WO2014028152A1 - Outils coupants de fond de trou présentant des structures coupantes hybrides - Google Patents

Outils coupants de fond de trou présentant des structures coupantes hybrides Download PDF

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Publication number
WO2014028152A1
WO2014028152A1 PCT/US2013/050509 US2013050509W WO2014028152A1 WO 2014028152 A1 WO2014028152 A1 WO 2014028152A1 US 2013050509 W US2013050509 W US 2013050509W WO 2014028152 A1 WO2014028152 A1 WO 2014028152A1
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WO
WIPO (PCT)
Prior art keywords
cutting
cutting element
planar
blades
bit
Prior art date
Application number
PCT/US2013/050509
Other languages
English (en)
Inventor
Michael Azar
Slim Hbaieb
Original Assignee
Smith International, Inc.
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
Priority claimed from US13/836,172 external-priority patent/US20140262536A1/en
Application filed by Smith International, Inc. filed Critical Smith International, Inc.
Priority to CN201380046979.XA priority Critical patent/CN104619946A/zh
Publication of WO2014028152A1 publication Critical patent/WO2014028152A1/fr

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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
    • E21B10/42—Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits
    • E21B10/43—Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits characterised by the arrangement of teeth or other cutting elements
    • 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
    • E21B10/54—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
    • E21B10/55—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits with preformed cutting elements
    • 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
    • E21B10/60—Drill bits characterised by conduits or nozzles for drilling fluids

Definitions

  • drill bits Many different types have been developed and found useful in drilling such boreholes.
  • Two predominate types of drill bits are roller cone bits and fixed cutter (or rotary drag) bits.
  • Most fixed cutter bit designs include a plurality of blades angularly spaced about the bit face. The blades project radially outward from the bit body and form flow channels therebetween.
  • cutting elements are typically grouped and mounted on several blades in radially extending rows. The configuration or layout of the cutting elements on the blades may vary widely, depending on a number of factors such as the formation to be drilled.
  • each cutting element disposed on the blades of a fixed cutter bit are typically formed of extremely hard materials.
  • each cutting element comprises an elongate and generally cylindrical tungsten carbide substrate that is received and secured in a pocked formed in the surface of one of the blades.
  • the cutting elements typically includes a hard cutting layer of polycrystalline diamond (PCD) or other superabrasive materials such as thermally stable diamond or polycrystalline cubic boron nitride.
  • PCD polycrystalline diamond
  • PDC bit or “PDC cutters” refers to a fixed cutter bit or cutting element employing a hard cutting layer of polycrystalline diamond or other superabrasive materials.
  • Bit 10 a conventional fixed cutter or drag bit 10 adapted for drilling through formations of rock to form a borehole is shown.
  • Bit 10 generally includes a bit body 12, a shank 13, and a threaded connection or pin 14 for connecting the bit 10 to a drill string (not shown) that is employed to rotate the bit in order to drill the borehole.
  • Bit face 20 supports a bladed cutting structure 15 and is formed on the end of the bit 10 that is opposite pin end 16.
  • Bit 10 further includes a central axis 11 about which bit 10 rotates in the cutting direction represented by arrow 18.
  • Cutting structure 15 is provided on face 20 of bit 10.
  • Cutting structure 15 includes a plurality of angularly spaced-apart primary blades 31, 32, 33, and secondary blades 34, 35, 36, each of which extends from bit face 20.
  • Primary blades 31 , 32, 33 and secondary blades 34, 35, 36 extend generally radially along bit face 20 and then axially along a portion of the periphery of bit 10.
  • secondary blades 34, 35, 36 extend radially along bit face 20 from a position that is distal bit axis 11 toward the periphery of bit 10.
  • secondary blade may be used to refer to a blade that begins at some distance from the bit axis and extends generally radially along the bit face to the periphery of the bit.
  • Primary blades 31 , 32, 33 and secondary blades 34, 35, 36 are separated by drilling fluid flow courses 19.
  • each primary blade 31, 32, 33 includes blade tops
  • each secondary blade 34, 35, 36 includes blade tops 52 for mounting a plurality of cutting elements.
  • cutting elements 40 each having a cutting face 44, are mounted in pockets formed in blade tops 42, 52 of each primary blade 31, 32, 33 and each secondary blade 34, 35, 36, respectively.
  • Cutting elements 40 are arranged adjacent one another in a radially extending row proximal the leading edge of each primary blade 31, 32, 33 and each secondary blade 34, 35, 36.
  • Each cutting face 44 has an outermost cutting tip 44a furthest from blade tops 42, 52 to which cutting element 40 is mounted.
  • FIG. 3 a profile of bit 10 is shown as it would appear with all blades (e.g., primary blades 31, 32, 33 and secondary blades 34, 35, 36) and cutting faces 44 of all cutting elements 40 rotated into a single rotated profile.
  • blade tops 42, 52 of all blades 31-36 of bit 10 form and define a combined or composite blade profile 39 that extends radially from bit axis 11 to outer radius 23 of bit 10.
  • composite blade profile refers to the profile, extending from the bit axis to the outer radius of the bit, formed by the blade tops of all the blades of a bit rotated into a single rotated profile (i.e., in rotated profile view).
  • Cone region 24 comprises the radially innermost region of bit 10 and composite blade profile 39 extending generally from bit axis 11 to shoulder region 25.
  • cone region 24 is generally concave.
  • shoulder region 25 is generally convex.
  • adjacent shoulder region 25 is the gage region 26 which extends parallel to bit axis 11 at the outer radial periphery of composite blade profile 39.
  • composite blade profile 39 of conventional bit 10 includes one concave region— cone region 24, and one convex region— shoulder region 25.
  • blade profile nose 27 refers to the point along a convex region of a composite blade profile of a bit in rotated profile view at which the slope of a tangent to the composite blade profile is zero.
  • the composite blade profile includes only one convex shoulder region (e.g., convex shoulder region 25), and only one blade profile nose (e.g., nose 27). As shown in FIGS.
  • cutting elements 40 are arranged in rows along blades 31-36 and are positioned along the bit face 20 in the regions previously described as cone region 24, shoulder region 25 and gage region 26 of composite blade profile 39.
  • cutting elements 40 are mounted on blades 31-36 in predetermined radially-spaced positions relative to the central axis 1 1 of the bit 10.
  • the cost of drilling a borehole is proportional to the length of time it takes to drill the borehole to the desired depth and location.
  • the drilling time is greatly affected by the number of times the drill bit must be changed in order to reach the targeted formation. This is the case because each time the bit is changed, the entire drill string, which may be miles long, must be retrieved from the borehole section by section. Once the drill string has been retrieved and the new bit installed, the bit must be lowered to the bottom of the borehole on the drill string, which again must be constructed section by section. This process, known as a "trip" of the drill string, requires considerable time, effort, and expense. Accordingly, it is always desirable to employ drill bits that will drill faster and longer and that are usable over a wider range of differing formation hardnesses.
  • embodiments disclosed herein relate to a drill bit having a bit body with a longitudinal axis extending there through and a bit face.
  • a plurality of blades extends from the bit body, wherein the plurality of blades has a blade profile including a nose.
  • a plurality of cutting elements are disposed on the plurality of blades, including a plurality of non-planar cutting elements and a plurality of rotatable cutting elements, wherein the plurality of non-planar cutting elements are disposed in a non-planar cutting element region on at least one of the blades between the longitudinal axis and the nose
  • embodiments disclosed herein relate to a downhole cutting tool having a tool body with a longitudinal axis extending there through and a cutting end.
  • a plurality of blades extends azimuthally from the tool body, and a plurality of cutting elements is disposed on the plurality of blades.
  • the plurality of cutting elements include at least one rotatable cutting element and at least one non-planar cutting element, wherein the at least one non-planar cutting element is in a non-planar cutting element region of the blades closest to the cutting end.
  • FIG. 1 shows a prior art drill bit.
  • FIG. 2 shows a top view of a prior art drill bit.
  • FIG. 3 shows a cross-sectional view of a prior art drill bit.
  • FIG. 4 shows a top view of a drill bit according to embodiments of the present disclosure.
  • FIG. 5 shows a cutting profile according to embodiments of the present disclosure.
  • FIG. 6 shows a conical cutting element according to embodiments of the present disclosure.
  • FIG. 7 shows a conical cutting element according to embodiments of the present disclosure.
  • FIG. 8 shows a conical cutting element according to embodiments of the present disclosure.
  • FIG. 9 shows cutting elements according to one embodiment of the present disclosure.
  • FIG. 10 shows rotatable cutting elements according to embodiments of the present disclosure.
  • FIG. 11 shows conical cutting elements according to embodiments of the present disclosure.
  • FIG. 12 shows a conical cutting element according to embodiments of the present disclosure.
  • FIG. 13 shows a side view of a bi-center bit according to embodiments of the present disclosure.
  • FIG. 14 shows a cutting profile of a bi-center bit according to embodiments of the present disclosure.
  • FIG. 15A-15B show a side view and cross-sectional view of a conical cutting element.
  • FIG. 16A-16B show a side view and a cross-sectional view of a pointed cutting element having a convex side surface.
  • FIG. 17 shows a cross-sectional view of a pointed cutting element having a concave side surface
  • embodiments disclosed herein relate to drill bits or other downhole cutting tools containing multiple types of cutting structures.
  • embodiments disclosed herein relate to cutting tools containing two or more types of cutting elements, each type having a different mode of cutting action against a formation.
  • Other embodiments disclosed herein relate to drill bits containing fixed cutting elements having a non-planar cutting end and rotatable cutting elements, including the placement of such cutting elements on a bit and variations on the cutting elements that may be used to optimize drilling.
  • non-planar cutting elements refers to cutting elements having a non-planar cutting end and may also be referred to as shaped cutting elements.
  • the shape of the non-planar cutting end may include any geometric shape in which the portion of the cutting element that engages with the formation is not planar.
  • a conventional cutter engages at the circumferential edge of the cylindrical compact and as the cutter cuts or digs into the formation, a portion of the planar cutting face engages with the formation.
  • Such cutters may also generally include a beveled or chamfered edge; however a substantial majority of the surface area of the cutting face is planar.
  • such shapes are not within the scope of the "non-planar cutting elements" as that term is defined herein.
  • a non-planar cutting element possesses a height extension above the transition from the cylindrical side surface and the cutting end, and a substantial majority of the cutting end is non-planar.
  • Such shapes may include generally pointed cutting elements and domed cutting elements.
  • Generally pointed cutting elements may have generally pointed cutting end, i.e. , having terminating in an apex, with a conical, convex, or concave side surfaces, shown in FIGS. 15-17.
  • cutting elements will generically refer to any type of cutting element, while “cutter” will refer those cutting elements with a planar cutting face, as described above in reference to FIGS. 1 and 2, and “non-planar cutting element” will refer to those cutting elements having a non-planar cutting end.
  • the term "conical cutting elements” refers to cutting elements having a generally conical cutting end 62 (including either right cones or oblique cones), i.e., a conical side wall 64 that terminates in a rounded apex 66, as shown in FIGS. 15A- 15B.
  • the conical cutting elements of the present disclosure possess an apex having curvature between the side surfaces and the apex.
  • a bullet cutting element 70 may be used.
  • the term "bullet cutting element” refers to cutting element having, instead of a generally conical side surface, a generally convex side surface 78 terminated in a rounded apex 76, as shown in FIGS. 16A-16B.
  • the apex 76 has a substantially smaller radius of curvature than the convex side surface 78.
  • the non-planar cutting elements of the present disclosure may also include other shapes, including, for example, a concave side surface terminating in a rounded apex, shown in FIG. 17.
  • the non-planar cutting elements may have a smooth transition between the side surface and the rounded apex (i.e., the side surface or side wall tangentially joins the curvature of the apex), but in some embodiments, a non-smooth transition may be present (i.e., the tangent of the side surface intersects the tangent of the apex at a non-180 degree angle, such as for example ranging from about 120 to less than 180 degrees).
  • the non-planar cutting elements may include any shape having an cutting end extending above a grip or base region, where the cutting end extends a height that is at least 0.25 times the diameter of the cutting element, or at least 0.3, 0.4, 0.5 or 0.6 times the diameter in one or more other embodiments.
  • conical cutting elements 128 may have a diamond layer 132 on a substrate 134 (such as a cemented tungsten carbide substrate), where the diamond layer 132 forms a conical diamond working surface.
  • a substrate 134 such as a cemented tungsten carbide substrate
  • conical cutting elements may be made of other materials, as it is their shape and not material that defines conical cutting elements.
  • the conical geometry may comprise a side wall that tangentially joins the curvature of the apex.
  • Conical cutting elements 128 may be formed in a process similar to that used in forming diamond enhanced inserts (used in roller cone bits) or by brazing of components together.
  • the interface (not shown separately) between diamond layer 132 and substrate 134 may be non-planar or non-uniform, for example, to aid in reducing incidents of delamination of the diamond layer 132 from substrate 134 when in operation and to improve the strength and impact resistance of the element.
  • the interface may include one or more convex or concave portions, as known in the art of non-planar interfaces. Additionally, one skilled in the art would appreciate that use of some non-planar interfaces may allow for greater thickness in the diamond layer in the tip region of the layer. Further, it may be desirable to create the interface geometry such that the diamond layer is thickest at a critical zone that encompasses the primary contact zone between the diamond enhanced element and the formation.
  • the diamond layer 132 may be formed from any polycrystalline superabrasive material, including, for example, polycrystalline diamond, polycrystalline cubic boron nitride, thermally stable polycrystalline diamond (formed either by treatment of polycrystalline diamond formed from a metal such as cobalt or polycrystalline diamond formed with a metal having a lower coefficient of thermal expansion than cobalt).
  • the apex of the conical cutting element may have curvature, including a radius of curvature.
  • the radius of curvature may range from about 0.050 to 0.125.
  • Such curvature may also be present in the types of cutting elements illustrated in FIGS. 16 and 17.
  • the curvature may comprise a variable radius of curvature, a portion of a parabola, a portion of a hyperbola, a portion of a catenary, or a parametric spline.
  • the cone angle 130 of the conical end may vary, and be selected based on the particular formation to be drilled.
  • the cone angle 130 may range from about 75 to 90 degrees.
  • an asymmetrical or oblique conical cutting element is shown. As shown in FIG. 8, the cutting conical cutting end portion 135 of the conical cutting element 128 has an axis that is not coaxial with the axis of the substrate 134. In a particular embodiment, at least one asymmetrical conical cutting element may be used on any of the described drill bits or reamers. Selection of an asymmetrical conical cutting element may be selected to better align a normal or reactive force on the cutting element from the formation with the cutting tip axis or to alter the aggressiveness of the conical cutting element with respect to the formation.
  • the angle 131 formed between the cutting end or cone axis and the axis of the substrate may range from 37.5 to 45, with an angle on a trailing side of the cutting element being greater, by 5-20 degrees more than a leading angle (measured from the leading side of the cutting element).
  • non-planar cutting elements of the present disclosure may be attached to a bit or other downhole cutting tool by methods known in the art, such as brazing, or may be rotatably retained on the downhole tool.
  • a non-planar cutting element may be rotatably retained on a downhole tool by one or more retention mechanisms, such as by retention balls, springs, pins, etc.
  • a non-planar cutting element may be rotatably retained in a pocket formed in a blade of a downhole tool, such as drill bit or reamer, using a plurality of retention balls disposed between corresponding grooves formed around the outer side surface of the conical cutting element body and the inner side surface of a sleeve, which is attached to the pocket.
  • a non-planar cutting element may be rotatably retained in a pocket formed in a blade of a downhole tool using changes in the non-planar cutting element body's diameter.
  • a non-planar cutting element body or substrate may have a first diameter proximate to the non-planar cutting end and a second diameter axially distant from the non-planar cutting end, wherein the second diameter is larger than the first diameter.
  • a sleeve surrounding the non-planar cutting element body (which may be attached to a pocket) or the pocket may have a first inner diameter corresponding with the first diameter of the non-planar cutting element.
  • non-planar cutting elements of the present disclosure may be rotatably retained on a downhole cutting tool, such as a drill bit or reamer
  • a downhole cutting tool such as a drill bit or reamer
  • non- planar cutting elements which refers to cutting elements having a non-planar cutting end
  • rotatable cutting elements which may similarly be rotatably retained on a downhole cutting tool, but do not have non-planar cutting ends.
  • rotatable cutting elements generally refers to cutting elements having at least one surface or portion of the cutting element rotate as it contacts a formation. As the rotatable cutting element contacts the formation, the cutting action may allow a portion of the cutting element to rotate around a cutting element axis extending through the cutting element. Rotation of at least a portion of the rotatable cutting element may allow for a cutting surface to cut the formation using the entire outer edge of the cutting surface rather than the same section of the outer edge, as observed in a conventional fixed cutting element. Rotatable cutting elements of the present disclosure may include various types and sizes of rotatable cutting elements.
  • rotatable cutting elements may be formed in sizes including, but not limited to, 9 mm, 13 mm, 16 mm and 19 mm. Further, rotatable cutting elements may include those held within an outer support element, held by a retention mechanism or blocker, or a combination of the two.
  • rotatable cutting elements examples include an inner rotatable cutting element disposed within an outer shell or within a cutter pocket and a retention mechanism.
  • the rotation of the inner rotatable cutting element may be controlled by the side cutting force and the frictional force between the bearing surfaces. If the side cutting force generates a torque which can overcome the torque from the frictional force, the rotatable portion will have rotating motion.
  • the side cutting force may be affected by cutter side rake, back rake and geometry, including the working surface patterns disclosed herein. Additionally, the side cutting force may be affected by the surface finishing of the surfaces of the cutting element components, the frictional properties of the formation, as well as drilling parameters, such as depth of cut. The frictional force at the bearing surfaces may affected, for example, by surface finishing, mud intrusion, etc.
  • the design of the rotatable cutting elements disclosed herein may be selected to ensure that the side cutting force overcomes the frictional force to allow for rotation of the rotatable portion.
  • Various design considerations of the present disclosure are described below, as well as exemplary embodiments of rotatable cutting elements. However, the present disclosure is not so limited.
  • a downhole cutting tool may have a tool body with a longitudinal axis extending there through and a cutting face.
  • a plurality of blades may extend azimuthally from the tool body, and a plurality of cutting elements, including at least one rotatable cutting element and at least one conical cutting element, may be disposed on the plurality of blades.
  • the conical cutting elements may be disposed on the blades in regions experiencing high impact during drilling operations, while the rotatable cutting elements may be disposed on the blades in regions experiencing high wear.
  • a plurality of conical cutting elements may be disposed on one or more blades in a region of the blade closest to the cutting face, and a plurality of rotatable cutting elements may be disposed in the remaining region of the blades.
  • a plurality of conical cutting elements may be disposed on one or more blades in a region of the blade closest to the longitudinal axis, or center line of the bit, and along the cutting face, and a plurality of rotatable cutting elements may be disposed in a region of each blade adjacent the conical cutting element region.
  • a conical cutting element region refers to an area having conical cutting elements disposed therein and a rotatable cutting element region refers to an area having rotatable cutting elements disposed therein.
  • FIG. 4 shows non-planar cutting elements (specifically conical cutting elements, but other types may be used in one or more other embodiments) and rotatable cutting element placement on a drill bit according to an embodiment of the present disclosure.
  • a drill bit 400 has a bit body 402 with a longitudinal axis 405 extending there through and a bit face 404.
  • a plurality of blades 410 extends radially along the bit face 404 from the longitudinal axis and axially along the bit body 402 from the bit face 404.
  • the bit shown in FIG. 4 has a plurality of primary blades 417 and a plurality of secondary blades 418, wherein the primary blades 417 extend from a point closer to the longitudinal axis than the secondary blades 418.
  • a plurality of conical cutting elements 420 and a plurality of rotatable cutting elements 430 are disposed on the blades 410.
  • the conical cutting elements 420 are disposed on at least one blade 410 in a region of the blade 410 closest to the longitudinal axis 405 and the rotatable cutting elements 430 are disposed in the remaining region of the blades 410.
  • the conical cutting element region extends a radial distance 411 from the longitudinal axis 405 around the bit face 404, and the rotatable cutting element region extends a distance along the bit body 402 from the conical cutting element region.
  • a blade of a cutting tool may include a single type of cutting element or may include more than one type of cutting element.
  • primary blades 417 have two types of cutting elements, including a plurality of conical cutting elements 420 and a plurality of rotatable cutting elements 430, while secondary blades 418 have one type of cutting element, a plurality of rotatable cutting elements 430.
  • the present disclosure is not necessarily so limited.
  • a blade may include only conical cutting elements.
  • a blade may include more than two types of cutting elements, such as a combination of conical cutting elements, rotatable cutting elements and fixed cutters, which may be placed in the gage region of a drill bit, for example.
  • the conical cutting elements 420 are disposed only on the primary blades 417, wherein the radial distance of the conical cutting element region does not overlap the secondary blades 418, as in rotated profile view.
  • conical cutting elements may be disposed only on select blades to form a conical cutting element region that extends a radial distance overlapping with blades without conical cutting elements.
  • conical cutting elements may be disposed on all blades of a cutting tool. In such embodiments, the conical cutting element regions formed on each blade may be equally positioned radially, such that the conical cutting element region on each blade occupies the same area, as in a rotated profile view.
  • the conical cutting element regions formed on each blade may be positioned differently and/or extend different radial distances, such that the conical cutting element regions occupy different areas, as in a rotated profile view.
  • a conical cutting element region and a rotatable cutting element region according to embodiments of the present disclosure are shown in a rotated profile view in FIG. 5.
  • a profile of a bit 500 is shown as it would appear with all blades 510 and cutting faces of all cutting elements rotated into a single rotated profile 512.
  • the blade tops of all blades 510 of a bit 500 form and define a combined or composite blade profile 512 that extends radially from the longitudinal axis 505 to the outer radius of the bit 500 and axially along the longitudinal axis 505.
  • the blade profile 512 has a nose 514, located at the axially uppermost point of the blade profile 512.
  • a plurality of conical cutting elements 520 is disposed in a region 525 of the blades 510 between the longitudinal axis 505 and the nose 514, wherein the conical cutting element region 525 extends a radial distance from the longitudinal axis 505.
  • a plurality of rotatable cutting elements 530 is disposed in a region 535 of the blades adjacent to the conical cutting element region 525, wherein the rotatable cutting element region 535 extends a distance from the conical cutting element region 525 along the bit body.
  • the rotatable cutting element region 535 may extend from the conical cutting element region 525 and the remaining distance of the blades, and in other embodiments, the rotatable cutting element region 535 may extend a distance from the conical cutting element region 525 and less than the remaining distance of the blades.
  • a non-planar cutting element region may extend the entire distance from the longitudinal axis to the nose.
  • the nose of the profile portion which is substantially tangential to a plane that is perpendicular to the bit axis.
  • a non-planar cutting element region may extend a partial distance positioned between the longitudinal axis and the nose, such as the non-planar cutting element region 525 shown in FIG. 5.
  • a non-planar cutting element region may extend from a position offset from the longitudinal axis to the nose, from a position offset from the longitudinal axis to a distance radially inward from the nose, or from the longitudinal axis to a distance radially inward from the nose.
  • a non-planar cutting element region may extend various radial distances at various positions within the area of a bit face between the longitudinal axis and the nose.
  • center coring element 524 may be included as a center coring element 524.
  • a coring element is attached directly to the bit body in a cavity formed between the blades instead of to a blade (as conical cutting elements 520 and rotatable cutting elements are attached).
  • the center non-planar coring element 524 may be set to have its apex lower than the cutting edge of the first radial cutting element 522 (whether it is a non-planar cutting element or other type of cutting element).
  • the apex of conical coring element may be at a height less than the cutting edge of the first radial cutting element, ranging from 0 to 1 inch in some embodiments, from 0.1 inches up to (0.35*bit diameter) in other embodiments, or up to (0.1 *bit diameter).
  • the conical coring element may have a cone angle ranging from 60 to 120 in some embodiments, or from 80 to 90 in yet other embodiments.
  • the diameter of the conical coring element may range from 0.25 to 1.5 inches and from 0.3 to 0.7 inches in other embodiment.
  • the ratio of the height offset from the cutting edge to the diameter of the conical cutting element may range from about 0.1 to 6 or from about 0.5 to 3 in other embodiments
  • the diameter of a central core or cavity in which the conical coring element is disposed i.e., the region between the plurality of blades
  • the diameter of a central core or cavity in which the conical coring element is disposed may be up to 3 times the diameter of the non- planar coring element. Coring elements are also described in U.S. Application No. 13/528,518, which is assigned to the present assignee and herein incorporated by reference in its entirety.
  • a non-planar coring element may be disposed on a bit centerline or adjacent a bit centerline, i. e. , spaced from 0 to up to the value of the radius of the non-planar coring insert (for symmetrical inserts).
  • the present disclosure also includes the use of asymmetrical non-planar coring inserts (similar to the geometry shown in FIG. 8), in which case the distance from the bit centerline may range from zero to up to the sum of the radius of the non-planar coring insert plus the offset between the apex of the conical cutting end and the insert centerline. Further, while the embodiment shown in FIG.
  • the non-planar coring element 524 being inserted so that its axis is coaxial with or parallel with a bit longitudinal axis 505, it is also within the scope of the present disclosure that the centerline of the coring non-planar insert is angled with respect to the bit longitudinal axis. Such angled insertion may be useful when using an asymmetrical non-planar coring insert. Further, the non-planar coring insert may be inserted into a hole in the center region of a bit such that the upper extent of the cylindrical base 526 of the non-planar coring element 524 is ⁇ 0.1 inches from the bit surface, and is preferably flush with the bit surface in various embodiments.
  • the first radial cutting element 522 may be a conical cutting element.
  • Such conical cutting elements may have a rounded apex having a radius of curvature ranging from 0.010 to 0.125 inches in particular embodiments.
  • the radius of curvature of the conical cutting element at the first radial position may range from a lower limit of any of 0.01 , 0.02, 0.04, 0.05, 0.06, or 0.075 inches, and an upper limit of any of 0.05, 0.06, 0.075, 0.085, 0.10, or 0.0125 inches, where any lower limit may be used in combination with any upper limit.
  • particular embodiments may use an asymmetrical or oblique cutting element, as shown in FIG.
  • a conical cutting end portion 135 of the conical cutting element 128 has an axis that is not coaxial with the axis of the substrate 134.
  • the angle may range from 0 to 45 degrees. In other embodiments, the angle may be greater than 0 degrees.
  • the angle may range from a lower limit of any of greater than 0, 2, 5, 10, 15, 20, or 30 degrees to an upper limit of any of 15, 20, 25, 30, 35, 40, or 45 degrees, where any lower limit may be used in combination with any upper limit. Placement of a conical cutting element in such a radial location may allow for weakening of the core strength of the rock core formed in the center region of the bit by allowing for the conical cutting element to create a score therein.
  • rotatable cutting elements 930 in combination with non-planar cutting elements 920 may allow for a single bit to possess two types of cutting action (represented by dashed lines): cutting by compressive fracture or gouging of the formation by non-planar cutting elements 920 in addition to cutting by shearing the formation by rotatable cutting elements 930, as shown in the schematics in FIG. 9.
  • the rotatable cutting elements when positioning rotatable cutting elements on a blade of a downhole cutting tool such as a bit or reamer, the rotatable cutting elements may be inserted into cutter pockets (or holes in the case of non-planar cutting elements) to change the angle at which the cutter strikes the formation.
  • the back rake i.e. , a vertical orientation
  • the side rake i.e., a lateral orientation
  • back rake is defined as the angle 150 formed between the cutting face of the rotatable cutting element 142 and a line that is normal to the formation material being cut. As shown in FIG.
  • the cutting face 44 is substantially perpendicular or normal to the formation material.
  • a cutter 142 having negative back rake angle 150 has a cutting face 44 that engages the formation material at an angle that is less than 90° as measured from the formation material.
  • a rotatable cutting element having a positive back rake angle has a cutting face that engages the formation material at an angle that is greater than 90° when measured from the formation material.
  • the rotatable cutting elements may have a negative back rack of >5 degrees, >10 degrees, >15 degrees, >20 degrees, >25 degrees, >30 degrees, and/or ⁇ 10 degrees, ⁇ 15 degrees, ⁇ 20 degrees, ⁇ 25, ⁇ 30 degrees, ⁇ 35 degrees, with any upper limit being used with any lower limit.
  • a rotatable cutting element may have a side rake ranging from 0 to ⁇ 45 degrees, for example 5 to ⁇ 35 degrees, 10 to ⁇ 35 degrees or 15 to ⁇ 30 degrees.
  • the direction (positive or negative) of the side rake may be selected based on the cutting element distribution, i.e., whether the rotatable cutting elements are arranged in a forward or reverse spiral configuration.
  • the side rake may be selected based on the location of the cutting element along the blade, such as in the cone region, shoulder region, nose region, etc.
  • each rotatable cutting element placed in the nose and/or shoulder region of the bit may have a side rake ranging from 10 to 30 degrees or -10 to 30 degrees.
  • each rotatable cutting element placed in the nose and/or shoulder region of the bit may have a side rake ranging from 20 to 30 degrees or -20 to -30 degrees.
  • rotatable cutting elements radially outside the shoulder, i.e., in the gage region may range from 5 to 35 degrees or -5 to -35 degrees.
  • rotatable cutting elements in the gage region may be >5 degrees, >10 degrees, >15 degrees, >20 degrees, >25 degrees, >30 degrees, and/or ⁇ 10 degrees, ⁇ 15 degrees, ⁇ 20 degrees, ⁇ 25, ⁇ 30 degrees, ⁇ 35 degrees, with any of such angles being positive or negative, and any upper limit being used with any lower limit.
  • rotatable cutting elements may be placed in the cone region of the bit may have a side rake of less than 20 degrees or ranging from 10 to 15 degrees in more particular embodiments.
  • cutting elements may be either fixedly attached or may be rolling, but may have such side rake range if fixed or rolling.
  • any of the side rake angles for any region may be used in singly or in combination with any of the other ranges for other regions.
  • non-planar cutting elements do not have a cutting face and thus the orientation of non-planar cutting elements must be defined differently.
  • the non-planar geometry of the cutting end also affects how and the angle at which the non-planar cutting element strikes the formation.
  • back rake is defined as the angle 150 formed between the axis of the conical cutting element 144 (specifically, the axis of the conical cutting end) and a line that is normal to the formation material being cut.
  • the axis of the conical cutting element 144 is substantially perpendicular or normal to the formation material.
  • a conical cutting element 144 having negative back rake angle 150 has an axis that engages the formation material at an angle that is less than 90° as measured from the formation material.
  • a conical cutting element 144 having a positive back rake angle 150 has an axis that engages the formation material at an angle that is greater than 90° when measured from the formation material.
  • Such orientation may be used to describe the back rake of all non-planar cutting elements.
  • the back rake angle of the non-planar cutting elements may be zero, or in another embodiment may be negative or positive.
  • the back rake of the non-planar cutting elements may range from -35 to 35, from -10 to 10 in other embodiments, from zero to 10 in yet other embodiments, and from -5 to 5 in yet other embodiments.
  • the back rake angles of non-planar cutting elements used in embodiments disclosed herein may be selected from one or a combination of back rake angles within these ranges.
  • the aggressiveness of the non-planar cutting elements may also be dependent on the apex angle or specifically, the angle between the formation and the leading portion of the non- planar cutting element.
  • the leading line of a conical cutting surface may be determined to be the firstmost points of the conical cutting element at each axial point along the conical cutting end surface as the bit rotates. Said in another way, a cross-section may be taken of a conical cutting element along a plane in the direction of the rotation of the bit, as shown in FIG. 12. The leading line 145 of the conical cutting element 144 in such plane may be considered in relation to the formation.
  • the strike angle of a conical cutting element 144 is defined to be the angle 155 formed between the leading line 145 of the conical cutting element 144 and the formation being cut.
  • strike angle 155 may range from about 5 to 100 degrees, and from about 20 to 65 in other embodiments. Further, the strike angles of the conical cutting elements (or other non-planar cutting element) in embodiments disclosed herein may be selected from these ranges.
  • a downhole cutting tool may have a tool body with a longitudinal axis extending there through and a cutting end.
  • the cutting end of a downhole tool refers to the longitudinal end of the tool that contacts and cuts the bottom of a wellbore, while a connection end is opposite from the cutting end and closest to the drill string that connects the tool to above ground equipment.
  • a plurality of blades may extend azimuthally from the tool body, and a plurality of cutting elements may be disposed on the plurality of blades.
  • the cutting elements include at least one rotatable cutting element and at least one non-planar cutting element, wherein the at least one non-planar cutting element is in a region of the blades closest to the cutting end.
  • the non-planar cutting elements may be conical cutting elements or other pointed cutting elements.
  • the downhole cutting tool may be a bi- centered bit having a tool body with a pilot section at the cutting end of the tool and a reamer section longitudinally offset from the pilot section.
  • a plurality of pilot blades may extend from the pilot section of the tool body, and a plurality of reamer blades may extend from the reamer section of the tool body.
  • FIG. 13 shows a side view of a bi-center bit according to embodiments of the present disclosure.
  • the bi- center bit 101 includes a pilot section 106 having pilot blades 108 extending therefrom and gauge pads 112 at the ends of the pilot blades 108 axially distant from the cutting end 103 of the bit 101.
  • a reamer section 107 having reaming blades 111 extending therefrom and gauge pads 117 is longitudinally offset from the pilot section 106.
  • the pilot section 106 is separated from the reamer section 107 by a longitudinal distance, which may include a spacer 102.
  • other bi-center bits may have a pilot section adjacent to the reamer section.
  • Disposed on the pilot blades 108 and reamer blades 1 1 1 are a plurality of non-planar cutting elements (conical cutting elements in the embodiment shown) 1 16 and a plurality of rotatable cutting elements 110.
  • the bi-center bit 101 has a body 114 and a threaded connection end 104 opposite from the cutting end 103.
  • the body 114 may include wrench flats 115 or the like for make up to a rotary power source such as a drill pipe or hydraulic motor.
  • At least one non-planar cutting element may be disposed on the pilot blades and/or the reamer blades, and at least one rotatable cutting element may be disposed on the pilot blades and/or the reamer blades.
  • FIG. 14 shows a rotated profile view of a bi-center bit 201 according to embodiments of the present disclosure.
  • the bit 201 has a pilot section 206 having a plurality of pilot blades 208 extending therefrom and a reamer section 207 having a plurality of reamer blades 21 1 extending therefrom.
  • a non-planar cutting element region 216 (an area of the cutting tool having non-planar cutting elements) may extend from the longitudinal axis of the bit 201 a distance along the bit face of the pilot section 206, and a rotatable cutting element region 210 (an area of the cutting tool having rotatable cutting elements) may extend the remaining distance along the pilot blades 208 of the pilot section 206. Additionally, as shown, a non-planar cutting element region 216 may extend from an area of the reamer blades 211 closest to the pilot section 206 a distance along the reamer blades 211, and a rotatable cutting element region 210 may extend the remaining distance of the reamer blades 211.
  • a non-planar cutting element region may extend the entire distance of the pilot blades 208, and a rotatable cutting element region may extend the entire distance of the reamer blades 211.
  • Other combinations of non- planar cutting element regions and rotatable cutting element regions, such as described with reference to the drag bits of FIGS. 4 and 5, may be used on the pilot section of a bi- centered bit.
  • various combinations of one or more non-planar cutting element regions and one or more rotatable cutting element regions may be used on the reamer section of a bit-centered bit.
  • at least one non-planar cutting element may be disposed on the reamer blades in a non-planar cutting element region closest to the cutting end of the tool, and at least one rotatable cutting element may be disposed in a rotatable cutting element region adjacent to the non-planar cutting element region.
  • At least one non-planar cutting element may be disposed on the reamer blades in a non- planar cutting element region closest to a connection end of the tool, and at least one rotatable cutting element may be disposed in a rotatable cutting element region closest to the cutting end of the tool.
  • non-planar cutting element regions may be formed on one or more of the reamer blades. As described above with reference to FIG. 5, non- planar cutting element regions may overlap, be adjacent to, or occupy the same position of the reamer blades when viewed in a rotated profile view.
  • the downhole cutting tool may be a reamer having a tool body and a plurality of blades extending therefrom.
  • Various combinations of one or more non-planar cutting element regions and one or more rotatable cutting element regions, such as described in reference to the reamer section of a bi-centered bit, may be used on reamer cutting tools.
  • non-planar cutting elements may provide improved impact resistance required for hard and heterogeneous drilling
  • rotatable cutting elements may provide wear resistance in abrasive formations.
  • conical cutting elements may have four times the impact resistance of conventional PDC cutters
  • rotatable cutting elements may have improved wear resistance due to better heat dissipation than conventional PDC cutters.

Abstract

L'invention concerne un trépan, le trépan possédant un corps de trépan ayant un axe longitudinal s'étendant dans celui-ci et une face de trépan. Une pluralité de lames s'étendent depuis le corps de trépan, la pluralité de lames ayant un profil de lame comprenant un nez. Une pluralité d'éléments coupants sont disposés sur la pluralité de lames, comprenant une pluralité d'éléments coupants non plans et une pluralité d'éléments coupants rotatifs, la pluralité d'éléments coupants non plans étant disposés dans une région d'élément coupant non plan sur au moins une des lames entre l'axe longitudinal et le nez.
PCT/US2013/050509 2012-08-17 2013-07-15 Outils coupants de fond de trou présentant des structures coupantes hybrides WO2014028152A1 (fr)

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CN201380046979.XA CN104619946A (zh) 2012-08-17 2013-07-15 具有混合切割结构的井下切割工具

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US201261684412P 2012-08-17 2012-08-17
US61/684,412 2012-08-17
US13/836,172 2013-03-15
US13/836,172 US20140262536A1 (en) 2013-03-15 2013-03-15 Downhole cutting tools having hybrid cutting structures

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CN105464599A (zh) * 2015-07-24 2016-04-06 四川深远石油钻井工具股份有限公司 一种具有增强定向易控性的pdc钻头
CN116988739A (zh) * 2023-09-26 2023-11-03 西南石油大学 一种高密度纵向布齿pdc钻头

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US11008814B2 (en) * 2018-11-12 2021-05-18 Ulterra Drilling Technologies, Lp Drill bit

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US6412579B2 (en) * 1998-05-28 2002-07-02 Diamond Products International, Inc. Two stage drill bit
US20100276145A1 (en) * 2009-05-04 2010-11-04 Smith International, Inc. Milling system and method of milling
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CN116988739A (zh) * 2023-09-26 2023-11-03 西南石油大学 一种高密度纵向布齿pdc钻头
CN116988739B (zh) * 2023-09-26 2023-12-26 西南石油大学 一种高密度纵向布齿pdc钻头

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