EP0154936A2 - An exposed polycrystalline diamond mounted in a matrix body drill bit - Google Patents
An exposed polycrystalline diamond mounted in a matrix body drill bit Download PDFInfo
- Publication number
- EP0154936A2 EP0154936A2 EP85102568A EP85102568A EP0154936A2 EP 0154936 A2 EP0154936 A2 EP 0154936A2 EP 85102568 A EP85102568 A EP 85102568A EP 85102568 A EP85102568 A EP 85102568A EP 0154936 A2 EP0154936 A2 EP 0154936A2
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- European Patent Office
- Prior art keywords
- matrix material
- diamond
- diamond body
- cutter
- drill bit
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- 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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Links
- 239000011159 matrix material Substances 0.000 title claims abstract description 160
- 239000010432 diamond Substances 0.000 title claims abstract description 126
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 114
- 230000000717 retained effect Effects 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 7
- HPNSNYBUADCFDR-UHFFFAOYSA-N chromafenozide Chemical compound CC1=CC(C)=CC(C(=O)N(NC(=O)C=2C(=C3CCCOC3=CC=2)C)C(C)(C)C)=C1 HPNSNYBUADCFDR-UHFFFAOYSA-N 0.000 abstract 1
- 238000005553 drilling Methods 0.000 description 24
- 238000005520 cutting process Methods 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
- 238000005755 formation reaction Methods 0.000 description 11
- 230000015572 biosynthetic process Effects 0.000 description 10
- 238000000034 method Methods 0.000 description 6
- 239000011435 rock Substances 0.000 description 6
- 239000012530 fluid Substances 0.000 description 5
- 230000001154 acute effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000003776 cleavage reaction Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000035515 penetration Effects 0.000 description 3
- 230000007017 scission Effects 0.000 description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 238000005219 brazing Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 240000003759 Erodium cicutarium Species 0.000 description 1
- 235000009967 Erodium cicutarium Nutrition 0.000 description 1
- 244000046052 Phaseolus vulgaris Species 0.000 description 1
- 235000010627 Phaseolus vulgaris Nutrition 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 239000003129 oil well Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 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
- E21B10/5673—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts having a non planar or non circular cutting face
-
- 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
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mining & Mineral Resources (AREA)
- Geology (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Earth Drilling (AREA)
- Carbon And Carbon Compounds (AREA)
- Drilling Tools (AREA)
Abstract
Description
- The invention relates to field of earth boring tools, and more particularly to diamond drill bits incorporating synthetic diamond cutting 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 the case 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 (111), (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 be described as a porous PCD,'as referenced in U.S. 4,224,380.
- Polycrystalline diamonds have been used in drilling products either. as individual 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 extended 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 o?r ?r?rfexposure recommended thus depended on the type of rock formation to be cut.
- The difficulties with such placements are several. The 3ifficulties 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 sticky. 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 the 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, by running the bit in the hole and after a fraction 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.
- Initial run-in in PCD diamond bits often breaks off the tip or point of the triangular cutter. Therefore, an extremely large initial exposure is required for synthetic diamonds. 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 dri lling 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 bits under the same drilling conditions.
- The invention is a cutter in a drill bit made of matrix material comprising a diamond body 'disposed in the matrix material of the drill bit and exposed above the surface of the drill bit. The diamond body has a predetermined geometric configuration and is disposed in the matrix material in such a fashion to establish at least two loccking points between the diamond body and the matrix material. The manner in which the diamond body is disposed in the matrix material is dependent in part on the geometry of the diamond body. In particular, the diamond body is oriented in the matrix material so that at least one surface or portion of a surface of the diamond body is acutely inclined with respect to the normal to the surface of the matrix material at the_ location of the diamond body. The matrix material thus forms a locking wedge over the diamond body where it is acutely inclined with respect to the normal to the matrix surface at the location of the diamond body on the bit.
- The invention is illustrated below in a plurality of geometric shapes including triangular prismatic shapes elements, prismatic rectangular elements, cylindrical elements, ovulate elements, and plate-like elements. In addition, the invention can be incorporated in free-form shapes which incorporate a negatively curved surface which produces a lip or pedestal extending and disposed below the surface of the matrix material or the bit face. By virtue of the spaced-apart locking points established on the diamond body and between the diamond body and the matrix material, the diamond body is securely retained in the drill bit while allowing substantial exposure of the diamond body above the matrix surface of the drill bit.
- These and other advantages of the invention and its various embodiments are better understood by now considering the following Figures wherein like elements are reference by like numerals.
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- Figure 1 is a pictorial perspective of a drill bit incorporating diamond elements raised above the face of the matrix surface.
- Figure 2 is a perspective view of a triangular prismatic element embedded according to the invention within the matrix body bit of Figure 1 while allowing substantial exposure upon the surface of the bit.
- Figure 3 is a perspective view of a cubic element attached to a matrix body bit according to the invention.
- Figure 4 is a- perspective view of a right circular cylinder embedded in a matrix.
- Figure 5 is a perspective view of a triangular prismatic element embedded in a generally axial orientation in the matrix body bit.
- Figure 6 is a generalized ovulate diamond body embedded in a matrix bit according to the invention.
- Figure 7 is a right circular disc embedded according to the invention in a matrix body bit.
- Figure 8 is a right circular cylindrical diamond element embedded in a generally tangential direction in a matrix body bit according to the invention.
- Figure 9 is a triangular prismatic element embedded in a generally tangential orientation.
- Figure 10 is a generally rectangular prismatic element embedded in a matrix body but in a generally tangential orientation.
- Figure 11 is a triangular plate like element embedded in a matrix body bit according to the invention in a generally tangential orientation.
- Figure 12 is a trapezoidal prismatic diamond element embedded in a matrix body bit in a generally tangential orientation.
- Figure 13 is a trapezoical prismatic element embedded in a matrix body bit in a generally axial orientation with backing or inclined support as shown in side view.
- Figure 14 is a view of the trapezoidal prismatic element shown in Figure 12.
- Figure 15 is a free form diamond body embedded in a matrix body bit according to the invention.
- The invention as exemplified in these various embodiments is better understood by now turning to the following detailed description which should be considered in light of the above drawings.
- The invention is the embedding and interlocking of a hard cutting element into a bit body. More particularly, the invention comprises the embedding and interlocking of a polycrystalline synthetic, diamond (PCD) element into a matrix body bit such that the diamond element is substantially exposed above the surface of the matrix. The embedment and interlocking of the diamond element is provided in such a way, as described in greater detail below that at least two locking points are provided between the diamond element and the matrix by virtue of the embedment and geometric configuration of the diamond element. The locking points provide means of interlocking the diamond element into the matrix in order to prevent movement or dislodging of the diamond matrix therefrom in substantially any direction including particularly the direction normal to the surface of the matrix. The invention as it is exemplified in various embodiments can better be understood by now considering the illustrated embodiments as set forth in the figures described above.
- Figure 1 is a pictorial perspective of a matrix body drill 11.
Bit face 17 is characterised by agage 19,shoulder portion 21,flank 23, nose 25 and apex 27. These portions of bit face 17 are also provided withconventional junk slots 29 and collectors andwaterways 31 in communication with an axial crowfoot (not shown). Between waterways andcollectors 31 are lands or pads 33 in which a plurality ofdiamond elements 35 are disposed according to the invention. The surface of lands 33 is defined as the matrix surface and is generally planar in the localized area of eachdiamond element 35. - Turn now to Figure 2 wherein a perspective view of a triangular prismatic PCD element, generally denoted by
reference numeral 10 is illustrated. Element -10 is configured as a triangular prism characterised by two opposing triangular end faces 12, only one of which is shown in Figure 2, and three adjacentrectangular sides 14, again only one of which is illustrated in Figure 2.Element 10 is prismatic, meaning that the shape ofelement 10 is generated by translating one triangular end face 12 in a parallel linear direction as defined bylongitudinal axis 16. Such PCD elements are well known to the art and are manufactured under the trademark "GEOSET" by General Electric Company. - According to the invention,
element 10 is embedded in and interlocked withmatrix 18 of bit 11 of Figure 1. Contrary to the teachings of the prior art,PCD element 10 is raised well abovesurface 20 ofmatrix 18, typically by more than 30% of height 22 of element 10: For example, in the case of a 2103 "GEOSET", which is in the form of an equilateral triangular prismatic element,element 10 may be mounted withinmatrix 18 and raised above the surface by more than 0.068 inch (1.73 mm). In such an instance, height 22 is 0.35 inch (5.20 mm). In :n such an instance, height 22 is 0.35 inch (5.20 mm). In general, regardless of geometry, according to the invention more than one-third of the linear dimension which is approximately perpendicular to the matrix surface is exposed. -
Element 10 is mounted and interlocked inmatrix 18 by having oneside 14 forming a base 14a opposing the dihedral angle forming anapical idge 24. Base 14a is disposed within matrix 18 belowsurface 20 by less than 30% of height 22, or in the case of the example of a 2103 "GEOSET" by less than 0.061 inch (1.56 mm).Apical ridge 24 forms the most outwardly extended portion ofelement 10 andelement 10 can be set onface 20 of the matrix bit in any orientation as desired without departing from the scope of the invention. For example,apical ridge 24 may be set lying in a direction parallel to the angular advance ofelement 10 as defined by the rotation of bit 11. This is termed a radial set in the case of a triangular prismatic element. Alternatively,apical ridge 24 may be set at right angles to the direction of advance ofelement 10 as defined by the rotation of the bit. This setting is then defined as a tangential setting. In both caseslongituidnal axis 16 ofelement 10 is oriented generally parallel to surface 20 ofmatrix 18 at the point of attachment ofelement 10 thereto. - In any of these orientations, triangular
prismatic element 10 is locked withinmatrix 18 by at least twolocking points 26, only one of which is illustrated in Figure 2. Locking embedded belowsurface 20 "intomatrix material 18. In the case of triangularprismatic element 10, lockingpoint 26 is actually an entire surface. The second locking point is a like portion of the adjacent surface 14 (not shown in Figure 2) which two surfaces join to form the dihedral angle defining theapical edge 24 ofelement 10. Lockingpoint 26 is thus in the embodiment of Figure 2 an inclined surface portion belowsurface 20.Element 10 is fabricated or molded into the matrix body bit by conventional infiltration techniques. As a result,matrix material 18 forms an innerlocking abutment against the sloped surface of lockingpoint 26 thereby providing a wedged shaped lock onelement 10. In other words, the embedded portions ofsurfaces 14 are inclined away from the normal to surface 20 and are spaced apart.Matrix material 18 forms integral overlying wedges so thatelement 10 is locked intomatrix 18 with respect to all directions. That is, a force in any direction tending to removeelement 10 fromsurface 20 would be resisted by lockingpoints 26. - In the embodiment of Figure 2, it was assumed that end surfaces 12 were perpendicular surfaces to
longitudinal axis 16 and thus lockingpoints 26 were formed only on opposingsurfaces 14 belowsurface 20. However, it is entirely within the scope of the invention that end surfaces 12 may be inclined with respect to longitudinally axes 16 thereby providing two additional spaced apart locking points, which together with lockingpoints 26, would form two othogonal pairs of such locking points, or in the case of Figure 2 locking surface portions. - Turn now to Figure 3 wherein the invention is illustrated in the context of a rectangular prismatic element, generally denoted by
numeral 28. For convenience, rectangularprismatic element 28 is shown as a cubic diamond element, which may either be a natural cubic element or may be synthetically manufactured. In either case,element 28 is disposed withinmatrix material 18 belowsurface 20 in such a manner that at least twolocking points point 30 is formed at onecorner 34 ofcubic element 28 while lockingpoint 32 is formed at theadjacent corners 36, one of which is illustrated in Figure 3.Element 28 is disposed withinmatrix 18 at an angle so that its normal axis ofsymmetry 38 is inclined with respect to surface 20 at the point of attachment ofelement 28 to the matrix bit. The inclination ofaxis 38 causes at least one of the four basal corners, in thiscase corner 34, to be cocked up at an angle so as to be disposed withinmatrix 18 at lesser depth than at least one other corner ofcubic element 28. In the most general case, the inclination ofaxis 38 is such that no face ofcubic element 28 is perpendicular to surface 20. In the illustrated embodiment of Figure 3, the inclination ofaxis 38 causescorner 34 to be the highest corner followed byadjacent corners 36 and lastly, by lowest opposing'corner 40. The angular orientation ofaxis 38 thus causesedge 42, which is adjacent to corner 34, to be inclined upwardly throughsurface 20 ofmatrix material 18 at an acute angle. Thus,matrix material 18 fills aroundcorner 34 forming an overlying wedged mass which lockscorner 34 into the matrix of a bit and prevents movement ofelement 28 in a normal direction at the point of attachment. Thus, in the embodiment of Figure 3, lockingpoint 30 atcorner 34 is a surface portion in the proximity ofcorner 34 of adjacent sides 44 which join together to form thedihedral angle 46 andedge 42. In fact, lockingpoints basal edge 48 fromcorner 34 toadjacent corner 36. In other words, ifcube 28 were to be lifted in a perpendicular direction fromsurface 20,matrix material 18 in contact with lockingpoint 30 betweencorners adjacent edge 48 and the adjacent symmetrically placed edge (not shown), provide a locking surface which tends to retaincubic element 28 withinmatrix material 18. - Clearly, the embedment of
cubic element 28 withinmatrix material 18 also provides a means of resisting any forces imparted onelement 28 in a direction parallel to surface 20.Cubic element 28 is not locked intomatrix 18 only in the direction ofaxis 38. Resistance to these parallel or azimuthal forces which may be applied toelement 28 would also be provided if axis of symmetry .38 were substantially perpendicular to surface 20. However, in this last case, lockingpoint 30 would have disappeared and there would be no mechanical means, other than cohesion, micromechanical attachment or other bonding betweenelement 28 andmatrix material 18 which would retain or lockelement 28 inmatrix material 18. - Turn now to Figure 4 wherein yet another embodiment of the invention is illustrated. In the embodiment of Figure 4 a right circular cylindrical element, generally denoted by
reference numeral 50, is illustrated.Cylindrical element 50 is characterised by a longitudinal axis ofsymmetry 52.Element 50 is disposed withinmatrix 18 belowsurface 20 in such a manner thataxis 52 is inclined at an acute angle to surface 20. By virtue of the angular orientation ofcylindrical element 50, a locking point or more strictly speaking, a plurality of locking points are formed on the lower surface ofelement 50 in the proximity ofbase 56. For convenience of illustration,base 56 is shown as a flat circular base while the opposing end ofcylindrical element 50 is illustrated as being generally domed. Clearly, the shape of opposing end 58 can be arbitrarily chosen. - Because of the angular orientation of
cylindrical element 50, alocking point 54 is formed on an inclined surface portion of cylindrical element belowsurface 20 ofmatrix 18.Matrix material 18 is molded about the embedded portion ofcylindrical element 50 and thereby forms a locking wedge against the acutely inclined surface portions. Thereby, by virtue of this embedment, both azimuthal forces parallel thesurface 20 and normal forces perpendicular to surface 20, are positively resisted by a mechanical lock ofelement 50 withinmatrix material 18. - Turn now to Figure 5 wherein yet another embodiment is illustrated. Figure 5 shows a perspective view of a triangular
prismatic element 10 which was shown and described in connection with Figure 2 disposed belowsurface 20 intomatrix material 18 in such a manner thatlongitudinal axis 16 is acutely inclined with respect to the normal to surface 20 rather than being perpendicular thereto as shown in Figure 2. At least one corner 60 is thus defined as being the highest corner ofelement 10 which is embedded withinmatrix material 18. Adjacent corner 62 is disposed withinmatrix material 18 at a greater depth as determined by the size ofelement 10 and the angular orientation oflongitudinal axis 16 with respect to the surface normal. At least onelocking point 64 and, in fact, a plurality of locking points are then formed on that portion ofside 14 disposed beneathsurface 20. In the case of the embodiment of Figure 5, locking points 64 are formed on twoadjacent sides 14 which join together to form thedihedral edge 24.Matrix material 18 is molded aboutsurface 14 once again forming an overlying wedge which lockselement 10 ontosurface 20 and which resists substantially all forces which may be exerted uponelement 10 which might tend to remove it fromsurface 20. - Whereas the embodiments of Figures 1-5 were triangular, cubical or cylindrical, the embodiment of Figure 6 has bean generalized to include an arbitrary ovulate diamond element, generally denoted by
reference numeral 66. In the illustrated embodiment, ovulateelement 66 is characterised by a major longitudinal axis 68 which'defines a direction of preferential or maximum elongation. The angular orientation of major axis 68 ofrelements 66 is inclined sufficiently with respect to the normal to surface 20 such that at least two locking points, again a surface portion defining the plurality of lockingpoints 70, are defined belowsurface 20 onelement 66. The curvature ofovulate element 66 is such that it begins to fall away from the normal to surface 20 as it approachessurface 20 from beneath. In other words,matrix material 18 is molded thereover and thus again forms a wedging mechanical lock to retainelement 66 inmatrix material 18. A locking resisting force exist for all directions except one, major axis 68. - The embodiments of Figures 2-6 described above are each rgenerally characterised by a diamond element having a longitudinal axis lying along a direction of major elongation of the element or at least in a direction of equal elongation as in t?r?rhe case of
cubic element 28 in Figure 3. Turn now to Figure 7 wherein a right circular diamond disk, generally denoted byreference numeral 72 is embedded withinmatrix material 18 and exposed abovesurface 20 according to the invention. In the illustratedembodiment 72 is characterised by an axis of symmetry 74. Axis 74 is again acutely aligned with respect to the normal atsurface 20 so that oneedge 76 is well exposed abovematrix surface 20 while the diametrically opposing edge 78 is embedded withinmatrix material 18 belowsurface 20. At least two locking points, again a plurality of locking points 80, are formed at a portion of the upper surface ofdisk 72 in the proximity of edge 78 and belowsurface 20. In other words,disk 72 is embedded insurface 20 of the matrix bit at an inclined angle such that the leading edge is fully exposed while the trailing edge is fully embedded with portions of the edges ofdisk 72 betweendiametric points 76 and 78 either being exposed or embedded to lesser or greater degrees depending on their proximity to diametricallyopposed points 76 and 78 respectively. Therefore,disk 72 is securely locked withinmatrix 18 against both azimuthal forces and normal forces to surface 20. - The invention is further illustrated in the embodiment of Figure 8 wherein a right circular
cylindrical element 50 as described in connection with the embodiment of Figure 4 is disposed intomatrix 18 belowsurface 20. Again, the exposed end 58 ofcylinder 50 is shown as having a domed shape purely for convenience and not as a means of limiting the invention. The opposing end orbase 56 is disposed at least partially withinmatrix material 18 so that at least two, and actually a plurality of lockingpoints 82, are formed thereon. In other words, at least a portion ofcylinder 50 is embedded deeply enough such tht the diameter of a perpendicularly cross section toaxis 52 is belowsurface 20. Even in the case wherein a portion ofbase 56 may be exposed abovesurface 20, a plurality of locking points.82 are formed on that portion abovecenterline point 84 ofbase 56 which is disposed belowsurface 20. The surface ofcylindrical element 50 falls away at an acute angle from the normal to surface 20 ofmatrix material 18 assurface 20 is approached. Thus,matrix material 18 is molded over the locking points 82 oncylindrical surface 50 and forms a locking wedge thereby retainingelement 50 withinmatrix material 18. - The invention is illustrated still further in the embodiment of Figure 9. Turn now to Figure 9 wherein a triangular prismatic element, generally denoted by
reference numeral 86, is disposed belowsurface 20 inmatrix material 18 so that a plurality of lockingpoints 88 are formed on its surface.Element 86 is similar to that described in connection with Figures 2 and 5, with the exception thatelement 86 has been elongated along longitudinal axis 90. However, the embodiment of Figure 9 should be interpreted to includeelement 10 of Figures 2 and 5 as well. Like the cylindrical embodiment of Figure 7,triangular element 86 of Figure 8 includes at least a portion embedded belowsurface 20 ofmatrix 18. At each point on the embedded portion ofside 92, the slope ofside 92 falls away froτ the normal to surface 20 assurface 20 is approached from below. Again,matrix material 18 is molded overside 92 thereby forming a wedge-shaped lock over the embedded portion ofside 92 and thus, the plurality of locking points 88. Meanwhile, a substantial forward portion ofelement 86 is completely exposed abovesurface 20 ofmatrix 18. In fact, it is not necessary that trailing corner 94 be flush withsurface 20 as illustrated in Figure 9. Instead, trailing corner 94 may be disposed well abovesurface 20 as well, locking points 88 remain established as long as any portion ofadjacent sides 92 remain disposed belowsurface 20 intomatrix 18. - Turn now to Figure 10 wherein yet another embodiment is illustrated showing an elongated rectangular prismatic element, generally denoted by reference numeral 96. In the illustrated embodiment of Figure 9, element 96 is embedded below
surface 20 intomatrix 18 with opposingsides 98 generally parallel to the normal tosurface 20. However, oneend surface 100 is substantially or fully exposed abovesurface 20 while the opposingend surface 102, only the edge of which is shown in Figure 10, is disposed beneathsurface 20. Thus,matrix material 18 is disposed over at least a portion of one end of element 96 and forms a plurality of locking points 104. A wedged-shape extension ofmatrix 18 is integrally formed oversubmerged end 102 thus providing the mechanical locking which prevents any substantial dislodgment of element 96 fromsurface 20. Again, element 96 has been shown as having a substantially elongated longitudinal axis 106, although it must be understood that the proportions of element 96 are arbitrarily fixed and could be chosen to include the embodiment of Figure 3, which is cubic, as well. - The invention continues to be illustrated in the embodiment of Figure 11 wherein a flat triangular element, generally denoted by
reference numeral 108, is shown in perspective view disposed withinmatrix 18.Triangular element 108 is characterised by alongitudinal axis 110 in a direction iormal to parallel and opposing end faces 112. The thickness ofelement 108 or the distance between opposing end faces 112 is smaller than the distance of the sides or height oftriangular Element 108 thereby resulting in a flat plate-like triangular element. According to the invention,element 108 is substantially exposed abovesurface 20 ofmatrix 18 and locked therein by a plurality of locking points 114. Lockingpoints 114 are formed on a lower portion ofend surface 112 which is disposed belowsurface 20 by virtue of the acute angular orientation ofelement 108 and itslongitudinal axis 110 from the normal.Matrix material 18 forms an integral edge over this lower portion ofelement 108 thus defining and forming locking points 114. - Turn now to the embodiment of Figure 12 wherein a trapezoidal prismatic element, generally denoted by
reference numeral 116, is shown in perspective view as embedded belowsurface 20.Element 116 includes at least two opposingparallel surfaces 118, the upper of which is shown in the view of Figure 12. Between opposingparallel surfaces 118 are four sides forming two opposing pairs, 120 and 122, at least one of which pairs 120 has a trapezoidal shape. In the illustrated embodiment of Figure 2,side 120, is trapezoidal, whileside 122 is generally rectangular as would be produced by truncating the triangularprismatic element 10 of Figure 2 along a plane parallel to base 14a. Therefore, in the embodiment of Figure 12 a plurality of lockingpoints 124 are formed along lower edge ofsides 122 in the same manner as lockingpoints 26 are formed in the embodiment of Figure 2 with respect toelement 10. Thus,element 116 is locked within thematrix 18 in substantially the same manner. - Turn now, however, to the embodiment of the invention as illustrated in Figures 13 and 14 wherein a trapezoidal
prismatic element 126 is shown as embedded in an inclined orientation in thematrix 18 and is locked therein by having portions belowsurface 20. More particularly,element 126 is shown in the illustrated embodiment of Figures 12 and 13 as fully trapezoidal in the sense that parallelrectangular faces 128 are connected by four adjacent trapezoidal-shaped faces formed in opposing pairs, namely surfaces 130 and 132. However, it must be expressly understood that the somewhat simplertrapezoidal element 116 of Figure 12 could be employed with appropriate modifications according to the invention in a substantially similar embodiment to that shown and described in connection with Figures 13 and 14. - With continued reference to Figures 13 and 14,
element 126 is disposed within aninclined portion 134 ofmatrix material 18 which portion134'of matrix material 18 forms an inclined slope or support into whichelement 126 is embedded and locked. The embodiments of Figures 13 and 14 incorporate the concept of an inclined land on the bit face. Supported cutter or tooth structures are distinguishable and are better shown in the following incorporated applications assigned to the same assignee of the present invention: - In the illustrated embodiment, one
end surface 132 as shown in Figures 13 and 14 is fully exposed and is generally coplanar withsurface 20. In addition thereto, the upper parallelrectangular side 128 is fully exposed as well. However, each of the three remaining side surfaces 130 and the opposingend surface 132 are embedded withinmatrix 18 belowsurface 20. On each of these embedded surfaces a plurality of lockingpoints 136 are thus formed by the integral extension ofmatrix 18 overunderlying sides sides 130 and possibly along opposinglower side 132 depending upon the angular orientation ofelement 126 with respect to the local surface normal, a plurality of lockingpoints 136 are defined and established which will prevent the movement ofelement 126 not only in any azimuthal direction acrosssurface 20, but in the vertical direction as well. - The embodiments thus described in connection with Figures 1-14 have been described in each case in connection with a regular geometric shape. Clearly, the invention could be employed with many other geometric shapes other than those shown and described according to the teachings set forth. For example, in addition to regular geometric shapes, specialized or free-form shapes can also be beneficially exploited to expose a diamond cutting element above a matrix face. Turn now to Figure 15 for one such embodiment. Figure 15 illustrates a perspective view of a curvalinear, free-form synthetic diamond element generally denoted by
reference numeral 138.Element 138 in the illustrated embodiment is shown as having an elongated body characterised by a smoothapical surface 140 and arounded nose portion 142 which may be oriented in the direction of cutting as defined by rotation of the drill bit. Fromapical surface 140, the sides ofelement 138 sloped downwardly and are flared outwardly to form a generally flatbasal surface 144 and aperipheral lip 146. The surface adjoining the sides ofelement 138 withlip 146 are thus characterised by a negative curvature evidenced through segment 148.Element 138 is therefore disposed withinmatrix 18 belowsurface 20 so thatlip 146 is substantially or fully embedded therein, including at least a portion of the negatively curved surface 148.Matrix material 18 is therefore molded about and abovelip 146, which forms a pedestal embedded intomatrix 18. The remaining portion ofdiamond element 138 is fully exposed abovematrix surface 20. Therefore, along the entire periphery oflip 146, a plurality of lockingpoints 150 are defined and established which provide a means of mechanically lockingdiamond element 138 onto and belowsurface 20. Clearly, many other free-form shapes other than that one which is arbitrarily chosen here to illustrate the invention in the embodiment of Figure 15 could be devised as well without departing from the teaching of the invention. - Many modifications and alterations may be made by those having ordinary skill in the art without departing from the teachings of the invention as set forth herein. The illustrated embodiments have been chosen only as a means of example and should not be taken as limiting the scope of the invention which is defined in the following claims.
Claims (22)
whereby said diamond cutter is securely attached to said drill bit while permitting substantial unsupported exposure above said surface of said drill bit.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US59036684A | 1984-03-16 | 1984-03-16 | |
US590366 | 1984-03-16 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0154936A2 true EP0154936A2 (en) | 1985-09-18 |
EP0154936A3 EP0154936A3 (en) | 1986-06-11 |
EP0154936B1 EP0154936B1 (en) | 1990-05-09 |
Family
ID=24361960
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP85102568A Expired EP0154936B1 (en) | 1984-03-16 | 1985-03-07 | An exposed polycrystalline diamond mounted in a matrix body drill bit |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0154936B1 (en) |
JP (1) | JPS60212588A (en) |
CA (1) | CA1248939A (en) |
DE (1) | DE3577586D1 (en) |
NO (1) | NO167224C (en) |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0285678A1 (en) * | 1985-08-02 | 1988-10-12 | Eastman Teleco Company | Earth boring bit for soft to hard formations |
BE1000489A3 (en) * | 1986-03-27 | 1988-12-27 | Shell Int Research | Rotary drilling tool. |
EP0391683A1 (en) * | 1989-04-05 | 1990-10-10 | De Beers Industrial Diamond Division (Pty) Limited | Drilling |
US5135061A (en) * | 1989-08-04 | 1992-08-04 | Newton Jr Thomas A | Cutting elements for rotary drill bits |
WO1992014906A1 (en) * | 1991-02-23 | 1992-09-03 | Brit Bit Limited | Improvements relating to drill bits |
WO1999004128A3 (en) * | 1997-07-15 | 1999-04-08 | Kennametal Inc | Rotatable cutting bit assembly with cutting inserts |
US6044920A (en) * | 1997-07-15 | 2000-04-04 | Kennametal Inc. | Rotatable cutting bit assembly with cutting inserts |
US6176332B1 (en) | 1998-12-31 | 2001-01-23 | Kennametal Inc. | Rotatable cutting bit assembly with cutting inserts |
EP1388641A1 (en) * | 2002-08-08 | 2004-02-11 | HILTI Aktiengesellschaft | Hard insert with PDC layer |
US9279290B2 (en) | 2012-12-28 | 2016-03-08 | Smith International, Inc. | Manufacture of cutting elements having lobes |
US11828108B2 (en) | 2016-01-13 | 2023-11-28 | Schlumberger Technology Corporation | Angled chisel insert |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
ZA864402B (en) * | 1985-06-18 | 1987-02-25 | De Beers Ind Diamond | Abrasive tool |
US9056799B2 (en) | 2010-11-24 | 2015-06-16 | Kennametal Inc. | Matrix powder system and composite materials and articles made therefrom |
US10508503B2 (en) | 2016-09-23 | 2019-12-17 | Baker Hughes, A Ge Company, Llc | Cutting elements, earth-boring tools including the cutting elements, and methods of forming the earth-boring tools |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3709308A (en) * | 1970-12-02 | 1973-01-09 | Christensen Diamond Prod Co | Diamond drill bits |
US3885637A (en) * | 1973-01-03 | 1975-05-27 | Vladimir Ivanovich Veprintsev | Boring tools and method of manufacturing the same |
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4234048A (en) * | 1978-06-12 | 1980-11-18 | Christensen, Inc. | Drill bits embodying impregnated segments |
-
1985
- 1985-03-04 CA CA000475707A patent/CA1248939A/en not_active Expired
- 1985-03-07 EP EP85102568A patent/EP0154936B1/en not_active Expired
- 1985-03-07 DE DE8585102568T patent/DE3577586D1/en not_active Expired - Lifetime
- 1985-03-14 NO NO851019A patent/NO167224C/en unknown
- 1985-03-15 JP JP60050665A patent/JPS60212588A/en active Pending
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3709308A (en) * | 1970-12-02 | 1973-01-09 | Christensen Diamond Prod Co | Diamond drill bits |
US3885637A (en) * | 1973-01-03 | 1975-05-27 | Vladimir Ivanovich Veprintsev | Boring tools and method of manufacturing the same |
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4234048A (en) * | 1978-06-12 | 1980-11-18 | Christensen, Inc. | Drill bits embodying impregnated segments |
Non-Patent Citations (1)
Title |
---|
OIL & GAS JOURNAL, vol. 82, no. 14, 2nd April 1984, pages 133-138, Tulsa, Oklahoma, US; J. WOOD: "Thermally stable cutters extend application of synthetic diamond bits to hard formations" * |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0285678A1 (en) * | 1985-08-02 | 1988-10-12 | Eastman Teleco Company | Earth boring bit for soft to hard formations |
BE1000489A3 (en) * | 1986-03-27 | 1988-12-27 | Shell Int Research | Rotary drilling tool. |
US4926950A (en) * | 1986-03-27 | 1990-05-22 | Shell Oil Company | Method for monitoring the wear of a rotary type drill bit |
EP0391683A1 (en) * | 1989-04-05 | 1990-10-10 | De Beers Industrial Diamond Division (Pty) Limited | Drilling |
US5025871A (en) * | 1989-04-05 | 1991-06-25 | Aulette Stewart | Drilling method and rotary drill bit crown |
US5135061A (en) * | 1989-08-04 | 1992-08-04 | Newton Jr Thomas A | Cutting elements for rotary drill bits |
WO1992014906A1 (en) * | 1991-02-23 | 1992-09-03 | Brit Bit Limited | Improvements relating to drill bits |
US6044920A (en) * | 1997-07-15 | 2000-04-04 | Kennametal Inc. | Rotatable cutting bit assembly with cutting inserts |
WO1999004128A3 (en) * | 1997-07-15 | 1999-04-08 | Kennametal Inc | Rotatable cutting bit assembly with cutting inserts |
US6109377A (en) * | 1997-07-15 | 2000-08-29 | Kennametal Inc. | Rotatable cutting bit assembly with cutting inserts |
EP1170460A2 (en) * | 1997-07-15 | 2002-01-09 | Kennametal Inc. | Rotatable cutting bit with cutting inserts |
EP1170460A3 (en) * | 1997-07-15 | 2003-01-29 | Kennametal Inc. | Rotatable cutting bit with cutting inserts |
US6176332B1 (en) | 1998-12-31 | 2001-01-23 | Kennametal Inc. | Rotatable cutting bit assembly with cutting inserts |
EP1388641A1 (en) * | 2002-08-08 | 2004-02-11 | HILTI Aktiengesellschaft | Hard insert with PDC layer |
US9279290B2 (en) | 2012-12-28 | 2016-03-08 | Smith International, Inc. | Manufacture of cutting elements having lobes |
US11828108B2 (en) | 2016-01-13 | 2023-11-28 | Schlumberger Technology Corporation | Angled chisel insert |
Also Published As
Publication number | Publication date |
---|---|
NO167224C (en) | 1991-10-16 |
EP0154936B1 (en) | 1990-05-09 |
DE3577586D1 (en) | 1990-06-13 |
CA1248939A (en) | 1989-01-17 |
NO167224B (en) | 1991-07-08 |
JPS60212588A (en) | 1985-10-24 |
EP0154936A3 (en) | 1986-06-11 |
NO851019L (en) | 1985-09-17 |
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