AU2002302020B2 - Drill Bit with Large Inserts - Google Patents

Description

S&F Ref: 425820D1

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name and Address of Applicant: Actual Inventor(s): Address for Service: Invention Title: Smith International, Inc.

16740 Hardy Street Houston Texas 77032 United States of America John Adam Meyers, Carl W. Keith, Huy D. Bui Spruson Ferguson St Martins Tower,Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) Drill Bit with Large Inserts The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c Drill Bit with Large Inserts The present invention relates to an earth boring drill bit, such as a percussion bit, having inserts extending from certain portions of the bit head.

Referring initially to Figure 1, a prior art percussion drill bit l is shown having a bit head 12 that includes a bit face 14 and a multitude of inserts 20 for impacting and fracturing the earthen formation (not shown).

Inserts 20 were typically disposed on various portions of the bit face 14. For example, inserts 20 are shown disposed on the central portion 19 of the bit face 14 in the proximity of the central axis 13 of the bit 10, and other inserts 20 are disposed in numerous circumferential rows on the bit face 14, such as a first row 72, second row 74, third row 76 and gage row 78. The term "gage row" as used herein refers to the row 70 extending around, or adjacent, the periphery, or edge, 15 of the bit face 14. All of the inserts 20 on the bit face 14 of the prior art hammer bit 10 had substantially the same geometric shape and size, such inserts 20 being referred to herein as "small" inserts 22. Typically, such inserts 22 had a diameter of inches (approx. 19mm) or smaller. The bit face 14 also included one or more fluid flow openings 16 and flow channels 18 for allowing the flow of circulation fluid (not shown) from within the bit 10 to the exterior 44 of the bit Different places on the bit head may see different conditions during drilling yet the same inserts typically are used at all places of the bit head of the prior art.

It is an object of the present invention to improve the drill bits available.

According to the present invention, there is provided an earth boring drill bit, the drill bit comprising: a bit head; at least a first plurality of first inserts and a second plurality of second inserts extending from the bit head; each of the first inserts having a first base portion mounted to the bit head and a first exposed portion extending from the bit head, the first exposed portion having a first profile and a first contact area; each of the second inserts having a second base portion mounted to the bit head and a second exposed portion extending from the bit head, each of the second exposed portions having a second profile that is substantially different from the first profile of the first exposed portion and a second contact area that is greater in size than the first contact area of the first exposed portion, at least some of said second exposed portions being enhanced with a superhard material, the second profiles being substantially different from the first profiles, wherein the bit head defines a first plurality of first cavities in which the first plurality of first inserts are disposed, and a second plurality of second cavities in which the second plurality of second inserts are disposed, wherein the depth of the second cavities is greater than the depth of the first cavities such that base planes of two adjacent cavities that are selected one each from the first cavities and the second cavities do not intercept in a bit section between the two adjacent cavities.

A drill bit of an embodiment of the invention has different inserts at different places on the bit head enabling the drill bit to better match the varying conditions or applications of different places on the bit head.

[R:\LIBLL] 11961 .doc:TCW:vjp The second inserts may vary from the first inserts by radius of curvature of the exposed portions and/or by diameter of the base portion.

Embodiments of the present invention will hereinafter be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 shows a front view of a percussion drill bit of the prior art; Figure 2 is a front view of a percussion drill bit of an embodiment of the present invention; Figure 3 is a front view of another embodiment of the present invention; Figure 4 is a partial profile view of the prior art percussion drill bit of Figure 1; Figure 5 is a partial profile view of the percussion drill bit of Figure 2; Figure 6 is a partial profile view of the percussion drill bit of Figure 3; Figure 7 is a partial cross-sectional view taken through line 7-7 of Figure 1; Figure 8 is a partial cross-sectional view taken through line 8-8 of Figure 2; Figure 9 is an isolated view of an insert of the prior art drill bit of Figure 1 and the earthen formation impact crater created thereby; Figure 10 is an isolated view of an insert of the drill bit of Figure 3 and the earthen formation impact crater created thereby; Figure 11 is an isolated view of an insert of a drill bit of the prior art; Figure 12 is an isolated view of an insert of a drill bit of the present invention; Figure 13 is a cross sectional view of aportion of the insert of Figure 11 showing various layers of the enhanced surface and the edge, or joint area, formed around the periphery of..:the enhanced surface; Figure 14 is a cross sectional view of a portion of the insert of Figure 12 showing various layers of the enhanced surface and the edge, or joint area, formed around the periphery of the enhanced surface; Figure 15 is an isolated view of an insert of the drill bit of Figure 3 disposed in the earthen formation; and, Figure 16 is an isolated view of an insert of the prior art drill bit of Figure 1 disposed in the earthen formation at the same depth as the insert of Figure Embodiments of the invention are shown in the aboveidentified figures and are described below. In illustrating and describing these embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or schematic form in the interest of clarity and conciseness.

A percussion bit 11 of the present invention, as shown, for example, in Figures 2 and 3, has a bit head 12, a bit face 14 and a multitude of inserts 20. It should be understood that while the present invention is described with respect to percussion bits, which are useful with percussion drilling assemblies, such as those shown and described in US-A-5322136, US-A-4932483 and US-A-4819739, the invention is not limited to percussion bits and may be used with any other type of earth boring drill bit having cutting elements for impacting, fracturing or crushing an earthen formation. The inserts 20 of the bit 11 are shown disposed on various portions of the bit face 14. Inserts 20 are disposed on the central portion 19 of the bit face 14 in the proximity of the central axis 13 of the bit 11, and other inserts 20 are disposed on numerous circumferential rows 70, such as a first row 72, second row 74, third row 76 and gage row 78. It should be understood f that the present invention is not limited to having inserts disposed in these particular locations on the bit face 14, or in the quantities shown.

Still referring to Figures 2 and 3, the bit 11 of the present invention includes small inserts 22 and "large" inserts 32. The large inserts 32 have a larger geometric size, a larger radius of curvature 36 (Figure 10) and larger contact surface 38 (Figure 10), as compared to the geometric size, radius of curvature 26 and contact surface 28 of the small inserts 22 (Figure The "contact surface" is that portion of the insert face surface 39 (Figures 13, 14) which engages the formation 120. Generally, the larger the insert face surface 39, the larger the "contact surface" In Figure 2, for example, the inserts 20 on the gage row 78 are large inserts 32, while all other inserts shown on the bit face 14 are small inserts 22. In Figure 3, all of the inserts 20 on the bit face 14 are large inserts 32, except the inserts 20 disposed on the central portion 19 of the bit face 14 proximate to the central axis 13 and the inserts 20 on row 72, which are small inserts 22. The present invention is, however, not limited to the particular combinations of large and small inserts 32, 22 shown in Figures 2 and 3, but encompasses any configuration of inserts 20 which includes large and small inserts 32, 22 capable of providing one or more of the aspects, or benefits, of the invention described herein.

So Now referring to Figures 5 and 6, the insertsi 20 are rccr preferably embedded, or emplaced, in cavities 50 in the bit head 12. The inserts 20 may possess any among a variety of geometric shapes, such as, for example, semi-round top, chisel and conical shaped inserts, as are or become known in the art. Further, any among a variety of types of inserts 20 that are or become known in the art may be used as small and large inserts 22, 32, such as, for example, tungsten carbide inserts, tungsten carbide inserts having a super-abrasive surface, such as polycrystalline diamond or cubic boron nitride and inserts constructed of a matrix of tungsten carbide and other material. The bit 11 of the present invention, as shown, for example, in Figures 5 and 6, preferably includes small inserts 22 having a diameter of .75 inches (approx. 19mm) -7or smaller, and large inserts 32 having a diameter of over inches (approx. 19mm), such as 22 millimeters.

However, the present invention-is not limited to the use of inserts 22, 32 of those sizes, but encompasses any suitable type of inserts 22, 32, of any suitable sizes so long as the large inserts 32 are larger than the small inserts 22, and the bit 11 is capable of providing one or more of the aspects, or benefits, of the invention described herein.

A typical bottom hole pattern of the earthen formation formed by bit 11 can generally be divided into three segments which differ with respect to the loading conditions on the inserts 20 of the bit face 14. A first or inner segment represents the portion of the bottom hole pattern most radially inboard relative, or proximate, to the central axis 13 of the bit 11. This first segment corresponds with, or is engaged by, the inserts 20 disposed on the central portion 19 of the bit face 14. These inserts 20 will be referred to as "inner inserts". A third or outer segment represents the bottom hole pattern most radially outboard relative to, or farthest from, the central axis 13 of the bit 11. This third section corresponds with, or is engaged by, the inserts 20 on the gage row 78 ("outer inserts"). A second or middle segment represents the portion of the bottom hole pattern disposed between the first and third segments, and corresponds with, or is engaged by, the inserts 20 disposed -8on the bit face 14 between the gage row 78 and the central portion 19, which will be referred to as "middle inserts" It is known that when the earthen formation includes substantial amounts of rock, the compressive strength of the formation across the bottom hole pattern increases substantially from the inner segment to the outer segment due to the confining pressure and the overburden pressure. The outer segment thus generally possesses the highest compressive strength followed by the middle segment, which is followed by the inner segment which has the lowest compressive strength. This places increasing load requirements on the inner, middle and outer inserts for fracturing or crushing the formation Thus, the bit 11 requires less load directed to the 'inner inserts to fracture or crush the formation than to the middle inserts, and much less load than needs to be directed to the outer inserts, due to the gradient in compressive strength of the formation across the segments. Uniform distribution of the load across the entire bit face 14, such as with the prior art bit 10 of Figure 4, results in inefficient drilling.

In accordance with the preferred embodiment of the present invention, it has been discovered that the use of large inserts 32 on certain areas of the bit face 14, as shown, for example in Figures 2 and 3, will optimize bit performance in view of the gradient in compressive strength of the earthen formation across the bottom hole pattern In the preferred embodiment, the gage row inserts are -9large inserts 32. The large contact surfaces 38 of the large inserts 32 enables the distribution of sufficient increaSed load to the outer segment-to overcome its higher strength, thus increasing drilling efficiency. The durability and survivability of the gage row inserts is preserved, or enhanced, because of the increased physical size, or robustness, and the larger radius of curvature 36 (Figure 10) of the large inserts 32. The forces upon the large inserts 32 of bit 11 from their interaction with the earthen formation 120 will be imparted across the larger, or broader, contact surface 38 of the insert 32 as compared to the contact surface 28 of the small inserts 22 (Figure As a result, the inserts 32 will be less susceptible to damage from interaction with the formation 120 and more durable than the inserts 22.

Referring to Figure 6, large inserts 32 are shown as middle inserts on rows 74 and 76 in addition to large inserts 32 on the gage row 78. The benefits described above will apply to this configuration, but to a lesser magnitude with respect to middle inserts on rows 74 and 76 because the gradually increasing compression strength and reaction forces of middle segment are not as great as those of outer segment, causing less increased load demand. In contrast, the use of small inserts 22 as inner inserts and middle inserts on row 72 provides sufficient load and penetration to fracture or crush the corresponding formation 120 and efficiently drill the bore hole (not shown), whereas the use of large inserts (not shown) at those locations may lead to inefficient drilling.

Now referring to Figures 11 and 12, inserts 20 may be used that include an enhanced surface 100, which is-known to generally increase insert longevity and improVe bit performance. For example, tungsten carbide inserts having a PCD surface 104, such as those disclosed in US-A-4694918 and US-A-4811801 which are hereby incorporated by reference herein in their entireties, may be used. When inserts are used having an enhanced surface 100, the surface 100 is subject to similar loading conditions as discussed above.

The use of large inserts 32 having an enhanced surface 100 in accordance with the preferred embodiment provides additional benefits to those described above.

Referring to Figures 13 and 14, the enhanced surface 100 may include one, or numerous, layers 101 of enhanced material disposed upon the insert face surface 39. An edge, or joint area, 190 is formed around the periphery of the enhanced surface 100 where the surface 100 begins, or blends into the insert substrate material, such as tungsten carbide, 86. The edge, or joint area, 190, is subject to cracking, flaking and breakage when contacted with the earthen formation, which can lead to breakage and failure of the enhanced surface 100. In accordance with the preferred embodiment, the edge, or joint area, 190 of the enhanced surface 100 is protected from contact with the earthen formation 120 as the insert 32 impacts, or interacts with, the formation 120. As shown in Figures -11and 16, the distance 222 between the enhanced surface edge, or joint area, 190 of large insert 32 and the earthen formation 120 is greater than the distance 220 between the enhanced surface edge, or joint area, 190 of small insert 22 and the formation 120 at uniform depths of penetration 224, decreasing the susceptibility of the enhanced surface edge, or joint area, 190 of the larger inserts 32 to contact with the formation 120.

Referring back to Figures 11 and 12, the enhanced surface 100 of the large inserts 32 is larger and has a larger contact surface 107, as compared to the size and contact surface 109 of the enhanced surface 100 of a small insert 22. The forces on the enhanced surface 100 of the large inserts 32 of bit 11 from interaction with the earthen formation are imparted across the larger, or broader, contact surface 107. As a result, the enhanced surface 100 of inserts 32 are less susceptible to damage from interaction with the formation, and more durable than the enhanced surface 100 of inserts 22.

Still referring to Figures 11 and 12, a preferred method to increase the size of the contact surface 107 of the enhanced surface 100 of insert 32 is by increasing the radius of curvature 106 of the enhanced surface 100, which is done by increasing the radius of curvature 36 of the insert 32. An increase in the radius of curvature 106 of the enhanced surface 100, such as PCD surface 104, reduces the highly concentrated contact stresses on the enhanced surface 100 caused by interaction with the earthen -12formation. These contact stresses cause micro-chipping, spalling and fracture of the enhanced surface 100, which are major failure modes of inserts 20 having an enhanced surface 100, such as a PCD surface 104. Thus, the enhanced surface 100 of inserts 32 will have reduced susceptibility to micro-chipping, spalling, and fracturing, preserving the integrity of the enhanced surface 100 and increasing its longevity.

Now referring again to Figures 13 and 14, during the manufacturing process of an insert 20 having a PCD surface 104, residual stress is generated in the PCD surface 104 and the tungsten carbide substrate 86 because of the mismatch of their differing thermal expansion coefficients.

Such residual stress weakens the enhanced surface 104 and the tungsten carbide substrate 86 and increases the insert's 20 susceptibility to breakage and failure. The magnitude of this residual stress, however, is proportional to the ratio of the thickness 210 of the PCD surface 104 to the radius 200 (Figure 14) of the substrate 86. In accordance with the preferred embodiment, the large insert 32 with a PCD surface 104 having a thickness 210 is designed with a larger substrate radius 200, as compared to the substrate radius 201 of a small insert 22 having a PCD surface 104 with a similar thickness 210, reducing the amount of residual stress.

Referring to Figures 11 and 12, another potential benefit of the preferred embodiment is reducing insert failure due to irregular side impact loading on the inserts -13- Such loading can cause shear failure in the carbide substrate 86, which is known to be weaker under shear than under compression stresses. A large diameter insert 32 will better withstand irregular side impact loading, thus reducing shear stress on the insert 20. Large inserts 32 are also better able to withstand impact loading from lateral movement, or vibration of the bit 11, as compared to small inserts 22.

Figures 9 and 10 illustrate the general impact patterns in the earthen formation 120 caused by a prior art bit 10 and a bit 11 of the preferred embodiment respectively. As shown in Figure 9, insert 22 of the prior art bit 10 has a radius of curvature 26 and contact surface 28 that generally create an impact crater 116 in the earthen formation 120 upon contact. As the impact crater 116 is formed by the insert 22, a pronounced ledge is generally created around the crater 116, serving as a barrier for the insert 22 to overcome as it rotates or indexes in the bore hole (not shown). The frictional engagement of the insert 22 and the ledge imparts forces on the insert 22, which causes higher torque on the bit increasing the bit's energy requirements and wear to the insert 22, while decreasing the bit's rate of penetration, or drilling. For percussion bits 10 used with certain types of percussion assemblies (not shown), such as, for example, those shown and described in US-A-5322136, excessive torque on the inserts 22, or bit 10, can cause the percussion assembly to stall, or become inoperable.

M

-14- Now referring to Figure 10, the contact surface 38 of the large inserts 32 of bit 11 is more gradually sloping as compared to the contact surface 28 of the small inserts 22 (Figure The large inserts 32 generally penetrate the earthen formation 120 less axially, or shallower,, in the formation 120, as compared to the small inserts 22 (Figure A shallow crater 116 with gradually sloping walls and a small, or no, ledge is created. As a result, the insert 32 advances across the formation 120 with less resistance and reduced torque on the bit 11.

The large inserts 32 of the bit 11 may be formed with a length 34 that is greater than the length 24 of the small inserts 22, as shown, for example, in Figures 7 and 8. In turn, the inserts 32 can be configured such that the (longer) large inserts 32 extend farther away from the face 14 of the bit 11 than the small inserts 22. For example, large inserts 32 can be embedded in the head 12 of bit 11 at a depth 57 that allows the inserts 32 to extend farther from the bit face 14 than small inserts 22 embedded at a depth 56 in the head 12 of bit 10 or 11. As a result, the bit face 14 of bit 11 has a larger bit standoff 33 from formation (not shown), as compared to the standoff 23 of the prior art bit 10. The larger bit standoff 33 provides more open space volume 42 between inserts 20, and between the bit face 14 and the earthen formation (not shown) during drilling operations. This increased open space volume 42 allows an increased flow of circulating fluid across the bit face 14, enhancing the fluid's ability to clean the bit face 14, move cuttings up the bore hole (not shown) and cool the inserts 20, improving operational efficiency and bit longevity. Further, the increased flow of circulating fluid will reduce the velocity of the fluid across the face 14 of the bit 11 and around the inserts reducing erosion to the bit face 14, bit head 12 and inserts 20, thus improving bit longevity.

It is generally known in the art that the bit head of a drill bit, such as a percussion bit, is subject to internal cracking from structural fatigue during normal operations. Referring again to Figures 7 and 8, when inserts 20 are disposed in the bit head 12 in cavities the bit head 12 is susceptible to the formation of internal fatigue cracks (not shown) proximate to the cavities 50. In particular, it has been discovered that fatigue cracks tend to form in the bit headl2 at cavity base corners 58.

Fatigue cracks also form at cavity side corners 60, which are located adjacent to a side corner, or change in shape, of the corresponding insert 20, such as where the taper begins on an embedded tapered insert. The corners 58, are highly susceptible locations for the formation, or initiation, of fatigue cracks. After such fatigue cracks form, they tend to migrate, or increase in size, along a path of least resistance through the bit head 12 during the continued use of the bit.

Still referring to Figures 7 and 8, catastrophic internal fatigue cracking can occur when inserts 20 are disposed in adjacent cavities at substantially uniform -16depths 56 in adjacent cavities 50, such as shown in the prior art bit 10 of Figure 7. The term "catastrophic internal fatigue cracking" as used herein refers to breakage, or significant fracture, of the bit head 12, or loosening, or loss, of inserts 20, which can lead to premature bit failure. The term "adjacent cavities" refers to two or more cavities 50, whereby one cavity 50 is outward of and proximate to another cavity 50. The term "outward" as used herein means away from the central axis 13 of the bit 10 (Figures 1, 5) on the bit head 12, or face 14. As shown in Figure 7, the adjacent cavities 50 of the prior art bit 10 are separated from one another by a short distance 64, or small section 65, of the bit head 12.

Further, the adjacent corners 58 of cavities 50 have base planes 62 that intersect between the cavities 50 in bit section 65. As a result, fatigue cracks initiating at adjacent corners 58 have a close path of least resistance extending between adjacent cavities 50 and are susceptible to joinder with one another or with the adjacent cavity which can lead to catastrophic internal fatigue cracking.

The same problems exist for fatigue cracks initiating at adjacent side corners 60 of adjacent cavities 50 in prior art bit It has been discovered that the use of small and large inserts 22, 32, disposed in adjacent cavities 50 of bit 11i, as shown, for example, in Figure 8, will reduce the bit's susceptibility to, or will delay, catastrophic internal fatigue cracking as described above. The base planes 62 of -17adjacent cavities 50 carrying large and small inserts 32, 22 of the example shown do not intersect in the bit section between the cavities 50. Further, the adjacent base corners 58 of adjacent cavities 50 are separated by a distance 66 that is greater than the distance 64 of the adjacent base corners 58 of adjacent cavities 50 of the typical prior art bit 10 (Figure As a result, a close path of least resistance for cracks forming at corners 58 in bit 11, as in the prior art bit 10 (Figure is not created. Thus, the possibility of joinder of fatigue cracks forming at adjacent corners 58 and the likelihood of catastrophic internal fatigue cracking thereabouts is reduced, increasing bit integrity and longevity. The same effect will occur with respect to cracks forming at adjacent side corners 60 of adjacent cavities 50 of bit 11.

Whilst this applies to adjacent insert cavities 50 that carry large and small inserts 32, 22 anywhere on the bit 11, it is particularly significant with respect to adjacent cavities 50 located on the gage and third rows 78, 76 because the inserts 20, bit head 12 and cavities 50 at the gage row 78 are subject to heightened stress and fatigue and are thus more susceptible to fatigue cracking than other areas of the bit 11.

It will be appreciated that variations in and modifications to the embodiments illustrated and described may be made within the scope of the invention as defined by the appended claims.

Claims (10)

1. An earth boring drill bit, the drill bit comprising: a bit head; at least a first plurality of first inserts and a second plurality of second inserts extending from the bit head; each of the first inserts having a first base portion mounted to the bit head and a first exposed portion extending from the bit head, the first exposed portion having a first profile and a first contact area; each of the second inserts having a second base portion mounted to the bit head and a second exposed portion extending from the bit head, each of the second exposed portions having a second profile that is substantially different from the first profile of the first exposed portion and a second contact area that is greater in size than the first contact area of the first exposed portion, at least some of said second exposed portions being enhanced with a superhard material, the second profiles being substantially different from the first profiles, wherein the bit head defines a first plurality of first cavities in which the first plurality of first inserts are disposed, and a second plurality of second cavities in which the second plurality of second inserts are disposed, wherein the depth of the second cavities is greater than the depth of the first cavities such that base planes of two adjacent cavities that are selected one each from the first cavities and the second cavities do not intercept in a bit section between the two adjacent cavities.

2. The drill bit of claim 1 wherein the first exposed portions are generally hemispherical and the second exposed portions are generally hemispherical and the radius of curvature of the second exposed portions is larger than the radius of curvature of the first exposed portions.

3. The drill bit of claim 1 or 2 wherein the first base portions and the second base portions are generally cylindrical and the diameter of the second base portions is larger than the diameter of the first base portions by at least 3mm.

4. The drill bit of claim 3 wherein the diameter of the first base portions is about 19mm.

The drill bit of any one of claims 1 to 4 wherein the standoff of the second inserts is larger than the standoff of the first inserts. [R:\LIBLL] 11961 .doc:TCW:vjp

6. The drill bit of any one of claims 1 to 5 wherein the second exposed portions are enhanced by having a layer of the superhard material over at least a portion thereof.

7. The drill bit of any one of claims 1 to 6 wherein the superhard material is comprised of polycrystalline diamond.

8. The drill bit of any one of claims 1 to 7 wherein the bit head has a periphery with a gage row having at least some of the second inserts located therein.

9. The drill bit of any one of claims 1 to 8 wherein: at least some of the first and second exposed portions are enhanced with a superhard material having a thickness; and the ratio of the thickness to the radius of curvature of the second exposed portions is less than the ratio of the thickness to the radius of curvature of the first exposed portions.

10. An earth boring drill bit substantially as hereinbefore described with reference to Figs. 2, 5, 8, 12 and 14 or Figs. 3, 6, 10, 12, 14 and 15 of the accompanying drawings. Dated 26 July, 2005 Smith International, Inc. Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON [R:\LIBLL] 11961 .doc:TCW:vjp