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 PDF

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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
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WO
WIPO (PCT)
Prior art keywords
cutting
fibers
cutting tool
matrix
steel
Prior art date
Application number
PCT/US2015/022965
Other languages
English (en)
Inventor
Kristian S. Drivdahl
Michael D. Rupp
Christian M. Lambert
Cody A. Pearce
Original Assignee
Longyear Tm, 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 US14/229,387 external-priority patent/US9540883B2/en
Application filed by Longyear Tm, Inc. filed Critical Longyear Tm, Inc.
Priority to CA2944197A priority Critical patent/CA2944197A1/fr
Priority to AU2015235836A priority patent/AU2015235836A1/en
Publication of WO2015148910A1 publication Critical patent/WO2015148910A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/48—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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Abstract

L'invention concerne des fibres pour des outils de coupe imprégnés de diamant et leurs procédés associés de fabrication et d'utilisation. Une matrice est formée, laquelle contient des fibres constituées de carbone, de verre, de céramique, de polymère et similaires. La matrice est ensuite frittée pour former une partie de coupe d'un trépan de forage. Le type et la concentration des fibres peuvent être modifiés en vue de commander la résistance à la traction et la vitesse d'érosion de la matrice afin d'optimiser l'efficacité de coupe des outils. En outre, les fibres peuvent être ajoutées à la section de coupe pour affaiblir la structure et permettre l'utilisation de liants à module supérieur pour les outils de coupe à un coût inférieur, permettant l'adaptation de la quantité de fibres pour de retenir les diamants dans la partie de coupe à la quantité souhaitée. À mesure que la partie de coupe s'érode, les fibres peuvent également accroître le pouvoir lubrifiant sur la face de la partie de coupe.
PCT/US2015/022965 2014-03-28 2015-03-27 Outils de coupe imprégnés de diamants contenant des fibres et leurs procédés de formation et d'utilisation WO2015148910A1 (fr)

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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

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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

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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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