazing and the thermal mechanical stress from drilling to be shifted away from the interface of the ultrahard layer and the substrate, and onto the cutter substrate. Thus, embodiments of the present invention may provide improved cooling, higher cutting efficiency, improved cutter durability, and longer lasting cutters when compared with prior art cutters.
FIG. 9 shows a cutter 400, in accordance with an embodiment of the invention, disposed in a cutter pocket 418 of a blade 414. In one embodiment, a relief groove 408 is formed on the outer surface of the cutter 400 and extends back a selected distance from the cutting face 410 of the cutter 400. In one embodiment, the relief groove 408 extends back a selected distance past the interface 406 of the ultrahard layer 404 and the substrate 402. In one embodiment, the relief groove 508 comprises a radiused edge 412. The relief groove 408 of the cutter 400 forms a relief gap 416 between the ultrahard layer 404 and the inside surface of the cutter pocket 418 of the blade 414.
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No. 11/365,298 filed Mar. 1, 2006.22Response filed Sep 26, 2006 to Combined Search and Examination Report issued in related GB Application No. 0604699.9 dated Jul. 7, 2006.Referenced byCiting PatentFiling datePublication dateApplicantTitleWO2013177278A1 *May 22, 2013Nov 28, 2013Baker Hughes IncorporatedCutting elements for earth-boring tools, earth-boring tools including such cutting elements, and related methods* Cited by examinerClassifications U.S. Classification175/428, 175/426International ClassificationE21B10/573Cooperative ClassificationE21B10/573European ClassificationE21B10/573Legal EventsDateCodeEventDescriptionNov 20, 2013FPAYFee paymentYear of fee payment: 4Mar 10, 2006ASAssignmentOwner name: SMITH INTERNATIONAL, INC., TEXASFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SHEN, YUELIN;ZHANG, JOHN YOUHE;REEL/FRAME:017676/0623;SIGNING DATES FROM 20060303 TO 20060308Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SHEN, YUELIN;ZHANG, JOHN YOUHE;SIGNED BETWEEN 20060303 AND 20060308;REEL/FRAME:17676/623Owner name: SMITH INTERNATIONAL, INC.,TEXASFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SHEN, YUELIN;ZHANG, JOHN YOUHE;SIGNING DATES FROM 20060303 TO 20060308;REEL/FRAME:017676/0623RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google