EP1606489A1 - Plaquette d'outil - Google Patents

Plaquette d'outil

Info

Publication number
EP1606489A1
EP1606489A1 EP04720105A EP04720105A EP1606489A1 EP 1606489 A1 EP1606489 A1 EP 1606489A1 EP 04720105 A EP04720105 A EP 04720105A EP 04720105 A EP04720105 A EP 04720105A EP 1606489 A1 EP1606489 A1 EP 1606489A1
Authority
EP
European Patent Office
Prior art keywords
region
tool component
component according
pcd
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.)
Withdrawn
Application number
EP04720105A
Other languages
German (de)
English (en)
Inventor
Bronwyn Annette Roberts
Geoffrey John Davies
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 EP1606489A1 publication Critical patent/EP1606489A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/56—Button-type inserts
    • E21B10/567—Button-type inserts with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts

Definitions

  • This invention relates to tool inserts and more particularly to cutting tool inserts for use in drilling and coring holes in subterranean formations.
  • a commonly used cutting tool insert for drill bits is one which comprises a layer of polycrystalline diamond (PCD) bonded to a cemented carbide substrate.
  • the layer of PCD presents a working face and a cutting edge around a portion of the periphery of the working surface.
  • Polycrystalline diamond also known as a diamond abrasive compact, comprises a mass of diamond particles containing a substantial amount of direct diamond-to-diamond bonding.
  • Polycrystalline diamond will generally have a second phase which contains a diamond catalyst/solvent such as cobalt, nickel, iron or an alloy containing one or more such metals.
  • such a cutting tool insert In drilling operations, such a cutting tool insert is subjected to heavy loads and high temperatures at various stages of its life. In the early stages of drilling, when the sharp cutting edge of the insert contacts the subterranean formation, the cutting tool is subjected to large contact pressures. This results in the possibility of a number of fracture processes. being activated such as the initiation of fatigue cracks, high energy impacts, in the normal direction, resulting in spalling of the PCD layer, and high energy impacts in the cutting direction, resulting in chipping of the PCD layer.
  • United States 5,135,061 describes a cutting tool insert for use in rotary drill bits of the kind generally described above.
  • the cutting element has a layer of superhard material such as PCD bonded to a cemented carbide substrate.
  • the layer of superhard material has a front layer at the cutting face and a second layer behind the front layer.
  • the front layer comprises a form of superhard material which is less wear-resistant than the super-hard material forming the second layer.
  • a plurality of further layers are stacked behind the second layer, the further layers being of reducing wear-resistance as they extend away from the second layer towards the substrate.
  • US 6,290,008 discloses a PCD enhanced insert which includes a body portion adapted for attachment to an earth-boring bit and a top portion for contacting an earthen formation.
  • the top portion of the insert is provided with two different compositions of polycrystalline diamond.
  • a tougher or less wear-resistant polycrystalline diamond layer is provided, whereas a more wear-resistant polycrystalline diamond layer is provided in the remaining region of the top portion.
  • polycrystalline boron nitride and other superhard materials may also be used.
  • US 6,443,248 describes a cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon.
  • the substrate comprises a grip portion and an extending portion.
  • the layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it.
  • the layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.
  • a tool insert comprises a working layer of ultra-hard abrasive, particularly PCD, bonded to a substrate along an interface, the working layer presenting a working surface and a periphery around the working surface which provides a cutting edge for the insert, the working layer of ultra-hard abrasive having a first region extending into the working layer from the working surface, and a second region in contact with the first region, the wear resistance of the first region being less than that of the second region, wherein the wear resistance of the first region is between 50% and 95% of that of the second region, preferably between 60% and 90%, most preferably between 70% and 89%.
  • the first and second regions will comprise layers, typically successive layers, extending from the working face into the working layer.
  • the regions, or at least one of the. regions may comprise .an ' annulus extending inwards from a periphery of the layer of ultra-hard abrasive.
  • the thickness of the first, thin region may be non-uniform across the diameter of the cutter; so that the interface between the first and second regions may be specifically designed for optimal behaviour.
  • a tool component of the invention comprises a layer of ultra-hard abrasive that has a first region which is less wear resistant than a second region thereof. Accordingly, essential to the invention is that the first region differs in material characteristics to that of the second region leading to a controlled and reduced spalling and reduced fatigue in the layer of ultra- hard abrasive.
  • the first region will generally be relatively thin and extend to a depth of about 750 microns, preferably no more than about 500 microns, and most preferably about 50 to 250 microns, for a wear ratio of between 50% and 95%, from the working surface.
  • the first region preferably has a wear resistance of between 50% and 95%, more preferably between 60% and 90%, and most preferably between 70% and 89% of the wear resistance of the second region.
  • An example of such a tool component, in one embodiment of the invention, is one in which the first region comprises a composite structure of two or more materials. The materials may be uniformly distributed throughout the region or randomly distributed. For example, the one material may be the same material as that of the second region and this will be combined with another material which provides that first region with a wear resistance lower than that of the second region.. ' . '
  • the tool component in a further embodiment of the invention can be designed such that the first and second regions are both regions of PCD and contain catalyst/solvent, the amount of catalyst/solvent in the first region being higher than that in the second region.
  • the tool component in yet a further embodiment of the invention can be designed such that the first region has ultra-hard abrasive particles of a unimodal particle size distribution only, and the second region has ultra-hard abrasive particles which have a multimodal particle size distribution.
  • the average grain or particle sizes in the two regions are similar.
  • the range of particle sizes in the second region will not differ materially from the range of particle sizes of the ultra-hard abrasive in the first region.
  • the tool component is one in which both the first and second regions comprise ultra-hard abrasive particles of more than one particle size, the size distribution of the particles in the first region being coarser than that of the second region.
  • the ultra-hard abrasive in the first region is preferably made from a mass which comprises at least 25% by mass particles having an average particle size in the range 10 to 100 microns and consisting of particles having three different average particle sizes and at least 4% by mass of the particles having an average particle size of less than 10 microns.
  • the ultra-hard abrasive in the second region preferably is made from a mass of particles which has an average particle size of less than 20 microns and consists of particles having at least three different average particle sizes.
  • the ultra-hard abrasive is PCD and the thermal stability of the PCD in the first region is less than that of the PCD in the second' region.
  • a metal or other material which has .thermal expansion properties significantly different to that of PCD may be provided in the first region.
  • the first region may have a second phase which includes in it a metal such as iron or manganese which can react with the diamond under high temperature.
  • the ultra-hard abrasive is PCD and sinter quality of the PCD in the first region is compromised by the introduction of a material such as a sintering agent in small quantities, which is not introduced into the second region.
  • the compromising material will generally not be present in quantities sufficient for the mechanical or thermal properties of the material itself to affect the properties of the first region.
  • the role of the compromising material is to influence the diamond sintering process during synthesis. This may be achieved in one of two ways. First, the material may act as an inhibitor/poison where the agent interferes with the sintering.
  • the material may be more catalytic, for example where the presence of the material encourages sintering, but at a too rapid rate, producing a less well-sintered structure. Further examples of compromising the quality of the PCD is by treatment of the diamond particle surface or the introduction of additional carbon material into the first region.
  • both the first and second regions are regions of PCD containing a catalyst/solvent in a second phase
  • the catalyst/solvent in the first region is cobalt with another transition metal such as nickel, or the other transition metal; and the catalyst/solvent in the second region is essentially cobalt.
  • the nickel will tend to increase the thermal stability of the PCD in the first region.
  • the sintering action of the nickel is less effective than another transition metal such as cobalt.
  • the presence of nickel in the PCD in the first region, where the other catalyst/solvent is cobalt will have the effect of reducing the overall strength of the sintered PCD in the first region and hence rendering it less wear resistant.
  • a number of tool inserts as generally described above (A1 , B1 and C1) were manufactured with respective first PCD abrasive regions or top layers each 150 ⁇ m in depth from their respective working surface.
  • the respective top layers of the tool inserts had different wear resistances relative to their respective second regions of PCD abrasive as follows: i) A1 - 0.94 (94%) wear resistance ratio; ii) B1 - 0.91 (91%) wear resistance ratio; and iii) C1 - 0.88 (88%) wear resistance ratio.
  • a number of tool inserts (A2, B2, C2 and D2) were manufactured with a wear ratio of the respective first regions or top layers to the respective second regions or top layers of 0.91 (91%).
  • the respective tool inserts had different depths of the top layers from their working surfaces as follows:
  • the wear resistance of the top layer will dominate the overall wear resistance of the cutter.
  • thinner layers will not yield the desired stress- reducing behaviours because of inadequate "rounding" of this layer.
  • Maximum cutting efficiency will be achieved by optimising the thickness of the top layer and the wear ratio between the top layer and the underlying PCD.
  • the top layer must be thick enough to reduce contact pressures on the cutting edge, but still thin enough that it does not negatively impact on the overall wear resistance of the cutter. The closer that the wear ratio is to 1, the less efficient this optimisation will be. In the case of lower wear ratios, the top layer will yield the required reduction in spalling behaviour, in an appropriate thickness region which still allows optimal cutter performance.
  • the invention has particular application to tool inserts wherein the ultra- hard abrasive is PCD and, more particularly, to such inserts which are intended to be used as cutting inserts for drill bits in the drilling or coring of drill holes or the like in subterranean formations.

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

Une plaquette d'outil comporte une couche de travail constituée d'un abrasif ultra-dur, en particulier en diamant polycristallin (PCD), liée à un substrat le long d'une interface. Cette couche de travail présente une surface de travail et une partie périphérique, autour de ladite surface, qui forme l'arête coupante de la plaquette. La couche de travail en abrasif ultra-dur présente une première région s'étendant dans la couche à partir de la surface de travail et une deuxième région en contact avec la première, la résistance à l'usure de la première région étant inférieure à celle de la deuxième. La première région présente une résistance à l'usure qui équivaut à 50 à 95 % de la résistance de la deuxième région, de préférence 60 à 90 %, et mieux encore 70 à 89 %.
EP04720105A 2003-03-14 2004-03-12 Plaquette d'outil Withdrawn EP1606489A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ZA200302083 2003-03-14
ZA200302083 2003-03-14
PCT/IB2004/000706 WO2004081336A1 (fr) 2003-03-14 2004-03-12 Plaquette d'outil

Publications (1)

Publication Number Publication Date
EP1606489A1 true EP1606489A1 (fr) 2005-12-21

Family

ID=32991533

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04720105A Withdrawn EP1606489A1 (fr) 2003-03-14 2004-03-12 Plaquette d'outil

Country Status (6)

Country Link
US (1) US20060260850A1 (fr)
EP (1) EP1606489A1 (fr)
AU (1) AU2004219847B2 (fr)
CA (1) CA2518946A1 (fr)
WO (1) WO2004081336A1 (fr)
ZA (1) ZA200507399B (fr)

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ATE353271T1 (de) 2003-05-27 2007-02-15 Element Six Pty Ltd Polykristalline abrasive diamantsegmente
BRPI0510973A (pt) * 2004-05-12 2007-11-27 Element Six Pty Ltd elemento abrasivo de diamante policristalino
GB0423597D0 (en) * 2004-10-23 2004-11-24 Reedhycalog Uk Ltd Dual-edge working surfaces for polycrystalline diamond cutting elements
PL2049306T3 (pl) * 2006-07-31 2013-12-31 Element Six Abrasives Sa Wypraski ścierne
JP5175933B2 (ja) * 2007-08-31 2013-04-03 エレメント シックス （プロダクション）（プロプライエタリィ） リミテッド 超硬質ダイヤモンド複合物
US8277722B2 (en) * 2009-09-29 2012-10-02 Baker Hughes Incorporated Production of reduced catalyst PDC via gradient driven reactivity
SA111320374B1 (ar) 2010-04-14 2015-08-10 بيكر هوغيس انكوبوريتد طريقة تشكيل الماسة متعدد البلورات من الماس المستخرج بحجم النانو
RU2559183C2 (ru) * 2010-04-28 2015-08-10 Бейкер Хьюз Инкорпорейтед Поликристаллические алмазные элементы, режущие инструменты и буровые инструменты, включающие такие элементы, а также способы изготовления таких элементов и буровых инструментов
RU2013102914A (ru) 2010-06-24 2014-07-27 Бейкер Хьюз Инкорпорейтед Режущие элементы для бурового инструмента, буровой инструмент с такими режущими элементами и способы формирования режущих элементов для бурового инструмента
US9140072B2 (en) 2013-02-28 2015-09-22 Baker Hughes Incorporated Cutting elements including non-planar interfaces, earth-boring tools including such cutting elements, and methods of forming cutting elements

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4694918A (en) * 1985-04-29 1987-09-22 Smith International, Inc. Rock bit with diamond tip inserts
GB2234542B (en) * 1989-08-04 1993-03-31 Reed Tool Co Improvements in or relating to cutting elements for rotary drill bits
ZA943646B (en) * 1993-05-27 1995-01-27 De Beers Ind Diamond A method of making an abrasive compact
ZA943645B (en) * 1993-05-27 1995-01-27 De Beers Ind Diamond A method of making an abrasive compact
US6315065B1 (en) * 1999-04-16 2001-11-13 Smith International, Inc. Drill bit inserts with interruption in gradient of properties
US6290008B1 (en) * 1998-12-07 2001-09-18 Smith International, Inc. Inserts for earth-boring bits
US7082939B2 (en) * 2002-12-10 2006-08-01 Diamond Innovations, Inc. Frame saw for cutting granite and method to improve performance of frame saw for cutting granite

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2004081336A1 *

Also Published As

Publication number Publication date
CA2518946A1 (fr) 2004-09-23
AU2004219847B2 (en) 2010-02-18
AU2004219847A1 (en) 2004-09-23
WO2004081336A1 (fr) 2004-09-23
US20060260850A1 (en) 2006-11-23
ZA200507399B (en) 2006-11-29

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Inventor name: ACHILLES, ROY, DERRICK

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