U.S. patent application number 12/239064 was filed with the patent office on 2010-04-01 for plate structure for earth-boring tools, tools including plate structures and methods of forming such tools.
Invention is credited to Robert J. Buske.
Application Number | 20100078223 12/239064 |
Document ID | / |
Family ID | 42056176 |
Filed Date | 2010-04-01 |
United States Patent
Application |
20100078223 |
Kind Code |
A1 |
Buske; Robert J. |
April 1, 2010 |
PLATE STRUCTURE FOR EARTH-BORING TOOLS, TOOLS INCLUDING PLATE
STRUCTURES AND METHODS OF FORMING SUCH TOOLS
Abstract
Plate structures attachable to earth-boring tools comprise a
disk including a circumferentially extending rim configured for
attachment to an earth-boring tool. An aperture is formed through a
portion of the disk and positioned radially interior from the rim.
The aperture is configured to at least partially align with at
least one junk slot of the earth-boring tool. Earth-boring tools
comprising such plate structures, and methods of forming such
earth-boring tools are also disclosed.
Inventors: |
Buske; Robert J.; (The
Woodlands, TX) |
Correspondence
Address: |
TRASKBRITT, P.C.
P.O. BOX 2550
SALT LAKE CITY
UT
84110
US
|
Family ID: |
42056176 |
Appl. No.: |
12/239064 |
Filed: |
September 26, 2008 |
Current U.S.
Class: |
175/325.5 ;
76/108.2 |
Current CPC
Class: |
C22C 1/1036 20130101;
C22C 1/051 20130101; C22C 29/08 20130101; B22F 2005/002 20130101;
E21B 10/28 20130101; E21B 17/10 20130101; E21B 17/1092
20130101 |
Class at
Publication: |
175/325.5 ;
76/108.2 |
International
Class: |
E21B 17/10 20060101
E21B017/10; B21K 5/02 20060101 B21K005/02 |
Claims
1. A plate structure attachable to an earth-boring tool,
comprising: a disk comprising a circumferentially extending rim
configured for attachment to an earth-boring tool; and an aperture
through a portion of the disk configured to at least partially
circumferentially align with at least one junk slot of an
earth-boring tool, the aperture being positioned radially interior
from the rim.
2. The plate structure of claim 1, wherein the rim has a chamfered
portion thereon.
3. The plate structure of claim 1, wherein the disk comprises a
material selected from the group consisting of a metal, a metal
alloy, and a particle-matrix composite.
4. The plate structure of claim 1, further comprising at least one
of a wear-resistant insert and a wear-resistant coating on at least
an outer surface of the rim.
5. The plate structure of claim 1, wherein the aperture comprises a
plurality of apertures through a portion of the disk, each aperture
of the plurality of apertures configured to at least partially
align with at least a portion of at least one junk slot.
6. The plate structure of claim 1, further comprising a plurality
of gussets attached to a trailing surface of the disk.
7. The plate structure of claim 6 wherein at least the rim and the
plurality of gussets comprise a hardfacing material over at least a
portion of a surface thereof.
8. An earth-boring tool, comprising: a body comprising a face at a
leading end thereof and structure at a trailing end thereof for
connecting to a drill string; a disk encompassing a portion of the
structure at the trailing end and comprising a rim extending around
an outer circumference thereof and at least one aperture through a
surface of the disk and positioned radially inward from the
rim.
9. The earth-boring tool of claim 8, wherein the body comprises a
longitudinally extending shaft, and further comprising: a pilot bit
coupled to a leading portion of the longitudinally extending shaft;
and a reamer assembly coupled to the body and trailing the pilot
bit.
10. The earth-boring tool of claim 9, wherein the pilot bit is
configured as a roller cone bit, a drag bit, or a hybrid bit.
11. The earth-boring tool of claim 9, wherein the reamer assembly
comprises a plurality of bit legs coupled to an outer periphery of
the body and forming a plurality of junk slots therebetween.
12. The earth-boring tool of claim 11, wherein the disk comprises a
plurality of apertures and wherein each aperture of the plurality
of apertures is at least partially circumferentially aligned with
at least a portion of at least one junk slot of the plurality of
junk slots.
13. The earth-boring tool of claim 8, wherein the rim comprises a
chamfered portion thereon.
14. The earth-boring tool of claim 8, further comprising at least
one of a wear-resistant insert and a wear-resistant coating on at
least an outer surface of the rim.
15. The earth-boring tool of claim 8, wherein the disk and the body
comprise an integral structure.
16. The earth-boring tool of claim 8, further comprising a
plurality of gussets attached to a trailing surface of the
disk.
17. The earth-boring tool of claim 8, further comprising a sleeve
structure, wherein the plurality of gussets is coupled to the
sleeve structure.
18. A method of forming an earth-boring tool, comprising: forming a
disk comprising a rim extending around an outer circumference
thereof; forming at least one aperture through a surface of the
disk and positioned radially inward from the rim; forming a body
comprising a face at a leading end thereof; and coupling the disk
to the body, wherein a connecting structure protrudes from the body
and extends through the disk radially inwardly of the at least one
aperture.
19. The method of claim 18, wherein forming at least one of the
body and the disk comprises: providing a powder mixture; pressing
the powder mixture to form a green powder compact; and at least
partially sintering the green powder compact.
20. The method of claim 18, wherein forming the disk comprises
forming the disk integrally and substantially simultaneously with
forming the body.
21. The method of claim 18, wherein forming the disk comprises
forming the disk separate from the body and coupling the disk to
the body.
22. The method of claim 18, further comprising forming a chamfered
portion on an outer surface of the rim.
23. The method of claim 18, further comprising disposing at least
one of a wear-resistant insert and a wear-resistant coating on at
least an outer surface of the rim.
24. The method of claim 18, further comprising: forming a plurality
of gussets; and securing the plurality of gussets to the disk.
25. The method of claim 24, further comprising securing the
plurality of gussets to a sleeve protruding axially from the
disk.
26. The method of claim 18, further comprising forming a plurality
of gussets coupled with the disk substantially simultaneously with
the formation thereof.
27. The method of claim 26, further comprising forming a sleeve
axially protruding from disk and secured to the disk and to the
sleeve substantially simultaneously with forming the disk and the
plurality of gussets.
28. The method of claim 18, further comprising substantially
circumferentially aligning a junk slot associated with the body
with the at least one aperture.
Description
TECHNICAL FIELD
[0001] Embodiments of the invention relate generally to
earth-boring tools and methods of forming earth-boring tools. More
particularly, embodiments of the present invention relate to
earth-boring tools comprising a plate structure and to methods of
forming such tools.
BACKGROUND
[0002] Drilling wells for oil and gas production conventionally
employs longitudinally extending sections, or so-called "strings,"
of drill pipe to which, at one end, is secured a drill bit of a
larger diameter. After a selected portion of the bore hole has been
drilled, a string of tubular members of lesser diameter than the
bore hole, known as casing, is placed in the bore hole.
Subsequently, the annulus between the wall of the bore hole and the
outside of the casing is filled with cement.
[0003] In drilling bore holes in subterranean earth formations by
the rotary method, drill bits fitted with one or more cutters are
conventionally employed. For example, rolling cutter or "rock bits"
that include three rolling cutters in the form of so-called
"cones," or drag bits that include fixed cutters may be employed.
So-called "hybrid" drill bits which employ, in combination, both
fixed and rolling cutters are also known in the art. The drill bit
is secured to the lower end of a drill string, which may be rotated
from the surface using a rotary table or top drive, from within the
bore hole using a down-hole motor or turbine, or using a
combination of drive systems. The rolling cutters or fixed cutters
mounted on the drill bit roll or slide on and across the exposed
surface of the formation at the bottom of the bore hole as the bit
is rotated, respectively crushing or shearing away the formation
material. Many conventional drill bits also include fluid paths
typically referred to as "junk slots" which extend longitudinally
along an outer surface of the drill bit. The junk slots provide a
pathway for cuttings, drill fluids, and other materials to travel
between the drill bit and the borehole wall, upward from the bottom
of the borehole and away from the drill bit. These junk slots
conventionally extend to the proximal or trailing end of the drill
bit.
BRIEF SUMMARY
[0004] Various embodiments of the present invention comprise a
plate structure configured to be coupled with an earth-boring tool
and providing a rim around an outer diameter of an earth-boring
tool, including the junk slots. In one or more embodiments, the
plate structure may comprise a disk comprising a circumferentially
extending rim having a chamfered portion thereon and configured for
attachment to an earth-boring tool. The disk may also include at
least one aperture through a portion thereof, the at least one
aperture being configured to at least partially circumferentially
align with at least one junk slot of the earth-boring tool. The at
least one aperture may be positioned radially interior from the
rim.
[0005] Other embodiments of the invention comprise earth-boring
tools including a plate structure. At least one embodiment may
comprise a body comprising a face at a leading end thereof and
structure at a trailing end thereof for connecting to a drill
string. A disk may be coupled to the body encompassing a portion of
the connecting structure. The disk may comprise a rim extending
around an outer circumference thereof and at least one aperture
through a surface of the disk. The at least one aperture may be
positioned radially inward from the rim.
[0006] Other embodiments of the invention comprise methods for
forming an earth-boring tool. One or more embodiments of such
methods may comprise forming a body comprising a face at a leading
end thereof. A disk may be formed comprising a rim extending around
an outer circumference thereof. One or more apertures may be formed
through a surface of the disk, the one or more apertures being
positioned radially inward from the rim. The disk may be coupled to
the body proximate a trailing end thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates an isometric view of a plate structure
110 according to at least one embodiment of the invention.
[0008] FIG. 2 illustrates an isometric view of the plate structure
of FIG. 1 including a plurality of gussets attached thereto.
[0009] FIG. 3 is an isometric view of an earth-boring tool
according to at least one embodiment of the invention.
DETAILED DESCRIPTION
[0010] The illustrations presented herein are, in some instances,
not actual views of any particular plate structure or drill bit,
but are merely idealized representations which are employed to
describe the present invention. Additionally, elements common
between figures may retain the same numerical designation.
[0011] Various embodiments of the present invention are directed
toward embodiments of a plate structure for an earth-boring tool.
FIG. 1 illustrates an isometric view of a plate structure 110
according to at least one embodiment of the invention. The plate
structure 110 comprises a disk 120 comprising a circumferentially
extending rim 130. The rim 130 extends continuously through the
circumference of the plate structure 110. The rim 130 may include a
chamfer 150 thereon to aid in removing an earth-boring tool to
which the plate structure 110 may be attached from a borehole. The
chamfer 150 may reduce the chances that an earth-boring tool to
which the plate structure 110 is coupled will get hung up on a
ledge or other irregularity on the borehole wall or on other
subterranean material when removing the earth-boring tool from the
borehole. The angle of the chamfer 150 may be selected according to
the specific application.
[0012] The disk 120 further includes at least one longitudinally
extending aperture 140 through a portion thereof. The at least one
aperture 140 is positioned radially interior from the rim 130 and
is configured to at least partially align with at least one junk
slot of an earth-boring tool to which the plate structure 110 may
be attached. The disk 120 may be formed from a durable material
such as those materials commonly known for use with conventional
earth-boring tools. By way of example only, the disk 120 may be
made from a metal or metal alloy such as steel, or a
particle-matrix composite material. In some embodiments, the disk
120 may comprise an axially extending opening 160 through a central
portion thereof, opening 160 sized and configured to fit around an
outer surface of a shank or stem of an earth-boring tool.
[0013] In some embodiments, the plate structure 110 may comprise a
plurality of ribs or gussets 170 attached to an upper, or trailing
surface thereof (as the plate is oriented during use and with
respect to the normal direction of drilling to form or enlarge a
borehole). FIG. 2 illustrates an isometric view of the plate
structure 110 of FIG. 1 including a plurality of gussets 170
attached thereto. According to some embodiments, the plurality of
gussets 170 may also be coupled to a sleeve structure 180. The
sleeve structure 180 may have another opening 190 sized similar to
the opening 160 (FIG. 1) so as to fit around an outer surface of a
shank or stem of an earth-boring tool. The gussets 170 may comprise
a durable material similar to those used for the disk 120. By way
of example and not limitation, the gussets 170 may comprise a metal
or metal alloy, such as steel, as well as a particle matrix
composite material. Gussets 170 provide reinforcement for, and
enhanced rigidity to, plate structure 110.
[0014] The plate structure 110 is configured to be coupled to an
earth-boring tool used in forming a borehole in subterranean
features. Accordingly, additional embodiments of the present
invention are directed to earth-boring tools which comprise a plate
structure 110 according to various embodiments. FIG. 3 is an
isometric view of an earth-boring tool 200 according to at least
one embodiment of the invention. The earth-boring tool 200
comprises a body 210 having cutting structure 220 at a distal or
leading portion thereof for engaging subterranean earth formations.
The cutting structure 220 may include a plurality of cutting
elements 240 over a portion thereof. Connecting structure 230 is
coupled to the body at a proximal or trailing portion thereof for
connecting to a drill string. Also coupled to the body 210 at a
trailing end thereof is a plate structure 110 according to any of
the embodiments described herein above or their equivalents.
[0015] In some embodiments, the earth-boring tool 200 may be
configured as a pilot reamer assembly 250. In such a configuration,
the body 210 may include a shaft 260 having a pilot bit 270 coupled
thereto at the leading portion thereof, and a reamer assembly 280
trailing the pilot bit 240 at the trailing end of the body 210. The
pilot bit 270 is shown as a roller cone bit, however, in other
embodiments, the pilot bit 270 may comprise a drag bit or a hybrid
bit, as are known generally to those of ordinary skill in the art.
The reamer assembly 280 may comprise a plurality of bit legs or
head sections 290 coupled to the outer periphery of the body 210,
forming a plurality of junk slots 300 therebetween. Although the
reamer assembly 280 is shown with cutters configured as roller
cones, the reamer assembly 280 may also be configured with
drag-type cutters or a combination of roller cone cutters and
drag-type cutters. The plate structure 110 is coupled to the body
210 at the trailing end thereof.
[0016] The plate structure 110 is aligned so that the apertures 140
are at least partially circumferentially aligned with the junk
slots 300. Such a circumferential alignment may allow cuttings,
drilling fluid, etc. to pass upward and away from the body 210 in a
borehole in the annulus formed between the drill string to which
earth-boring tool 200 is attached, and the wall of the borehole.
With the rim 130 extending continuously about the circumference of
the plate structure 110, the cuttings, drilling fluid, etc. passing
through the apertures 140 will pass radially inside with respect to
the rim 130. The rim 130, therefore, may provide a continuous
surface, including at those regions where the junk slots 300 are
located, to aid in removing the earth-boring tool 200 from a
borehole, among other things. As discussed above, the rim 130 may
include a chamfer which may reduce the chances that the
earth-boring tool 200 will get hung up on a ledge or other
irregularity on the borehole wall or on other subterranean material
when being removed from the borehole.
[0017] The plate structure 110 may comprise an outer diameter
substantially equivalent to the outermost diameter of the body 210.
In other embodiments, the sleeve structure 220 may comprise an
outer diameter which is less than the outermost diameter of the
body 210. Such a configuration may avoid excessive wear to the
outermost portion of the plate structure 110. In some embodiments,
the plate structure 110 may include wear resistant coatings and/or
inserts as known in the art to inhibit excessive wear thereto. By
way of example and not limitation, the wear resistant coatings
and/or inserts may include hardfacing material, tungsten carbide
inserts, natural or synthetic diamonds, or a combination
thereof.
[0018] Further embodiments of the present invention are directed to
methods of forming earth-boring tools which comprise a body 210 and
a plate structure 110 according to various embodiments. A body 210
may be formed and coupled to connecting structure 230. The
connecting structure 230 may be formed as a shank comprising a
trailing portion including structure comprising an American
Petroleum Institute (API) thread connection for attachment to a
drill string. The connecting structure 230 may be formed separate
from the body 210 in some embodiments and may be attached to the
body 210 by welding or otherwise affixing the connecting structure
230 to the body 210. The weld may be formed by any conventional
welding process as is known to those of ordinary skill in the art.
Other methods of securing connecting structure 230 to a bit body
are also known, and may be employed. In other embodiments, the
connecting structure 230 and the body 210 are formed as a single,
unitary piece. Cutting structure 220 may be formed on the body 210
at a leading portion thereof and may include cutting elements
conventionally used for earth-boring tools.
[0019] A plate structure 110 is formed comprising a disk 120
including a rim 130 extending continuously through the
circumference of the disk 120. In some embodiments, the body 210 as
well as the plate structure 110 may be formed as an integral
structure. In such embodiments, the body 210 and the plate
structure 110 may be formed simultaneously and of a similar
material. In other embodiments, the body 210 and the plate
structure 110 may each be formed separately as individual pieces
which are subsequently joined. In such embodiments, the plate
structure 110 is secured to the body 210. By way of example and not
limitation, in some embodiments the opening 160 (FIG. 1), as well
as the another opening 190 (FIG.2) when present, may comprise a
diameter configured to create an interference fit with the
connecting structure 230 of the body 210. In some embodiments, the
plate structure 110 may be welded to the body 210 as well as to the
connecting structure 230.
[0020] In embodiments comprising gussets 170, the gussets 170 may
be formed separately from the body 210 and disk 120. The gussets
170 may be formed from a flat plate, the gussets 170 being
machined, punched or cut from the flat plate material or otherwise
formed according to conventional methods. In some embodiments, the
gussets 170 may be attached directly to the disk 120. In other
embodiments, the gussets 170 may be attached to a sleeve structure
180, the sleeve structure 180 with the gussets 170 being attached
to the disk 120. In some embodiments, the another opening 190 (FIG.
2) of the sleeve structure 180 may comprise a diameter configured
to create an interference fit with the connecting structure 230 of
the body 210. The gussets 170 and sleeve structure 180 may also be
welded to the disk 120, the connecting structure 230, or both.
[0021] The body 210 as well as the plate structure 110, including
any gussets 170, may comprise a metal or metal alloy, such as
steel, or a particle-matrix composite material. In the case of a
particle-matrix composite material, the body 210 and/or the plate
structure 110 may be formed by conventional infiltration methods
(in which hard particles (e.g., tungsten carbide) are infiltrated
by a molten liquid metal matrix material (e.g., a copper based
alloy) within a refractory mold), as well as by newer methods
generally involving pressing a powder mixture to form a green
powder compact, and sintering the green powder compact to form a
body 210 and/or plate structure 110. The green powder compact may
be machined as necessary or desired prior to sintering using
conventional machining techniques like those used to form steel
bodies or steel plate structures. Furthermore, additional machining
processes may be performed after sintering the green powder compact
to a partially sintered brown state, or after sintering the green
powder compact to a desired final density.
[0022] One or more wear resistant inserts and/or a wear resistant
coatings may be disposed on a radially outer surface of the rim 130
of the plate structure 110, as well as the plurality of gussets 170
if present. Wear resistant inserts may be attached to the plate
structure 110 using a bonding material such as an adhesive or, more
typically, a braze alloy may be used to secure the wear resistant
inserts to the plate structure 110. A wear resistant coating may
comprise a hardfacing or similar material. The wear resistant
coating may be disposed over the outer surfaces of the rim 130, the
disk 120, as well as over surfaces of the gussets 170 when present.
The wear resistant coating may be disposed employing a conventional
welding process such as oxy-acetylene, MIG, TIG, SMA, SCA, PTA,
etc.
[0023] While the present invention has been described herein in
relation to embodiments of earth-boring pilot reamers that include
roller cone cutters, other types of earth-boring tools such as, for
example, core bits, eccentric bits, bicenter bits, reamers, mills,
fixed-cutter rotary drill bits, and other such structures known in
the art may incorporate embodiments of the present invention and
may be formed by methods according to embodiments of the present
invention, and, as used herein, the term "body" encompasses bodies
of earth-boring rotary drill bits, as well as bodies of other
earth-boring tools including, but not limited to, core bits,
eccentric bits, bicenter bits, reamers, mills, roller cone bits, as
well as other drilling and downhole tools.
[0024] While certain embodiments have been described and shown in
the accompanying drawings, such embodiments are merely illustrative
and not restrictive of the scope of the invention, and this
invention is not limited to the specific constructions and
arrangements shown and described, since various other additions and
modifications to, and deletions from, the described embodiments
will be apparent to one of ordinary skill in the art. Thus, the
scope of the invention is only limited by the literal language, and
legal equivalents, of the claims which follow.
* * * * *