EP0156264A2 - Multi-component cutting element using triangular, rectangular and higher order polyhedral-shaped polycrystalline diamond disks - Google Patents
Multi-component cutting element using triangular, rectangular and higher order polyhedral-shaped polycrystalline diamond disks Download PDFInfo
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- EP0156264A2 EP0156264A2 EP85103002A EP85103002A EP0156264A2 EP 0156264 A2 EP0156264 A2 EP 0156264A2 EP 85103002 A EP85103002 A EP 85103002A EP 85103002 A EP85103002 A EP 85103002A EP 0156264 A2 EP0156264 A2 EP 0156264A2
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- European Patent Office
- Prior art keywords
- diamond
- cutting
- elements
- cutter
- pcd
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- 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
- E21B10/5676—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts having a cutting face with different segments, e.g. mosaic-type inserts
Definitions
- the present invention relates to the field of earth boring tools and in particular relates to diamond cutters used on rotating bits.
- Rotating diamond drill bits were initially manufactured with natural diamonds of industrial quality.
- the diamonds were square, round or of irregular shape and fully embedded in a metallic bit body, which was generally fabricated by powder metallurgical techniques.
- the natural diamonds were of a small size ranging from various grades of grit to larger sizes where natural diamonds of 5 or 6 stones per carat were fully embedded in the metal matrix. Because of the small size of the natural diamonds, it was necessary to fully embed the diamonds within the matrix in order to retain them on the bit face under the tremendous pressures and forces to which a drill bit is subjected during rock drilling.
- PCD polycrystalline diamond
- prior art diamond synthesizers have developed a polycrystalline sintered diamond element from which the metallic interstitial components, typically cobalt, carbide and the like, have been leached or otherwise removed.
- leached polycrystalline synthetic diamond is manufactured by the General Electric Company under the trademark GEOSET, for example 2102 GEOSETS, which are formed in the shape of an equilateral prismatic triangle 4 mn, on a side and 2.6 mm deep (3 per carat), and as a 2103 GEOSET shaped in the form of an equilateral triangular prismatic element 6 mm on a side and 3.7 mm deep (1 per carat).
- the diamond compact slug cutters STRATAPAX
- the diamond compact slug cutters STRATAPAX
- the leached triangular prismatic diamonds GEOSETS
- the cutting rate of a diamond rotating bit is substantially improved by the size of the exposed diamond element available for useful cutting. Therefore, according to the prior art, the increased temperature stability of leached diamond products has been achieved only at the sacrifice of the size of the diamond elements and therefore the amount of diamond available in a bit design for useful cutting action.
- PCD cutter which is characterised by the temperature stability and characteristics of leached diamond products, and yet has the size available for useful cutting action which is characterised by the larger unleached diamond products.
- the invention is a diamond cutter for use in a drill bit.
- the diamond cutter comprises a plurality of thermally stable, prefabricated, synthetic polycrystalline diamond (P CD ) elements.
- a cutting slug is provided and is characterized by a cutting face.
- the cutting slug is comprised of a metallic matrix material.
- the PCD elements are disposed in the cutting slug and retained therein by the matrix material.
- the matrix material also incorporates a dispersion of diamond grit, at least in that portion of the matrix material adjacent to the cutting face of the cutting slug.
- the invention is a diamond cutter for use in a rotating drill bit comprising a plurality of leached PCI triangular prismatic and prefabricated elements.
- a cutting slug is provided and is comprised of a metallic matrix material anc characterized by a cutting face.
- the plurality of PCD elements are disposed in an array within the cutting slug. Each one o: the PCD elements has at least one surface which is fully exposes on the cutting face of the cutting slug.
- the matrix materia also incorporates diamond grit in at least that portion of th cutting slug adjacent to the cutting face, and preferabl uniformally throughout the volume of the matrix material.
- a cutting slug i provided which has a geometry similar to that now only obtained by unleached PCD product but is characterised by the physical temperature and wear properties of leached PCD product.
- the invention is an enlarged diamond cutter in a rotating bit comprised of a plurality of synthetic polycrystalline diamond elements.
- the diamond elements are bonded or embedded in a cutting slug formed of matrix material.
- the matrix material further incorporates diamond grit so that the arrayed PCD elements, each of which have exposed surfaces on the cutting face of the cutting slug, together with the diamond impregnated matrix material therebetween simulates an integral enlarged diamond table.
- the composite diamond table made from these components in turn is characterised by the physical, temperature and wear characteristics of the smaller components which may be chosen from leached diamond product. Therefore, diamond cutters having the geometric size and design configuration of the traditionally larger unleached diamond compacts can be fabricated using a multiple component array of leached diamond elements according to the invention.
- the invention is better understood by first considering the embodiment in Figure 1.
- Diamond cutter 10 is diagrammatically depicted in perspective view as forming the diamond table for an infiltrated integral matrix tooth, also generally denoted by reference numeral 12.
- Diamond cutter 10 is comprised of a plurality of synthetic PCD elements 14.
- diamond elements 14 are triangular prismatic elements such as are sold by General Electric Company under the trademarks 2102 GEOSET and 2103 GEOSET. This material is leached diamond material which exerts greater temperature stability and improved wear characteristics than unleached diamond material, such as sold by General Electric Company under the trademark STRATAPAX.
- Diamond elements 14 are arranged and grouped in an array which collectively comprises diamond cutter 10.
- diamond elements 14 are equilateral triangular prismatic elements
- four such elements can be arranged to collectively form a larger equilaterial triangular prismatic shape.
- 2103 GEOSETs are used as diamond elements 14
- four such elements can be combined to form an equilateral prismatic triangular shape having a side of 12 mm, and not 6 mm as in the case of a 2103 GEOSET.
- the number of PCD elements 14 can be increased to construct even larger triangular arrays than that depicted in Figure 1.
- the triangular array formed by diamond cutter 10 contemplates a compact array of diamond elements 14 wherein each diamond element is in contact with, or in the immediate proximity of, at least one adjacent diamond element 14.
- each diamond element 14 in the array is bonded to an adjacent diamond by a thin layer of matrix material generally constituted of tungsten carbide and such other elements and compounds as are well known in the art in powder metullurgy for inclusion in such metallic matrices.
- Matrix material layer 16 is shown in Figure 1 simply as a dimensionless line. It is entirely within the scope of the invention that diamond elements 14 may also be arranged in a spaced-apart relationship with the interstitial spaces completely filled with matrix material 16.
- PCD elements in the invention in a compact array may actually touch each other or may be separated by a thin layer of matrix material which tends to bond the adjacent elements together.
- either situation or its equivalent shall be defined as an "immediately proximate* configuration.
- matrix material 16 as shown in Figure 1 includes diamond grit dispersed at least in that portion of matrix material 16 in the proximity of the cutting face of diamond cutter 10.
- the mesh or grit size of the natural or synthetic diamond incorporated then matrix material 16 may be of any magnitude or range according to the granularity and wear resistance properties ultimately desired as dictated by well known principles. Generally, a grit diameter in the range of 0.01 inch (0.254mm) to 0.05 inch (1.27mm) suffices. Generally, a diamond grit concentration uniformly dispersed Throught matrix material 16 of 50% to 100% by volume is utilized.
- a diamond cutter generally denoted by reference numeral 18 is shown as a part of an integral matrix tooth in a matrix body bit.
- Diamond cutter 18 is comprised of a plurality of triangular prismatic diamond elements 14 disposed within a cutting slug 20.
- Cutting slug 20 may have a variety of geometric shapes such as semicircular as shown in Figure 2.
- Diamond elements 14 in the illustrated embodiment of Figure are set within cutting slug 20 in a spaced-apart relationship wherein matrix material 16 is disposed between adjacent diamond elements 14.
- Diamond elements 14 and matrix material 16 are identical to the like numbered elements described above in connection with the embodiment of Figure 1.
- the first and second embodiments of Figures 1 and 2 respectively are-formed as part of a infiltrated matrix body bit, only the tooth of which is diagrammatically shown in the figures.
- Cutting slugs 10 and 20 can be formed by conventional hot press techniques or by infiltration techniques separately from the matrix body bit or may be formed simultaneously through infiltration techniques with the bit body.
- Triangular prefabricated synthetic diamonds 14 are placed within an appropriately shaped mold in the desired array. Thereafter, a mixture of metallic powder containing the dispersed diamond grit is tamped into the mold and distributed between diamond elements 14.
- a substantially greater thickness of diamond bearing metallic powder is placed in the mold than the thickness of PCDs 14.
- This differential thickness is to compensate for the greater compressibility of the powder as compare6 to the relatively noncompressible diamonds 14.
- the mold is closed by one or more anvils, typically made with the same material as the mold, such as carbon.
- the filled mold and anvils are then placed within a conventional hot press which typically heats the mold and its contents by an induction heater. Pressure and temperature is then applied to the filled mold, causing the diamond impregnated metallic powder to amalgamate and sinter, ultimately compressing to the shape of cutting slug 10 or 20, as defined by the mold.
- a pressure of 200 psi and a temperature of 1900°F held for 3 minutes is generally suitable for producing the desired cutting slug.
- the pressures and temperatures employed are well outside the diamond synthesis or diamond-to-graphite conversion phase regions so that substantially no diamond is created or destroyed in the process.
- An infiltration technique may also be employed to either separately manufacture cutting-slugs 10 and 20 or to manufacture cutting slugs 10 and 20 integrally with the matrix tooth.
- an appropriately shaped carbon mold is fabricated and diamonds 14 set therein in the desired array.
- diamond impregnated metallic matrix powder is filled within the mold and mold then furnaced. The powder is allowed to sinter and infiltrate between diamonds 14 to form the finished cutting sluc.
- the preformed cutting slug may then be placed within a carbon mold for a matrix bit and fabricated into the bit in a conventional manner.
- diamond elements 14 may be individually glued into a mold for a matrix body bit in the desired array and position.
- the matrix body bit is filled first with a layer of diamond impregnated metallic powder and then is continued to be filled with various grades of metallic powder according to conventional matrix bit fabrication techniques.
- the entire mold is then furnaced so that the cutting slug is simultaneously and integrally formed with the body of the matrix bit.
- cutting slug 22 is comprised of an array of a plurality of prefabricated, synthetic PCDs 14a and 14b. Again, these diamonds are generally triangular prismatic elements such as 2103 and 2102 GEOSETS and are disposed in a diamond impregnated metallic matrix 16.
- the array of diamonds shown in the embodiment of Figure 3 is comprised of a first grouping of diamonds 14a and a second grouping 14b.
- grouping 14a are a plurality of diamonds in spaced apart relationship to form staggered rows of exposed triangular faces in an alternating inverted pattern.
- Group 14b of diamonds are placed along the circumference of circular cutting slug 22 so that their apical points 26 are directed in a generally radially 5outward direction. As cutting slug 22 wears, the apical points will begin to be exposed and provide for an aggressive cuttinc action along the edge of cutting slug 22.
- Diamonds in grouping 14a simulate a planar diamond table adapted for cutting salt rock.
- the two groupings 14a and 14b of diamonds in the embodiment of Figure 3 are only shown hypothetically to illustrate that different arrays which can be employed, and to demonstrate that diamond groupings on a single cutting slug 22 may be varied at different regions within the cutting slug in order to provide edges or faces characterised by a different diamond profile and cutting behavior.
- Cutting slug 22 is bonded by soldering, brazing and other means as diagrammatically indicated by braze layer 28, shown in greatly exaggerated view in Figure 3. Stud 24 is then press fit, soldered or otherwise fitted into a bit body, typically a steel bit body as is well known to the art. Many such studs are known and could be advantageously combined with the cutting slugs of the present invention.
- FIG. 4 a fourth embodiment of the invention is illustrated, again shown as a cutting tooth of a matrix bit body.
- the cutting slug generally denoted by reference numerals 30, is rectangular or square in gross geometric outline and is comprised of an array of prefabricated PCDs 14 which are again generally triangular and prismatic in shape.
- Diamonds 14 are mounted within cutting slug 30 in a spaced apart relationship so that the interstitial spaces between diamonds 14 are again filled with diamond impregnated matrix material 16.
- Those diamonds 14 along the periphery of cutting slug 30 are oriented to have one side face 32 exposed and art coplanar with the flat sides of rectangular cutting slug 30.
- the end faces 34 of diamonds 14 are similarly exposed on the cutting face 36 of cutting slug 30.
- a rectangular cutting slug 30 such as shown in Figure 4 could be well adapted to a step bit where it could be bonded, soldered or brazed to the corners of the rectangular steps of the bit.
- a cutting slug is comprised of a plurality of compactly arrayed diamonds 14. More particularly, diamonds 14 are bonded together in groups of six to form a regular hexagonal slug 40. Individual diamond elements 14 are bonded together by a thin matrix layer 16 between each adjacent diamond element 14.
- cutting slug 40 is fabricated by a conventional hot press or infiltration technique. The completed cutting slug 40 is similarly bonded to a stud 42 by soldering, brazing or other means as diagrammatically depicted by brazing layer 44.
- the equilateral triangular prismatic diamond elements 14 of the embodiment of Figure 5 can be generalized to form larger structures as shown in plan view in Figure 6.
- a number of hexagonal arrays, each generally denoted by reference numeral 48, :an be combined to form a larger cutting slug 46.
- Each hexagonal subarray 48 which forms part of larger array 46 is bonded together by diamond impregnated matrix material 16 as previously described.
- FIG. 7 Heretofore, the cutting slugs in each embodiment have been described as being built up of triangular prismatic prefabricated synthetic PCDs.
- the embodiment of Figure 7 generalizes the teachings of the prior embodiments by incorporating prefabricated rectangular prismatic PC D or cubic diamond elements 50. Cubic diamond elements 50 are then combined and bonded together by thin layers of diamond impregnated metallic matrix 16 as before to form a larger cutting slug, generally denoted by reference numeral 52.
- matrix material 16 may also frame or provide an outer encapsulating rectangular enclosure for the array of diamonds 50 for additional security.
- the rectangular or square cutting slug 52 of the embodiment of Figure 7 can then be bonded to a stud cutter or integrally formed within a matrix body bit.
- FIG. 8 wherein a higher order, regular polyhedral shaped diamond element 54 is combined with other like-shaped diamond elements of the same or different orders of polyhedral shapes in a compact or spaced-apart array to form an enlarged cutting slug, generally denoted by reference numeral 56.
- pentagonal elements 54 are employed in an array wherein some of the elements 54 may contact each other while others remain in spaced-apart relationship.
- elements 54 are bound to each other and in cutting slug 56 by amalgamation in a diamond impregnated matrix material 16 formed by hot pressing or infiltration.
Abstract
Description
- The present invention relates to the field of earth boring tools and in particular relates to diamond cutters used on rotating bits.
- Rotating diamond drill bits were initially manufactured with natural diamonds of industrial quality. The diamonds were square, round or of irregular shape and fully embedded in a metallic bit body, which was generally fabricated by powder metallurgical techniques. Typically, the natural diamonds were of a small size ranging from various grades of grit to larger sizes where natural diamonds of 5 or 6 stones per carat were fully embedded in the metal matrix. Because of the small size of the natural diamonds, it was necessary to fully embed the diamonds within the matrix in order to retain them on the bit face under the tremendous pressures and forces to which a drill bit is subjected during rock drilling.
- Later, the commercial production of synthetically produced diamond grit and polycrystalline stones became a reality. For example, synthetic diamond was sintered into larger 3isk shapes and were formed as metal compacts, typically forming an amalgam of polycrystalline sintered diamond and cobalt carbide. Such diamond tables are commercially manufactured by General Electric Company. under the trademark STRATAPAX. The diamond tables are bonded, usually within a diamond press to a cobalt carbide slug and sold as an integral slug cutter. The slug cutters are then attached by the drill bit manufacturers to a tungsten carbide slug which is fixed within a drill bit body according to the design of the bit manufacturer.
- However, such prior art polycrystalline diamond (PCD) compact cutting slugs are characterised by a low temperature stability. Therefore, their direct incorporation into an infiltrated matrix bit body is not practical or possible at this time.
- In an attempt to manufacture diamond cutting elements of improved hardness, abrasion resistance and temperature stability, prior art diamond synthesizers have developed a polycrystalline sintered diamond element from which the metallic interstitial components, typically cobalt, carbide and the like, have been leached or otherwise removed. Such leached polycrystalline synthetic diamond is manufactured by the General Electric Company under the trademark GEOSET, for example 2102 GEOSETS, which are formed in the shape of an equilateral prismatic triangle 4 mn, on a side and 2.6 mm deep (3 per carat), and as a 2103 GEOSET shaped in the form of an equilateral triangular prismatic element 6 mm on a side and 3.7 mm deep (1 per carat). However, due to present fabrication techniques, in order to leach the synthetic sintered PCD and achieve the improved temperature stability, it is necessary that these diamond elements be limited in size. Therefore, whereas the diamond compact slug cutters, STRATAPAX, may be formed in the shape of circular disks of 3/8" (9.5 mm) to 1/2" (12.7 mm) in diameter, the leached triangular prismatic diamonds, GEOSETS, have maximum dimensions of 4 mm to 6 mm. It is well established that the cutting rate of a diamond rotating bit is substantially improved by the size of the exposed diamond element available for useful cutting. Therefore, according to the prior art, the increased temperature stability of leached diamond products has been achieved only at the sacrifice of the size of the diamond elements and therefore the amount of diamond available in a bit design for useful cutting action.
- What is needed then is a PCD cutter which is characterised by the temperature stability and characteristics of leached diamond products, and yet has the size available for useful cutting action which is characterised by the larger unleached diamond products.
- The invention is a diamond cutter for use in a drill bit. The diamond cutter comprises a plurality of thermally stable, prefabricated, synthetic polycrystalline diamond (PCD) elements. A cutting slug is provided and is characterized by a cutting face. The cutting slug is comprised of a metallic matrix material. The PCD elements are disposed in the cutting slug and retained therein by the matrix material. The matrix material also incorporates a dispersion of diamond grit, at least in that portion of the matrix material adjacent to the cutting face of the cutting slug. By reason of this combination of elements, an enlarged diamond cutter is provided for mounting in the drill bit.
- More particularly, the invention is a diamond cutter for use in a rotating drill bit comprising a plurality of leached PCI triangular prismatic and prefabricated elements. A cutting slug is provided and is comprised of a metallic matrix material anc characterized by a cutting face. The plurality of PCD elements are disposed in an array within the cutting slug. Each one o: the PCD elements has at least one surface which is fully exposes on the cutting face of the cutting slug. The matrix materia also incorporates diamond grit in at least that portion of th cutting slug adjacent to the cutting face, and preferabl uniformally throughout the volume of the matrix material. B reason of this combination of elements, a cutting slug i provided which has a geometry similar to that now only obtained by unleached PCD product but is characterised by the physical temperature and wear properties of leached PCD product.
- These and other embodiments of the invention can best be understood by considering the following figures wherein like elements are referenced by like numerals.
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- Figure I is a diagrammatic perspective view of a first embodiment incorporating a triangular PCD element.
- Figure 2 is a diagrammatic perspective view of a second embodiment of the invention incorporating a triangular diamond element.
- Figure 3 is a diagrammatic perspective view of a third embodiment of the invention incorporating a triangular diamond element.
- Figure 4 is a perspective view of a fourth embodiment of the invention incorporating a triangular diamond element.
- Figure 5 is a perspective view of a fifth embodiment of the invention incorporating a triangular diamond element.
- Figure 6 is a plan view of a sixth embodiment of the invention incorporating a triangular diamond element.
- Figure 7 is a perspective view of a seventh embodimen of the invention incorporating a rectangular diamond element.
- Figure 8 is a diagrammatic perspective view of th eighth embodiment of the invention incorporating a higher orde polyhedral shaped diamond element.
- The invention and its various embodiments are better understood by considering the above Figures in light of the following detailed description.
- The invention is an enlarged diamond cutter in a rotating bit comprised of a plurality of synthetic polycrystalline diamond elements. The diamond elements are bonded or embedded in a cutting slug formed of matrix material. The matrix material further incorporates diamond grit so that the arrayed PCD elements, each of which have exposed surfaces on the cutting face of the cutting slug, together with the diamond impregnated matrix material therebetween simulates an integral enlarged diamond table. However, the composite diamond table made from these components in turn is characterised by the physical, temperature and wear characteristics of the smaller components which may be chosen from leached diamond product. Therefore, diamond cutters having the geometric size and design configuration of the traditionally larger unleached diamond compacts can be fabricated using a multiple component array of leached diamond elements according to the invention. The invention is better understood by first considering the embodiment in Figure 1.
- Turn now to Figure 1 wherein a diamond cutter, generally denoted by
reference numeral 10, is diagrammatically depicted in perspective view as forming the diamond table for an infiltrated integral matrix tooth, also generally denoted byreference numeral 12.Diamond cutter 10 is comprised of a plurality ofsynthetic PCD elements 14. In the illustrated embodiment,diamond elements 14 are triangular prismatic elements such as are sold by General Electric Company under the trademarks 2102 GEOSET and 2103 GEOSET. This material is leached diamond material which exerts greater temperature stability and improved wear characteristics than unleached diamond material, such as sold by General Electric Company under the trademark STRATAPAX. -
Diamond elements 14 are arranged and grouped in an array which collectively comprisesdiamond cutter 10. In the case of Figure 1, whereindiamond elements 14 are equilateral triangular prismatic elements, four such elements can be arranged to collectively form a larger equilaterial triangular prismatic shape. For example, in the case where 2103 GEOSETs are used asdiamond elements 14, four such elements can be combined to form an equilateral prismatic triangular shape having a side of 12 mm, and not 6 mm as in the case of a 2103 GEOSET. Clearly, the number ofPCD elements 14 can be increased to construct even larger triangular arrays than that depicted in Figure 1. - The triangular array formed by
diamond cutter 10 contemplates a compact array ofdiamond elements 14 wherein each diamond element is in contact with, or in the immediate proximity of, at least oneadjacent diamond element 14. In the illustrated embodiment, eachdiamond element 14 in the array is bonded to an adjacent diamond by a thin layer of matrix material generally constituted of tungsten carbide and such other elements and compounds as are well known in the art in powder metullurgy for inclusion in such metallic matrices.Matrix material layer 16 is shown in Figure 1 simply as a dimensionless line. It is entirely within the scope of the invention thatdiamond elements 14 may also be arranged in a spaced-apart relationship with the interstitial spaces completely filled withmatrix material 16. PCD elements in the invention in a compact array may actually touch each other or may be separated by a thin layer of matrix material which tends to bond the adjacent elements together. For the purposes of this specification, either situation or its equivalent shall be defined as an "immediately proximate* configuration. - Again, according to the invention,
matrix material 16 as shown in Figure 1, for example, includes diamond grit dispersed at least in that portion ofmatrix material 16 in the proximity of the cutting face ofdiamond cutter 10. The mesh or grit size of the natural or synthetic diamond incorporated thenmatrix material 16 may be of any magnitude or range according to the granularity and wear resistance properties ultimately desired as dictated by well known principles. Generally, a grit diameter in the range of 0.01 inch (0.254mm) to 0.05 inch (1.27mm) suffices. Generally, a diamond grit concentration uniformly dispersedThrought matrix material 16 of 50% to 100% by volume is utilized. - Turn now to Figure 2, wherein the second embodiment is illustrated in perspective view. Again, a diamond cutter generally denoted by
reference numeral 18 is shown as a part of an integral matrix tooth in a matrix body bit.Diamond cutter 18 is comprised of a plurality of triangularprismatic diamond elements 14 disposed within a cuttingslug 20. Cuttingslug 20 may have a variety of geometric shapes such as semicircular as shown in Figure 2.Diamond elements 14 in the illustrated embodiment of Figure are set within cuttingslug 20 in a spaced-apart relationship whereinmatrix material 16 is disposed betweenadjacent diamond elements 14.Diamond elements 14 andmatrix material 16 are identical to the like numbered elements described above in connection with the embodiment of Figure 1. - The first and second embodiments of Figures 1 and 2 respectively are-formed as part of a infiltrated matrix body bit, only the tooth of which is diagrammatically shown in the figures. Cutting
slugs synthetic diamonds 14 are placed within an appropriately shaped mold in the desired array. Thereafter, a mixture of metallic powder containing the dispersed diamond grit is tamped into the mold and distributed betweendiamond elements 14. Typically, a substantially greater thickness of diamond bearing metallic powder is placed in the mold than the thickness ofPCDs 14. This differential thickness is to compensate for the greater compressibility of the powder as compare6 to the relativelynoncompressible diamonds 14. Thereafter, the mold is closed by one or more anvils, typically made with the same material as the mold, such as carbon. The filled mold and anvils are then placed within a conventional hot press which typically heats the mold and its contents by an induction heater. Pressure and temperature is then applied to the filled mold, causing the diamond impregnated metallic powder to amalgamate and sinter, ultimately compressing to the shape of cuttingslug - An infiltration technique may also be employed to either separately manufacture cutting-
slugs slugs diamonds 14 set therein in the desired array. Once again, diamond impregnated metallic matrix powder is filled within the mold and mold then furnaced. The powder is allowed to sinter and infiltrate betweendiamonds 14 to form the finished cutting sluc. Thereafter, the preformed cutting slug may then be placed within a carbon mold for a matrix bit and fabricated into the bit in a conventional manner. Alternatively,diamond elements 14 may be individually glued into a mold for a matrix body bit in the desired array and position. Thereafter, the matrix body bit is filled first with a layer of diamond impregnated metallic powder and then is continued to be filled with various grades of metallic powder according to conventional matrix bit fabrication techniques. The entire mold is then furnaced so that the cutting slug is simultaneously and integrally formed with the body of the matrix bit. - Turn now to Figure 3 wherein a third embodiment is illustrated showing a cutting slug, generally denoted by
reference numeral 22, bonded to a steel ortungsten carbide stud 24 also well known to the art. Again, cuttingslug 22 is comprised of an array of a plurality of prefabricated,synthetic PCDs 14a and 14b. Again, these diamonds are generally triangular prismatic elements such as 2103 and 2102 GEOSETS and are disposed in a diamond impregnatedmetallic matrix 16. The array of diamonds shown in the embodiment of Figure 3 is comprised of a first grouping ofdiamonds 14a and a second grouping 14b. First ; grouping 14a are a plurality of diamonds in spaced apart relationship to form staggered rows of exposed triangular faces in an alternating inverted pattern. Group 14b of diamonds are placed along the circumference ofcircular cutting slug 22 so that theirapical points 26 are directed in a generally radially 5outward direction. As cuttingslug 22 wears, the apical points will begin to be exposed and provide for an aggressive cuttinc action along the edge of cuttingslug 22. Diamonds ingrouping 14a simulate a planar diamond table adapted for cutting salt rock. The twogroupings 14a and 14b of diamonds in the embodiment of Figure 3 are only shown hypothetically to illustrate that different arrays which can be employed, and to demonstrate that diamond groupings on asingle cutting slug 22 may be varied at different regions within the cutting slug in order to provide edges or faces characterised by a different diamond profile and cutting behavior. - Cutting
slug 22 is bonded by soldering, brazing and other means as diagrammatically indicated bybraze layer 28, shown in greatly exaggerated view in Figure 3.Stud 24 is then press fit, soldered or otherwise fitted into a bit body, typically a steel bit body as is well known to the art. Many such studs are known and could be advantageously combined with the cutting slugs of the present invention. - Turn now to Figure 4 wherein a fourth embodiment of the invention is illustrated, again shown as a cutting tooth of a matrix bit body. Here the cutting slug, generally denoted by
reference numerals 30, is rectangular or square in gross geometric outline and is comprised of an array ofprefabricated PCDs 14 which are again generally triangular and prismatic in shape.Diamonds 14 are mounted within cuttingslug 30 in a spaced apart relationship so that the interstitial spaces betweendiamonds 14 are again filled with diamond impregnatedmatrix material 16. Thosediamonds 14 along the periphery of cuttingslug 30 are oriented to have oneside face 32 exposed and art coplanar with the flat sides of rectangular cuttingslug 30. The end faces 34 ofdiamonds 14 are similarly exposed on the cuttingface 36 of cuttingslug 30. Although diagrammatically depicted as incorporated within amatrix tooth 38, arectangular cutting slug 30 such as shown in Figure 4 could be well adapted to a step bit where it could be bonded, soldered or brazed to the corners of the rectangular steps of the bit. - Turn now to Figure 5 wherein yet a fifth embodiment of the invention is diagrammatically illustrated in perspective view. In the fifth embodiment a cutting slug, generally denoted by
reference numeral 40, is comprised of a plurality of compactly arrayeddiamonds 14. More particularly,diamonds 14 are bonded together in groups of six to form a regularhexagonal slug 40.Individual diamond elements 14 are bonded together by athin matrix layer 16 between eachadjacent diamond element 14. As with the prior embodiments, cuttingslug 40 is fabricated by a conventional hot press or infiltration technique. The completed cuttingslug 40 is similarly bonded to astud 42 by soldering, brazing or other means as diagrammatically depicted by brazinglayer 44. - The equilateral triangular
prismatic diamond elements 14 of the embodiment of Figure 5 can be generalized to form larger structures as shown in plan view in Figure 6. Thus, a number of hexagonal arrays, each generally denoted byreference numeral 48, :an be combined to form alarger cutting slug 46. Eachhexagonal subarray 48 which forms part oflarger array 46 is bonded together by diamond impregnatedmatrix material 16 as previously described. - Turn now to Figure 7. Heretofore, the cutting slugs in each embodiment have been described as being built up of triangular prismatic prefabricated synthetic PCDs. The embodiment of Figure 7 generalizes the teachings of the prior embodiments by incorporating prefabricated rectangular prismatic PCD or cubic diamond elements 50. Cubic diamond elements 50 are then combined and bonded together by thin layers of diamond impregnated
metallic matrix 16 as before to form a larger cutting slug, generally denoted by reference numeral 52. In addition to forming the thin interstitial layer, bonding adjacent diamond elements 50,matrix material 16 may also frame or provide an outer encapsulating rectangular enclosure for the array of diamonds 50 for additional security. The rectangular or square cutting slug 52 of the embodiment of Figure 7 can then be bonded to a stud cutter or integrally formed within a matrix body bit. - Turn finally to the embodiment of Figure 8 wherein a higher order, regular polyhedral shaped
diamond element 54 is combined with other like-shaped diamond elements of the same or different orders of polyhedral shapes in a compact or spaced-apart array to form an enlarged cutting slug, generally denoted byreference numeral 56. In the embodiment of Figure 8,pentagonal elements 54 are employed in an array wherein some of theelements 54 may contact each other while others remain in spaced-apart relationship. Again,elements 54 are bound to each other and in cuttingslug 56 by amalgamation in a diamond impregnatedmatrix material 16 formed by hot pressing or infiltration. - Many other modifications or alterations may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. The illustrated embodiment has only been shown by way of an example and should not be taken as limiting the invention which is defined in the following claims.
Claims (21)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US59310284A | 1984-03-26 | 1984-03-26 | |
US593102 | 1996-01-30 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0156264A2 true EP0156264A2 (en) | 1985-10-02 |
EP0156264A3 EP0156264A3 (en) | 1986-06-11 |
EP0156264B1 EP0156264B1 (en) | 1990-09-05 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP85103002A Expired - Lifetime EP0156264B1 (en) | 1984-03-26 | 1985-03-15 | Multi-component cutting element using triangular, rectangular and higher order polyhedral-shaped polycrystalline diamond disks |
Country Status (5)
Country | Link |
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EP (1) | EP0156264B1 (en) |
JP (1) | JPS60226995A (en) |
AU (1) | AU4021885A (en) |
CA (1) | CA1241946A (en) |
DE (1) | DE3579484D1 (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2177144A (en) * | 1985-06-18 | 1987-01-14 | De Beers Ind Diamond | Cutting tool for a mining machine |
GB2181472A (en) * | 1985-08-22 | 1987-04-23 | Anderson Strathclyde Plc | Cutter tools and tip inserts therefor |
GB2190412A (en) * | 1986-05-16 | 1987-11-18 | Nl Petroleum Prod | Improvements in or relating to rotary drill bits |
US4943488A (en) * | 1986-10-20 | 1990-07-24 | Norton Company | Low pressure bonding of PCD bodies and method for drill bits and the like |
US5030276A (en) * | 1986-10-20 | 1991-07-09 | Norton Company | Low pressure bonding of PCD bodies and method |
US5116568A (en) * | 1986-10-20 | 1992-05-26 | Norton Company | Method for low pressure bonding of PCD bodies |
GB2304358A (en) * | 1995-08-22 | 1997-03-19 | Smith International | Polycrystalline diamond composite cutters |
GB2309991A (en) * | 1995-08-22 | 1997-08-13 | Smith International | A method of making multiple layer polycrystalline diamond composite cutters |
US5979578A (en) * | 1997-06-05 | 1999-11-09 | Smith International, Inc. | Multi-layer, multi-grade multiple cutting surface PDC cutter |
GB2353810A (en) * | 1999-09-03 | 2001-03-07 | Camco Internat | Polycrystalline diamond insert including carbonate as a sintering binder catalyst |
GB2429471A (en) * | 2005-02-08 | 2007-02-28 | Smith International | Thermally stable polycrystalline diamond cutting elements |
CN102409981A (en) * | 2010-09-25 | 2012-04-11 | 中国石油集团渤海石油装备制造有限公司 | Assembled diamond compound sheet |
US8622154B2 (en) | 2008-10-03 | 2014-01-07 | Smith International, Inc. | Diamond bonded construction with thermally stable region |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH03202278A (en) * | 1989-12-28 | 1991-09-04 | Mitsui Mining & Smelting Co Ltd | Composite grindstone |
JP2006321006A (en) * | 2005-05-19 | 2006-11-30 | Naniwa Kenma Kogyo Kk | Manufacturing method of grinding chip body and rotating grinding wheel for peeling coating film |
Citations (10)
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US1522593A (en) * | 1919-10-13 | 1925-01-13 | Rowland O Pickin | Rotary drilling tool |
GB576757A (en) * | 1944-04-28 | 1946-04-17 | Nachmann Julius Slutzky | Improvements in or relating to diamond tools |
DE2013198A1 (en) * | 1969-03-19 | 1971-01-07 | Kennametal Inc | Diamond products and processes and apparatus for their manufacture |
US3902864A (en) * | 1970-06-03 | 1975-09-02 | Gen Dynamics Corp | Composite material for making cutting and abrading tools |
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4244432A (en) * | 1978-06-08 | 1981-01-13 | Christensen, Inc. | Earth-boring drill bits |
US4299297A (en) * | 1979-06-06 | 1981-11-10 | Lloyd Thomas C | Rotary percussion bit |
GB2081347A (en) * | 1980-08-08 | 1982-02-17 | Christensen Inc | Drill tool for deep wells |
US4452325A (en) * | 1982-09-27 | 1984-06-05 | Conoco Inc. | Composite structure for cutting tools |
EP0127077A2 (en) * | 1983-05-20 | 1984-12-05 | Eastman Christensen Company | A rotatable drill bit |
-
1985
- 1985-03-15 DE DE8585103002T patent/DE3579484D1/en not_active Expired - Lifetime
- 1985-03-15 EP EP85103002A patent/EP0156264B1/en not_active Expired - Lifetime
- 1985-03-21 AU AU40218/85A patent/AU4021885A/en not_active Abandoned
- 1985-03-25 CA CA000477320A patent/CA1241946A/en not_active Expired
- 1985-03-26 JP JP5969085A patent/JPS60226995A/en active Pending
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1522593A (en) * | 1919-10-13 | 1925-01-13 | Rowland O Pickin | Rotary drilling tool |
GB576757A (en) * | 1944-04-28 | 1946-04-17 | Nachmann Julius Slutzky | Improvements in or relating to diamond tools |
DE2013198A1 (en) * | 1969-03-19 | 1971-01-07 | Kennametal Inc | Diamond products and processes and apparatus for their manufacture |
US3902864A (en) * | 1970-06-03 | 1975-09-02 | Gen Dynamics Corp | Composite material for making cutting and abrading tools |
US4190126A (en) * | 1976-12-28 | 1980-02-26 | Tokiwa Industrial Co., Ltd. | Rotary abrasive drilling bit |
US4244432A (en) * | 1978-06-08 | 1981-01-13 | Christensen, Inc. | Earth-boring drill bits |
US4299297A (en) * | 1979-06-06 | 1981-11-10 | Lloyd Thomas C | Rotary percussion bit |
GB2081347A (en) * | 1980-08-08 | 1982-02-17 | Christensen Inc | Drill tool for deep wells |
US4452325A (en) * | 1982-09-27 | 1984-06-05 | Conoco Inc. | Composite structure for cutting tools |
EP0127077A2 (en) * | 1983-05-20 | 1984-12-05 | Eastman Christensen Company | A rotatable drill bit |
Cited By (27)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2177144A (en) * | 1985-06-18 | 1987-01-14 | De Beers Ind Diamond | Cutting tool for a mining machine |
GB2181472A (en) * | 1985-08-22 | 1987-04-23 | Anderson Strathclyde Plc | Cutter tools and tip inserts therefor |
GB2190412A (en) * | 1986-05-16 | 1987-11-18 | Nl Petroleum Prod | Improvements in or relating to rotary drill bits |
EP0246789A2 (en) * | 1986-05-16 | 1987-11-25 | Nl Petroleum Products Limited | Cutter for a rotary drill bit, rotary drill bit with such a cutter, and method of manufacturing such a cutter |
EP0246789A3 (en) * | 1986-05-16 | 1988-12-14 | Nl Petroleum Products Limited | Cutter for a rotary drill bit, rotary drill bit with such a cutter, and method of manufacturing such a cutter |
US4943488A (en) * | 1986-10-20 | 1990-07-24 | Norton Company | Low pressure bonding of PCD bodies and method for drill bits and the like |
US5030276A (en) * | 1986-10-20 | 1991-07-09 | Norton Company | Low pressure bonding of PCD bodies and method |
US5116568A (en) * | 1986-10-20 | 1992-05-26 | Norton Company | Method for low pressure bonding of PCD bodies |
GB2304358A (en) * | 1995-08-22 | 1997-03-19 | Smith International | Polycrystalline diamond composite cutters |
GB2309991A (en) * | 1995-08-22 | 1997-08-13 | Smith International | A method of making multiple layer polycrystalline diamond composite cutters |
GB2309991B (en) * | 1995-08-22 | 1997-10-29 | Smith International | A method of making multiple diamond layer polycrystalline diamond composite cutters |
GB2304358B (en) * | 1995-08-22 | 1997-10-29 | Smith International | Multiple diamond layer polycrystalline diamond composite cutters and a method for making the same |
US5979578A (en) * | 1997-06-05 | 1999-11-09 | Smith International, Inc. | Multi-layer, multi-grade multiple cutting surface PDC cutter |
US6272753B2 (en) | 1997-06-05 | 2001-08-14 | Smith International, Inc. | Multi-layer, multi-grade multiple cutting surface PDC cutter |
GB2353810A (en) * | 1999-09-03 | 2001-03-07 | Camco Internat | Polycrystalline diamond insert including carbonate as a sintering binder catalyst |
US6248447B1 (en) | 1999-09-03 | 2001-06-19 | Camco International (Uk) Limited | Cutting elements and methods of manufacture thereof |
GB2353810B (en) * | 1999-09-03 | 2003-10-08 | Camco Internat | Cutting elements and methods of manufacture thereof |
GB2429471B (en) * | 2005-02-08 | 2009-07-01 | Smith International | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
US7533740B2 (en) | 2005-02-08 | 2009-05-19 | Smith International Inc. | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
GB2429471A (en) * | 2005-02-08 | 2007-02-28 | Smith International | Thermally stable polycrystalline diamond cutting elements |
US7836981B2 (en) | 2005-02-08 | 2010-11-23 | Smith International, Inc. | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
US7946363B2 (en) | 2005-02-08 | 2011-05-24 | Smith International, Inc. | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
US8157029B2 (en) | 2005-02-08 | 2012-04-17 | Smith International, Inc. | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
US8567534B2 (en) | 2005-02-08 | 2013-10-29 | Smith International, Inc. | Thermally stable polycrystalline diamond cutting elements and bits incorporating the same |
US8622154B2 (en) | 2008-10-03 | 2014-01-07 | Smith International, Inc. | Diamond bonded construction with thermally stable region |
US9404309B2 (en) | 2008-10-03 | 2016-08-02 | Smith International, Inc. | Diamond bonded construction with thermally stable region |
CN102409981A (en) * | 2010-09-25 | 2012-04-11 | 中国石油集团渤海石油装备制造有限公司 | Assembled diamond compound sheet |
Also Published As
Publication number | Publication date |
---|---|
EP0156264B1 (en) | 1990-09-05 |
CA1241946A (en) | 1988-09-13 |
DE3579484D1 (en) | 1990-10-11 |
AU4021885A (en) | 1985-10-03 |
JPS60226995A (en) | 1985-11-12 |
EP0156264A3 (en) | 1986-06-11 |
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