EP1565642B1 - Werkzeugeinsatz - Google Patents

Werkzeugeinsatz Download PDF

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Publication number
EP1565642B1
EP1565642B1 EP03809804A EP03809804A EP1565642B1 EP 1565642 B1 EP1565642 B1 EP 1565642B1 EP 03809804 A EP03809804 A EP 03809804A EP 03809804 A EP03809804 A EP 03809804A EP 1565642 B1 EP1565642 B1 EP 1565642B1
Authority
EP
European Patent Office
Prior art keywords
protective layer
tool insert
substrate
cutting edge
ultra
Prior art date
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.)
Expired - Lifetime
Application number
EP03809804A
Other languages
English (en)
French (fr)
Other versions
EP1565642A1 (de
Inventor
Klaus Tank
Raymond Albert Chapman
Roy Derrick Achilles
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Element Six Pty Ltd
Original Assignee
Element Six Pty Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Element Six Pty Ltd filed Critical Element Six Pty Ltd
Publication of EP1565642A1 publication Critical patent/EP1565642A1/de
Application granted granted Critical
Publication of EP1565642B1 publication Critical patent/EP1565642B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00—Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/06—Cutting windows, e.g. directional window cutters for whipstock operations

Definitions

  • THIS invention relates to tool inserts and more particularly tool inserts which can be used as cutting elements in rotary drilling bits intended for subterranean rock drilling.
  • diamond compacts also known as PCD
  • PCD diamond compacts
  • cutters in drilling operations is well known due to the high abrasion resistant properties of diamond cutters. It is also well established that diamond cutters cannot be used satisfactorily for milling or drilling through ferrous substrates such as steel. Therein lies a problem in the use of diamond cutters in certain down the hole drilling operations, particularly with regard to subterranean directional drilling, such as drilling horizontally into a rockbed from an underground location in a vertical borehole or shaft.
  • a steel casing is typically positioned down the vertical borehole or shaft, creating a lining therefor in the region requiring horizontal drilling.
  • a deflector which is positioned adjacent the position where horizontal drilling is to be carried out. The function of the deflector, which is generally wedge-shaped, is to cause the drill to change direction and begin milling through the steel casing to create a window to the bedrock.
  • tungsten carbide cutters are typically used in the drill bit to mill through the steel casing. Once through the casing, the tungsten carbide inserts have to be replaced with abrasive resistant cutters such as diamond cutters in order to drill into the bedrock. This means that the drill bit has to be removed and replaced with an appropriate bit. As the drill strings that have to be removed are very long, this is a time consuming exercise that results in costly downtime.
  • US-A-5 979 571 which is considered the closest prior art, discloses a combination metal milling and earth drilling tool, for use in performing a single trip kickoff from a casing in a well bore.
  • the combination milling and drilling tool has a first, relatively more durable cutting structure, such as tungsten carbide, and a second, relatively harder cutting structure, such as polycrystalline diamond.
  • the more durable first cutting structure is better suited for milling metal casing, while the harder second cutting structure is better suited for drilling through a subterranean formation, especially a rock formation.
  • the first cutting structure is positioned outwardly relative to the second cutting structure, so that the first cutting structure will mill through the metal casing while shielding the second cutting structure from contact with the casing.
  • the first cutting structure can wear away while milling through the casing and upon initial contact with the rock formation, thereby exposing the second cutting structure to contact with the rock formation.
  • the second cutting structure can then be used to drill through the rock formation.
  • US-A-2001/0035302 discloses a dual function drag bit that is used in a method for both milling well casing or liner and subsequently drilling rock formation without the sequential removal of a milling assembly and replacement with a drilling assembly.
  • the method employs a cutting tool that is capable of both milling steel pipe casing in a well bore and subsequently drilling rock formation outside the well bore after passing through the casing.
  • an insert embedded into the surface of the cutting tool comprises at least an outer layer, such as cemented tungsten carbide, capable of milling steel casing, and at least a second layer, such as polycrystalline diamond, capable of drilling formation, the two layers being bonded together and to a carbide substrate.
  • inserts with a polycrystalline diamond cutting face for drilling rock formation are in parallel with cemented tungsten carbide cutters for milling steel casing.
  • a tool insert comprises:
  • a tool insert comprises:
  • a method of drilling a horizontal or angled hole in a subterranean rock formation includes the steps of:
  • the above method can also be used for the drilling of multiple directional holes from a central vertical borehole.
  • a drill assembly 10 consists of a rotary drill string 12 and a rotary drill bit 14, of the drag bit kind in this case.
  • the drill bit 14 is directed down a passage 16 within a steel tubular casing 18.
  • the steel casing 18 is anchored in a borehole or shaft 20 drilled into a subterranean bedrock or rock formation 22.
  • a deflector 26 which is attached to the casing 18 and which has previously been positioned adjacent the region 'X', causes the bit 14 to change direction in this manner.
  • the deflector 26 is supported by an anchor 28.
  • the layer of ultra-hard abrasive material will generally be a layer of PCD, although under appropriate conditions PCBN may also be used.
  • the layer may also be a layer of diamond produced by chemical vapour deposition, called CVD diamond.
  • the substrate of the tool insert will generally be a cemented carbide substrate.
  • Such substrates are well known in the art and are generally cemented tungsten carbide substrates.
  • the protective layer which may be an extension of the substrate or a separate layer, will also generally be of cemented tungsten carbide, although it may be of a different grade to that of the substrate. In certain instances, the protective layer may be formed of tool steel or other appropriate material suited to milling through steel or other material used for the casing or lining.
  • a cemented carbide substrate 40 has a planar base surface 42 and an upper surface 44.
  • a centrally located recess 46 is formed in the upper surface 44.
  • the recess 46 is surrounded by an annular region 48 and has a surface 50. Although the recess 46 is centrally located in this embodiment, it could also be positioned off centre.
  • the recess 46 is filled with diamond particles. Thereafter, the diamond-filled substrate 40 is placed in a reaction capsule and the reaction capsule placed in the reaction zone of a conventional high pressure/high temperature apparatus. The capsule is exposed to conditions of high pressure and temperature suitable to produce a diamond abrasive compact (PCD) 52. Under these conditions the PCD 52 will form and bond to the cemented carbide substrate over the entire surface which defines the recess 46. A cutting edge 54, the primary cutting edge of the tool insert, is defined by the periphery of the PCD 52.
  • PCD diamond abrasive compact
  • the cemented carbide / PCD body is then removed from the reaction capsule using known techniques. As such the cemented carbide / PCD body forms a precursor of a tool insert.
  • the annular region 48 of the substrate 40 is ground or otherwise removed so as to leave a predetermined depth, indicated by the numeral 56, of tungsten carbide material.
  • This depth of material 56 is selected so as to correspond to the amount of tungsten carbide material required to mill through the wall of a steel casing or lining of a borehole, as described above.
  • the depth of tungsten carbide 56 provides a protective layer for the primary cutting edge 54 of the PCD 52, and also a secondary cutting edge 58 for milling through the steel casing. Once a window has been milled through the steel casing, ideally the layer 56 should be almost expended so as to expose the cutting edge 54 for drilling into the rockbed.
  • the tungsten carbide substrate 40 whilst having the desired properties for forming the PCD layer 52, may not have the desired properties for milling through a steel casing or lining.
  • the annular protective layer 48 may be replaced by tungsten carbide of a different grade or by another suitable material, such as tool steel, for example.
  • the annular region 48 in such a case could be formed as a ring in situ or, alternatively, could be formed as a separate ring component which is attached to the tool insert.
  • the ring 48 may be attached to the tool insert, which has been machined to accept the ring, by for example brazing, press fitting, shrink fitting or any other convenient method.
  • a first embodiment of a tool insert of the invention is illustrated in figures 4 and 5 of the accompanying drawings.
  • the tool insert consists of a cemented carbide substrate 80, a PCD layer 82, having a cutting edge 84, and a tungsten carbide protective segment 86, having a cutting edge 88, bonded to the substrate 80.
  • the tungsten carbide segment 86 could be an extension of the substrate 80.
  • the tungsten carbide segment 86 could be formed of a tungsten carbide material of a different grade that is adapted to the particular substrate to be milled.
  • the depth of the tungsten carbide segment 86 is once again selected so as to protect the cutting edge 84 whilst drilling through a steel casing, but to expose the cutting edge 84 soon after encountering the subterranean bedrock.
  • a tungsten carbide substrate 90 includes a number of parallel recesses 92 in which parallel PCD segments or strips 94 are formed.
  • the PCD segments 94 are protected by respective tungsten carbide segments or strips 96.
  • the cutting edges 98 of respective PCD segments 94 are protected by the tungsten carbide segments 96, which in turn have cutting edges 100.
  • This arrangement allows the tool insert to be used for cutting through successive layers of steel and subterranean bedrock and can therefore be used multiple times.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Earth Drilling (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Processing Of Terminals (AREA)
  • Gripping On Spindles (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)
  • Surgical Instruments (AREA)
  • Sampling And Sample Adjustment (AREA)
  • Eye Examination Apparatus (AREA)

Claims (10)

  1. Werkzeug-Einsatz Umfassend:
    ein Substrat (80);
    eins Schicht aus ultrahartem abrasiven Material (82), das mit dem Substrat verbunden ist, wobei die Schicht aus ultrahartem abrasiven Material eine Seitenfläche und eine obere Oberfläche aufweist, wobei ein Abschnitt des Randgablets der oberen Oberfläche des ultraharten abrasiven Materials einen primären Schneidrand (84) für den Warkzeug-Einsatz schafft; und
    eine Schutzschicht (86), wobei eine Oberfläche der Schutzschicht mit der oberen Oberfläche und/oder der Seitenfläche des ultraharten abrasiven Materials verbunden ist, um den primären Schneidrand desselben zu schürtzen, wobei ein Randgebiet der Schutzschicht einen sekundären Schneldrand (88) für den Werkzeug-Einsatz schaft, wobei die Stärke der Schutzschicht so ausgewählt wird, dass sie ausreicht, um den primären Schneidrand beim Schneiden, Fräsen oder Bohren eines Fensters durch eine erste Substanz (18) zu schützen, den primären Schneidrand beim Auftreifen auf eine zweite Substanz (22) jedoch freizulegen dadurch gekennzeichnet, dass die Schutzschicht eine Segment bildet, welches benachbart zu der Schicht aus ultrahartem abrasiven Material mit dem Substrat verbunden ist.
  2. Werkzeug-Einsatz nach Anspruch 1, wobei das Substrat (80) ein Wolframkarbid-Substrat ist.
  3. Werkzeug-Einsatz nach Anspruch 1 oder Anspruch 2, wobei die Schutzschicht (86) einteilig mit dem Substrat ausgebildet ist und aus demselben Material wie das Substrat besteht.
  4. Werkzeug-Einsatz nach Anspruch 1 oder Anspruch 2, wobei die Schutzschicht (86) in situ als eine separate Komponente ausgebildet ist.
  5. Werkzug-Einsatz nach Anspruch 1 oder Anspruch 2, wobei die Schutzschicht (86) als eine separate Komponente ausgebildet ist, welche mit dar oberen Oberfläche und/oder der Seitanfläche des ultraharten abrasiven Materials (82) verbunden ist.
  6. Werkzeug-Einsatz nach einem der Ansprüche 1 bis 5, wobei eine Vietzahl Von Streifen aus ultrahartem abrasiven Material (94) und Schutzschicht-Streifen (96) abwechseind auf dem Substrat angeordnet ist, wobei einer der Schutzschicht-Streifen (96) ein Segment bildet, welches benachbart einem der Streifen aus ultrahartem abrasiven Material (94) ist und wobei aufeinander folgende Streifen aus ultrahartem abrasiven Material eine Reihe von primären Schneklrädern schaffen und aufeinander folgende Schutzchicht-Streifen eine Reihe von sekundären Schneidrändem schaffen.
  7. Werkzeug-Einsatz nach einem dar vorhergehenden Ansprüche, wobei die Schutzschicht (86, 96) aus demseiben Materialtyp wie das Substrat (80, 90), jedoch mit einer vorn Substrat untereschiedlichen Qualität, oder aus Werkzeugstahl oder aus einem anderen geeigneten Material, abhängig von der ersten Substanz, ausgeblidet ist.
  8. Werkzeug-Einsatz nach einem der vorhergehenden Ansprüche, wobei die erste Substanz eine Ausfülterung (18) oder eine Auskleidung eines Bohrlochs oder Schachts in einem Grundgestein ist, und die zweite Substanz das Grundgestein (22) ist.
  9. Verfahren zum Bohren eines horizontalen oder abgewinkelten Lochs in einer unterirdischen Gesteinsformation, wobei das Verfahren die Schritte umfasst, dass:
    1) die Stelle für die horizontale oder abgewinkelte Bohrung vorbereitet wird, indem a) ein bestehendes Bohrloch verwendet wird, oder, falls keines verfügbar ist, ein Bohrloch bis auf eine geeignete Tiefe in eine unterirdische Gesteinsformation gebehrt wird, und b) das Bohrloch zumindest in dem Bereich, in dem die horizontale oder abgewinkelte Bohrung vorgenommen werden soll, mit einer Ausfütterung oder einer Auskleidung die einen Durchgang und ein in dem Durchgang befestigtes Umlenkmittel aufweist, ausgekleidet wird;
    2) ein Bohreinsatz mit zumindest einem Schneidwerkzeug-Einsatz nach einem der vorbergahenden Ansprüche wird, wobei der bzw. jeder Schneidwerkzeug-Einsatz ein Substrat, eine Schicht aus ultrahartern abrasiven Material, das mit dem Substrat verbunden ist, wobei das ultraharte abrasive Material einem primären Schneidrand für den Werkzeug-Einsatz schallt, sowie eine Schutzschicht zum Schutz des primären Schneidrandes und zur Schalfung eines sekundären Schneidrandes umfasst;
    3) der Bohreinsatz durch des Bohrloch nach unten geführt wird, bis er mit dem Umlenkelement in Kontakt gelangt, und zu der Ausfütterung oder der Auskleidung hin umgelenkt wird.
    4) ein Fenster durch die Ausfülterung oder die Auskleidung zu der unterirdischen Gesteinsformation gefräst wird; und
    5) ein Loch in die unterirdische Gesteinzsformation gebohrt wird,
    wobei die Stärke der Schutzschicht derart ausgestaltet ist, dass der primäre Schneidrand beim Fräsen durch die Ausfütterung oder die Auskleldung geschützt wird und der primäre Schneidrand beim Auftreffen auf die unterindische Gesteinformation freigelegt wird.
  10. Verfahren nach Anspruch 9, welches zum Bohren von Löchern in mehrere Richtungen von einem zentralen vertikalen Bohrloch aus verwendet wird.
EP03809804A 2002-10-30 2003-09-12 Werkzeugeinsatz Expired - Lifetime EP1565642B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ZA200208777 2002-10-30
ZA200208777 2002-10-30
PCT/IB2003/003892 WO2004040095A1 (en) 2002-10-30 2003-09-12 Tool insert

Publications (2)

Publication Number Publication Date
EP1565642A1 EP1565642A1 (de) 2005-08-24
EP1565642B1 true EP1565642B1 (de) 2010-12-29

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EP03809804A Expired - Lifetime EP1565642B1 (de) 2002-10-30 2003-09-12 Werkzeugeinsatz

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US (1) US20060144621A1 (de)
EP (1) EP1565642B1 (de)
CN (1) CN100557188C (de)
AT (1) ATE493559T1 (de)
AU (1) AU2003259458A1 (de)
CA (1) CA2504518C (de)
DE (1) DE60335568D1 (de)
WO (1) WO2004040095A1 (de)
ZA (1) ZA200503785B (de)

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Publication number Publication date
EP1565642A1 (de) 2005-08-24
CN100557188C (zh) 2009-11-04
ZA200503785B (en) 2006-08-30
CA2504518C (en) 2011-08-09
ATE493559T1 (de) 2011-01-15
WO2004040095A1 (en) 2004-05-13
CN1714225A (zh) 2005-12-28
US20060144621A1 (en) 2006-07-06
CA2504518A1 (en) 2004-05-13
AU2003259458A1 (en) 2004-05-25
DE60335568D1 (de) 2011-02-10

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