WO2015148910A1 - Outils de coupe imprégnés de diamants contenant des fibres et leurs procédés de formation et d'utilisation - Google Patents
Outils de coupe imprégnés de diamants contenant des fibres et leurs procédés de formation et d'utilisation Download PDFInfo
- Publication number
- WO2015148910A1 WO2015148910A1 PCT/US2015/022965 US2015022965W WO2015148910A1 WO 2015148910 A1 WO2015148910 A1 WO 2015148910A1 US 2015022965 W US2015022965 W US 2015022965W WO 2015148910 A1 WO2015148910 A1 WO 2015148910A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cutting
- fibers
- cutting tool
- matrix
- steel
- Prior art date
Links
- 238000005520 cutting process Methods 0.000 title claims abstract description 175
- 239000000835 fiber Substances 0.000 title claims abstract description 123
- 238000000034 method Methods 0.000 title abstract description 17
- 239000010432 diamond Substances 0.000 claims abstract description 47
- 239000011159 matrix material Substances 0.000 claims abstract description 23
- 239000011230 binding agent Substances 0.000 claims abstract description 13
- 239000000919 ceramic Substances 0.000 claims abstract description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 5
- 239000011521 glass Substances 0.000 claims abstract description 4
- 229910003460 diamond Inorganic materials 0.000 claims description 41
- 238000005070 sampling Methods 0.000 claims description 19
- 229910052751 metal Inorganic materials 0.000 claims description 18
- 239000002184 metal Substances 0.000 claims description 18
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 16
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 14
- 229910045601 alloy Inorganic materials 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 239000011236 particulate material Substances 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 239000010941 cobalt Substances 0.000 claims description 11
- 229910017052 cobalt Inorganic materials 0.000 claims description 11
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 11
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 10
- 229910052721 tungsten Inorganic materials 0.000 claims description 10
- 239000010937 tungsten Substances 0.000 claims description 10
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 9
- 239000011733 molybdenum Substances 0.000 claims description 9
- 229910052750 molybdenum Inorganic materials 0.000 claims description 9
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 8
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 8
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 239000013078 crystal Substances 0.000 claims description 6
- 239000010936 titanium Substances 0.000 claims description 6
- 229910052719 titanium Inorganic materials 0.000 claims description 6
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 5
- 229910052725 zinc Inorganic materials 0.000 claims description 5
- 239000011701 zinc Substances 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- -1 stainless stee! Inorganic materials 0.000 claims description 4
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- 239000010962 carbon steel Substances 0.000 claims description 3
- 229910052718 tin Inorganic materials 0.000 claims description 3
- 229910001149 41xx steel Inorganic materials 0.000 claims description 2
- 229910001018 Cast iron Inorganic materials 0.000 claims description 2
- 229910000599 Cr alloy Inorganic materials 0.000 claims description 2
- 229910001021 Ferroalloy Inorganic materials 0.000 claims description 2
- 229910000997 High-speed steel Inorganic materials 0.000 claims description 2
- 229910000805 Pig iron Inorganic materials 0.000 claims description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 2
- 229910001315 Tool steel Inorganic materials 0.000 claims description 2
- 229910052709 silver Inorganic materials 0.000 claims description 2
- 239000004332 silver Substances 0.000 claims description 2
- 239000011135 tin Substances 0.000 claims description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims 2
- 229910000677 High-carbon steel Inorganic materials 0.000 claims 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 claims 1
- 229910000954 Medium-carbon steel Inorganic materials 0.000 claims 1
- 230000003628 erosive effect Effects 0.000 abstract description 7
- 229920000642 polymer Polymers 0.000 abstract description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 36
- 238000000576 coating method Methods 0.000 description 19
- 239000011248 coating agent Substances 0.000 description 16
- 239000011324 bead Substances 0.000 description 15
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 10
- 230000015572 biosynthetic process Effects 0.000 description 9
- 238000005755 formation reaction Methods 0.000 description 9
- 230000008901 benefit Effects 0.000 description 7
- 238000005553 drilling Methods 0.000 description 7
- 229920000049 Carbon (fiber) Polymers 0.000 description 6
- 239000004917 carbon fiber Substances 0.000 description 6
- 239000012255 powdered metal Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 238000000227 grinding Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229910000851 Alloy steel Inorganic materials 0.000 description 3
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 3
- 230000009471 action Effects 0.000 description 3
- 238000005461 lubrication Methods 0.000 description 3
- 239000011572 manganese Substances 0.000 description 3
- 229910052748 manganese Inorganic materials 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- 229910000531 Co alloy Inorganic materials 0.000 description 2
- 229910000914 Mn alloy Inorganic materials 0.000 description 2
- 229910000990 Ni alloy Inorganic materials 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000010438 granite Substances 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 229910000570 Cupronickel Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910001128 Sn alloy Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 235000012216 bentonite Nutrition 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 239000000788 chromium alloy Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000001033 ether group Chemical group 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000011010 flushing procedure Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 230000001012 protector Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
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
- E21B10/48—Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of core type
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
- B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
- B24D3/10—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/04—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with circular or cylindrical saw-blades or saw-discs
- B28D1/041—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with circular or cylindrical saw-blades or saw-discs with cylinder saws, e.g. trepanning; saw cylinders, e.g. having their cutting rim equipped with abrasive particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/08—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with saw-blades of endless cutter-type, e.g. chain saws, i.e. saw chains, strap saws
Definitions
- This application relates generally to cutting tools and their methods of use.
- this application relates to diamond -impregnated cutting tools that may contain fibers.
- Cutting tools can be impregnated with diamonds so that they can be used to grind, polish, or otherwise cut a variety of materials that normal cutting tools cannot.
- the part of these tools that performs the cutting action (or the cutting portion of the too!) is generally formed of a matrix that contains a powdered metal or a hard particulate material, such as tungsten carbide. This material is sometimes infiltrated with a binder, such as a copper alloy. Fina lly, the cutting portion of these tools is impregnated with diamond crystals or some other form of abrasive cutting media.
- the cutting portion of the tool erodes and exposes new layers of the diamond crystal (or other cutting media) so that a sharp surface is always available for the cutting process. Any diamond-impregnated cutting tool may continue to cut efficiently until the diamond impregnated portion of the tool is completely consumed. At that point, the tool becomes dull and must be replaced with another one.
- diamond-impregnated cutting tools may be expensive and their replacement may be time consuming, costly, as well as dangerous.
- the replacement of a diamond-impregnated core sampling drill bit requires removing (or tripping out) the entire drill string out of the hole that has been drilled (the borehole). Each section of the drill rod must be sequentially removed from tne borehole. Once the drill bit is replaced, the entire drill string must be assembled section by section and then tripped back into the borehole. Depending on the depth of the hole and the characteristics of the materials be-ng drilled, this process may need to be repeated multiple times for a single borehole.
- conventional diamond-impregnated cutting tools often have several characteristics that can add to the consumption rate of the cutting portion and, therefore, increase the operating costs associated with those cutting tools.
- the binder materials in the tools may be relatively soft in comparison to the cutting media. Accordingly, the cutting portion may erode and allow diamonds or other abrasive cutting materials to slough off prematurely.
- the erosion r te of the cutting portion can be increased by insufficient lubrication to and around the cutting face of the tool, or the interface between the cutting portion of the tool and the material being cut.
- conventional impregnated cutting tools may also be too wear resistant to expose and renew layers of the cutting portion.
- the cutting tools contain a diamond- impregnated cutting portion that may contain fibers made from carbon, glass, ceramic, polymer, and the like.
- the fibers can be in any form, including chopped and milled fibers.
- the fibers may also be coated with metal, ceramic, or other performance-enhancing coatings.
- the fibers may be used to both control the tensile strength control the erosion rate cf the matrix in the cutting portion to optimize the cutting performance of the tools.
- the fibers may also weaken the structure and allow higher modulus binders to be used for the cutting tools at a lower cost, ailowing the amount of fibers to be tailored to retain the diamonds in the cutting portion for the desired amount of time. And as the cutting portion erodes, the fibers may also increase tne lubricity at the face of the cutting portion. Using the fibers allows the cutting tools to last longer and make them safer and more economical because they need to be replaced less often.
- Figure 1 contains an exemplary view of s core sampling drill bit
- Figure 2 contains an exemplary view of a cross section of a diamond wire
- Figure 3 contains an exemplary view of a cross section of anoiher diamond wire
- Figure 4 contains an exemplary view of a cross section of an individual diamond w ' re bead.
- Ranges can be expressed herein as from “about” one particular value, and/or to
- the cutting tools described herein can be used to cut stone, subterranean mineral formations, ceramics, asphalt, concrete, and ether hard materials. These cutting tools may induce core sampling drill bits, drag-type drill bits, roller cone drill bits, diamond wire, grinding cups, diamond blades, tuck pointers, crack chasers, and the like.
- the cutting tools may be any type of earth drill bit (i.e., core sampling drill bit, drag drill bit, roller cone bit, navi-driii, full hole drill, hoie saw, hole opener, etc.), diamond saw blade (e.g., laser welded blade, concave diamond blade, segmented blade, continuous rim blade, wavy core blade, ventilated cere blade, etc.), grinding cup (e.g., single row cup, double row cup, grinding cup w ' th T-shaped segments, etc.), tuck pointer (e.g., triple row, etc.), crack chaser, polishing disk, and so forth.
- the cutting tools are core sampling drill bits and diamond wire.
- the part of the cutting tools that performs the cutting action contains a matrix with a powdered metal or a hard particulate material, such as tungsten carbide or any other super-atrasive material.
- This material can sometimes be infiltrated with a binder, such as a copper alloy or a substantial equivalent, and can be sintered to form a segment.
- the cutting portion of these tools can also be impregnated with diamonds, or some other form of abrasive cutting media, and mixed (and, in some embodiments, reinforced) with fibrous materials (or fibers) as described in detail in the embodiments where the cutting tool is a core sampling drill bit and a diamond wire.
- Figure 1 illustrates one example of a fiber-containing cutting tool, a fiber- containing (and, in some embodiments, fiber- reinforced) core sampling drill bit.
- the drill bit 20 contains a first section 21 that connects to the rest of the drill string.
- the drill bit 20 also contains a second section 22 that is used to cut the desired materials during the drilling process.
- Trie body of the drill bit 20 has an outer surface and an inner surface containing a noliow portion therein. With this configuration, pieces of the material being drilled can pass through the hollow portion, up ; nto a drill string to which the drill bit is connected, and then be collected.
- the drill bit 20 may be any size, and may therefore be used to collect core samples of any size. While the drill bit may have any circumference and may be used to remove and collect core samples with any desired diameter, the diameter generally ranges from about 2 to about 12 inches. As well, while the kerf of the drill bit (the radius of the outer surface minus the radius of the inner surface) may be any width, it generally ranges from about 1/2 of an inch to about 6 inches.
- the first section 21 of the driil bit may be made of any suitable material known in the art.
- the first section may be made of steel cr a matrix casting of a hard particulate material in a binder, in some embodiments, the first section 21 may contain a chuck end, sometimes called a blank, bit body, or shank, that may be used for any purpose, including connecting the drill bit to the nearest part of the driil string.
- the chuck end can be configured as known in the art to connect the drill bit 20 to any desired part of the driil string.
- the second section 22 of the core sampling drill bit 20 contains a cutting portion with cutting elements 12 having a cutting face 14.
- the cutting elements 12 have a space 16 between them so that, as known in the art, a drilling fluid following the path shown by the arrow may be used during drilling.
- the cutting portion of the cere sampling drill bit often called the crown, may be constructed of any material(s) known in the art.
- This type of drill bit (a core sampling bit) is generally formed of steel or a matrix of powdered metal, which is a hard particulate material, such as tungsten carbide, tungsten, iron, cobalt, and/or molybdenum.
- This material may then be infiltrated with a binder, such as a copper alloy, zinc, silver, molybdenum, nickel, cobalt, or a substantial equivalent, and/or may be sintered.
- a binder such as a copper alloy, zinc, silver, molybdenum, nickel, cobalt, or a substantial equivalent
- the cutting portion of the drill bit may also be impregnated with any form or combination of forms of cutting media, such as diamond crystals.
- the cutting media used may have any desired characteristic or grain, quality, grit, concentration, etc.
- the cutting media may be very small and substantially round in order to leave a smooth finish on the material being cut by the cere sampling drill bit. In other embodiments, the cutting media may be larger to cut aggressively into the material being cut.
- the cutting media may be contained homogeneously or
- the cutting media may be aligned in a particular maimer so that the cutting properties of the media are presented in an adva ntageous position with respect to ihe cutting portion of the drill bit.
- the cutting media may be contained in the drill bit in a variety of densities as desired for a particular use. For example, large abrasive particles spaced further apart may cut material more quickiy than small abrasive particles packed tightly together. But the size, density, and shape of the abrasive particles may be provided in a variety of combinations depending on desired cost and performance of the drill bit.
- the cutting portion of the drill bit may be made of one or more layers.
- the cutting portion may contain two layers: a matrix layer that performs the cutting operation and a backing layer, which connects the matrix layer to the first section of the drill bit.
- the matrix layer contains the actual cutting media that abrades and erodes the material being drilled. The portion of the matrix layer that comes in contact with the material being cut is known as the cutting face.
- a cutting tool comprises a fiber-containing (and, in some embodiments, a fiber-reinfcrced) diamond wire segments or beads.
- Diamond wire may be used to cut a variety of hard materials. For example, a relatively large diamond wire may be used to cut large blocks of granite cut of a granite formation in a quarry for further processing. However, in ether uses, a relatively small diamond wire may be used in a laboratory to cut a sample of a hard material for testing.
- a diamond wire is shown in Figure 2. In Figure 2, the diamond wires contain a core wire 2 made of any suitable strong material, such as steel, that may be coated with a cutting materia! coating 4.
- the coating 4 in such wires may act as the cutting portion of the diamond wire.
- the coating 4 may contain a binder (e.g., a copper alloy, iron, silicon carbide, etc.) and a base material that may be formed from steel or a matrix of powdered metal/hard particulate material (e.g., tungsten carbide, tungsten, iron, cobalt, molybdenum, etc.).
- the coating 4 may also be impregnated with any cutting media 8, such as diamond crystals.
- the cutting media 8 in the coating 4 may have any desired characteristic, including any size, shape, alignment, grain, quality, grit, concentration, disbursement s and so forth.
- the coating 4 of the diamond wire may be made of one or more layers, in such embodiments, each layer may be made of any desired material.
- the backing layer may contain an iron alloy and the bond between the matrix and backing layer is usually achieved with a copper alloy or braze alloy.
- Figure 3 illustrates another example of a f ber- containing diamond wire.
- the diamond wires may have abrasive beads that are applied to a core portions on the diamond wire.
- the abrasive beads may be formed from any suitable material.
- the abrasive beads may have a diamond matrix 27 formed of a base material, like powdered metal or a hard particulate material (e.g. , tungsten carbide, tungsten, cobalt, molybdenum, etc.).
- the base material may be infiltrated with a binding material (e.g., a copper alloy).
- the abrasive beads may be impregnated with any cutting media (e.g., diamond crystals) having any desired characteristic, including any size, shape, alignment, grain, quality, grit, concentration, disbursement, and the like.
- Figure 4 illustrates an individual diamond wire bead 26 that is used with the diamond wire shown in Figure 3.
- the bead 26 may be of any shape and size known in the art and may be applied to the core wire in any manner known in the art.
- the diamond wire in Figure 3, for example, may be made by manufactur i ng the bead 26 to contain a coating 34 with abrasive particles 38 and fibers 36 and a channel 32.
- the bead 26 may then be attached to a steel ferrule, which may be threaded ontc the core wire. Therefore, the beads 26 on the diamond wire may be manufactured separately from the core wire and then strung on the core wire with other beads to create the diamond wire.
- the diamond wires may also be any size and may therefore be used in any known process using diamond wire.
- the diamond wire in Figure 3 may range in length from about 5 meters to more than 100 meters and have beads 26 with a diameter of from about 4 millimeters to about 12 millimeters.
- the length can be about 30 centimeters long and the diameter of the core wire and cutting material coating can be about a few microns.
- the diamond wire can be longer or shorter than the lengths in the previous examples and may also have beads and a cable of eny desired diameter.
- the diamond-impregnated cutting tools-including the core sampling drill bits or diamond wires- may have any additional feature known in the art.
- a cere sampling drill bit may have additional gauge protection, hard-strip deposits, various bit profiles, and combinations thereof.
- Protector gauges on or in a drill bit may be included to reduce the damage to the drill bit and well casing as the drill bit cuts the formation.
- the core sampling drill bit may have hard-metal strips applied that may prevent the premature erosion of the support portion of the drill bit.
- the cutting portior.(s) of the diamond-impregnated cutting tools contain fibers. Any known fiber, or combination of fibeis, may be added to the cutting tool.
- the cutting portion of a diamond-impregnated cutting tool may include fibers such as carbon fibers, metal fibers (e.g., fibers made of tungsten, tungsten carbide, iron, molybdenum, cobalt, or combinations thereof), glass fibers, polymeric fibers ⁇ e.g. , fibers made of evlar), ceramic fibers (e.g., fibers made of silicon carbide), coated fibers, and/or the like.
- exemplary metal fibers can comprise steel alloys such as, without limitation, carbon steel (Iow/mild/high alloy), ferroalloys, cast iron alloys, pig iron alloys, chromoly steel alloys, high-speed steel alloys, stainless steel alloys, tool steel alloys, and the like.
- steel alloys such as, without limitation, carbon steel (Iow/mild/high alloy), ferroalloys, cast iron alloys, pig iron alloys, chromoly steel alloys, high-speed steel alloys, stainless steel alloys, tool steel alloys, and the like.
- the exemplary steel fiber can have a 0.1 mm diameter x 1.7mm length and can comprise medium carbon low-alloy steel.
- the exemplary steel fiber can be sized between about 0.004mm to about 15mrn in diameter and between about 0.05mm to about 75mm in length.
- the exemplary steel fiber can be sized between about C.008mm to about 10mm in diameter and bet'.veen about 0.1 mm to about 50mm >n length.
- the typical composition of the steel metal fiber can comprise at least cne or more of: Aluminum (between about 0.95% to about 1.3%); Bismuth (0.01% to about 0.15%); Carbon (between about 0.05% to about 2.1%); Chromium (between about G.5% to about 18.0%); Copper (between about 0.1 % to abo t 0.4%); Lead (0.01% to about C.
- the metal fibers can comprise one or more of alloys selected from titanium and titanium alloys, cobalt and cobalt alloys, nickel and nickel alloys, manganese and manganese alloys, chromium and chromium alloys, and the like.
- the coating materials described herein can comprise can comprise one or more of alloys selected from titanium and titanium alloys, cobalt and cobalt alloys, copoer and copper alloys, nickel and nickel alloys, manganese and manganese alloys, chromium and chromUm alloys, tin and tin alloys, tungsten and tunsgten alloys, and zinc and zinc alloys.
- the cutting portion of a diamond-impregnated cutting tool may contain any carbon fibers. Any known type of carbon fiber may be included in the cutting portion of a diamond-impregnated cutting tool.
- the fibers may optionally be coated with one or more additional matenai(s) before being included in the cutting tool
- Such coatings may be used for any performance-enhancing purpose.
- a fiber coating may be used to help retain fibers in the cutting tool.
- a fiber coating may be used to mcrease lubricity near the cutting face of a cutting tool as the fiber coating erodes away and forms a fine particulate material that acts to reduce friction.
- a fiber coatmg may act as an abrasive material and thereby be used to aid in the cutting process.
- any known material may be used to coat the type of fiber(s) that is used in the cutting tool.
- any desired metal, ceramic, polymer, glass, sizing, wetting agent, flux, or other substance could be used to coat a desired type of fiber(s) that may be included in a cutting tool.
- carbon fibers could be coated with a metal, such as iron, titanium, nickel, copper, molybdenum, lead, tungsten, aluminum, chromium, tungsten, copper, tin, zinc or combinations thereof.
- carbon fibers may be coated with a ceramic material, such as SiC, SiO, Si02, or the like.
- the coating material may cover any portion of the fibers and may be of any desired thickness. Accordingly, a coating material may be applied to the fibers in any manner known in the art. For example, the coating may be applied to fibers through spraying, brushing, electroplating, immersion, vapor deposition, or chemical vapor deposition.
- the fibers in the cutting portion of a diamond-impregnated cutting tool may be of ⁇ ny size or combination of sizes, including mixtures of different sizes.
- fibers may be of any length and have any desired diameter.
- the fibers may be approximately 10 to about 25,0C0 microns long and may have a diameter of approximately 1 to about 500 microns.
- the fibers may be approximately 150 microns in length and may have a diameter of approximately 7 microns.
- the fibers may be of any shape or combination of shapes.
- the fibers may be ribbon-like, cylindrical, polygonal, elliptical, straight, curved, curly, coiled, bent at angles, etc.
- Figure 2 illustrates that in some embodiments, the majority of the fibers 6 may be curved. In other embodiments, such as when the cutting tool comprises a core sanpling drill bit, the fibers have a substantially cylindrical shape.
- the fibers may also be of any type or combination of types.
- the types of fibers include chopped, milled, braided, woven, grouped and v/ound, or tows.
- the fibers can contain a mixture of chopped and milled fibers.
- a diamond-impregnated cutting tool contains one type of fiber.
- the cutting tool may contain multiple types of fibers. In such instances, where a cutting tool contains more than one type of fiber, any combination of fiber type, quality, size, shape, grade, coating, and/or fiber with any other characteristic may be used.
- the fibers may be found in any desired concentration in the cutting tool.
- the cutting portion of a cutting tool may have a very high concentration of fibers, a very low concentration of fibers, or any concentration in between, in some embodiments, the cutting tool may contain fibers ranging from about 0.1 to about 70 vol %. In ctner embodiments, the cutting tool may contain fibers ranging fro about 0.1 to about 30 vol %.
- a first portion of the cutting tool may have a first concentration of a particular type of reinforcing fiber and another portion may have a different concentration (either lower or higher) of the same or another type of reinforcing fiber.
- fibers may be homogenously dispersed throughout the cuttmg portion of a cutting tool, in other embodiments, though, the concentration of fibers may vary throughout any desired portion of a cutting tool, as desired. Indeed, any desired variation of the concentration of fibers may be implemented in a cutting tool.
- the cutting too! comprises a core sampling driil bit
- it may contain a gradient of fibers.
- the portion of the matrix layer that is closest to the cutting face of the drill bit may contain a first concentration of fibers and the concentration of fibers could gradually decrease or increase towards the backing layer.
- Such a drili bit may be used to drill a formation that begins with a soft, abrasive,
- the dispersal of the fibers in the drill bit can be customized to the desired earth formation through which it will be drilling.
- the fiber concentration may also vary in any desired manner in Ihe cutting tool.
- a cutting tool may comprise sections, strips, spots, rings, ⁇ * ⁇ any other formation that contains a different concentration or mixture of fiber reinforcements than ether parts of the cutting tool.
- the cutting portion of a drill bit may comprise multiple layers, rings, or segments of matrix layer containing fibers. Each ring, layer, or segment of the drill bit may have a roughly homogenous (or heterogeneous) concentration of fibers throughout the entire ring, layer or segment. Yet the concentration of fibers may vary from ring to ring (or from segment to segment, etc. . .).
- the various rings of differing fiber gradients may be arranged in any order, may contain different fibers cr combinations of fibers, and may be of a y desired thickness.
- the outer and inner surfaces of a drill bit could be provided with a different concentration of fibers than the inner parts of the drill bit.
- the fibers may be located in the cutting portion of a cutting tool in any desired orientation or alignment. In some embodiments, the fibers may run roughly parallel to each other in any desired direction. However, Figures 2 and 4 illustrate that, in other embodiments, the fibers may be randomly configured and may thereby be oriented in practically any and/or every direction.
- the diamond- impregnated cutting tools with fibers can be made using any known method that provides them with the features described above.
- the drill bit described above can be made in the following exemplary manner, in this example, the first section of the dri'l bit can be made with any known method.
- the fibers can be incorporated into the drill bit using any method that provides the desired fibers in the desirea location with the desired concentration.
- the fibers may be mixed in with the powdered metal, that is used to make the crown cf the drill bit. This mixture may then be sintered and/or infiltrated with a binder.
- the fibers may be incorporated by just placing them into the mold that is used to make the crown of the drill bit.
- the first section of the drill bit can then be connected to the second section using any method known in the art.
- the first section may be present in the mold that is used to form the second section of the drill bit and the two ends of the body may be fused together.
- the first and second sections can be mated in a secondary process such as by brazing, welding, or adhesive bending.
- the diamond-impregnated cutting tools with fibers may be used for any purpose known in the art, which depends on the type of cutting tool.
- a diamond-impregnated core sampling drill bit may be attached to the end of a drill string, which is in turn connected to a drilling rig. As the drill string and therefore the drill bit is rotated and pushed by the drill bit, it grinds away the materials in the subterranean formations that are being drilled. The core samples that are drilled away are withdrawn from the drill string. The cutting portion cf the drill bit will erode over time because of the grinding action. This process may continue until the cutting portion of a drill bit has been consumed and the drilling siring need be tripped out of the borehole and the drill bit replaced.
- the described fibers give diamond- impregnated cutting tools several added advantages when compared to conventional cutting tools that lack fibers.
- the addition of the fibers can control the tens ' le strength and the erosion rate of the cutting tool, whether to strengthen or weaken these properties.
- the presence of the fibers can be used to modify the amount of voids in the cutting portion of the tools.
- modifying the amount of the fibers can be used to tailor the tensile strength and the erosion rate to the amount needed for the particular end use of the cutting tool. This increased tensile strength can also increase the life cf a cutting tool, allowing the cutting portion of the tools to wear at a desired pace and improving the r ate at which the tool cuts.
- the addition of fibers may also weaken the structure of the cutting portion and aliow higher modulus binders to be used for the cutting tools, but at a lower cost.
- the amount of fibers in the cutting portion can be tailored to retain the diamonds in the cutting portion for the desired length of time.
- a third advantage is that the fibers may also act as abrasive cutting media that aid in the cutting process.
- a fourth advantage is that as the fibers in the cutting portion erode away, their fine particulate matter can reduce friction and increase ihe lubrication at the interface between ihe cutting portion and the surface being cut, allowing easier cutting and better flushing. This increased lubrication may also reduce the amount of cutting lubricants (such as drilling muds, polymers, bentonites, etc. . .) that are needed, reducing the costs as well as the environmental impact that can be associated with using diamond- impregnated cutting tools.
- cutting lubricants such as drilling muds, polymers, bentonites, etc. . .
- Fener ation Rate The average penetralicn rates of the first set of drill bits ranged from about 30 to about 40 meters per shift. Nevertheless, with the second set of fiber-reinforced bits, the drillers consistently achieved about 50 meters per shift. This equates to an increase in penetration rate of about 25% to about 67%.
- Bit life The average bit life cf the first set of drill bits was 64 meters.
- the average bit life of the second set of drill bits was about 104 meters. This equates to an increase in bit life of about 60%.
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- Engineering & Computer Science (AREA)
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- Chemical & Material Sciences (AREA)
- Geology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Physics & Mathematics (AREA)
- Inorganic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- Ceramic Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Polishing Bodies And Polishing Tools (AREA)
- Drilling Tools (AREA)
Abstract
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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CA2944197A CA2944197A1 (fr) | 2014-03-28 | 2015-03-27 | Outils de coupe impregnes de diamants contenant des fibres et leurs procedes de formation et d'utilisation |
AU2015235836A AU2015235836A1 (en) | 2014-03-28 | 2015-03-27 | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US14/229,387 US9540883B2 (en) | 2006-11-30 | 2014-03-28 | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
US14/229,387 | 2014-03-28 |
Publications (1)
Publication Number | Publication Date |
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WO2015148910A1 true WO2015148910A1 (fr) | 2015-10-01 |
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ID=54196436
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2015/022965 WO2015148910A1 (fr) | 2014-03-28 | 2015-03-27 | Outils de coupe imprégnés de diamants contenant des fibres et leurs procédés de formation et d'utilisation |
Country Status (3)
Country | Link |
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AU (1) | AU2015235836A1 (fr) |
CA (1) | CA2944197A1 (fr) |
WO (1) | WO2015148910A1 (fr) |
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US9404311B2 (en) | 2006-11-30 | 2016-08-02 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
US9540883B2 (en) | 2006-11-30 | 2017-01-10 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
CN109898034A (zh) * | 2017-12-08 | 2019-06-18 | 江苏赛尔亚环保科技有限公司 | 一种除臭设备用箱体材料 |
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US5536485A (en) * | 1993-08-12 | 1996-07-16 | Agency Of Industrial Science & Technology | Diamond sinter, high-pressure phase boron nitride sinter, and processes for producing those sinters |
US6063332A (en) * | 1995-09-25 | 2000-05-16 | Sintokogio, Ltd. | Heat resisting metal fiber sintered body |
US6394192B1 (en) * | 1997-08-15 | 2002-05-28 | Benthic Geotech Pty Ltd | Methods for seabed piston coring |
AU2011226849A1 (en) * | 2006-11-30 | 2011-10-13 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools |
US8146686B2 (en) * | 2006-11-30 | 2012-04-03 | Longyear Tm, Inc. | Fiber-containing cutting tools |
US20140013675A1 (en) * | 2012-06-29 | 2014-01-16 | Yinggang Tian | Abrasive Article and Method Of Forming |
-
2015
- 2015-03-27 CA CA2944197A patent/CA2944197A1/fr not_active Abandoned
- 2015-03-27 WO PCT/US2015/022965 patent/WO2015148910A1/fr active Application Filing
- 2015-03-27 AU AU2015235836A patent/AU2015235836A1/en not_active Abandoned
Patent Citations (6)
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US5536485A (en) * | 1993-08-12 | 1996-07-16 | Agency Of Industrial Science & Technology | Diamond sinter, high-pressure phase boron nitride sinter, and processes for producing those sinters |
US6063332A (en) * | 1995-09-25 | 2000-05-16 | Sintokogio, Ltd. | Heat resisting metal fiber sintered body |
US6394192B1 (en) * | 1997-08-15 | 2002-05-28 | Benthic Geotech Pty Ltd | Methods for seabed piston coring |
AU2011226849A1 (en) * | 2006-11-30 | 2011-10-13 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools |
US8146686B2 (en) * | 2006-11-30 | 2012-04-03 | Longyear Tm, Inc. | Fiber-containing cutting tools |
US20140013675A1 (en) * | 2012-06-29 | 2014-01-16 | Yinggang Tian | Abrasive Article and Method Of Forming |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9404311B2 (en) | 2006-11-30 | 2016-08-02 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
US9540883B2 (en) | 2006-11-30 | 2017-01-10 | Longyear Tm, Inc. | Fiber-containing diamond-impregnated cutting tools and methods of forming and using same |
CN109898034A (zh) * | 2017-12-08 | 2019-06-18 | 江苏赛尔亚环保科技有限公司 | 一种除臭设备用箱体材料 |
Also Published As
Publication number | Publication date |
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AU2015235836A1 (en) | 2016-10-06 |
CA2944197A1 (fr) | 2015-10-01 |
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