U.S. patent application number 12/262690 was filed with the patent office on 2010-05-06 for downhole cutting tool and method of making.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. Invention is credited to Andrew D. Ponder, Calvin J. Stowe, II.
Application Number | 20100108402 12/262690 |
Document ID | / |
Family ID | 42130057 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100108402 |
Kind Code |
A1 |
Ponder; Andrew D. ; et
al. |
May 6, 2010 |
DOWNHOLE CUTTING TOOL AND METHOD OF MAKING
Abstract
A downhole cutting tool includes, a body, a first contoured
cutting element in operable communication with the body, and at
least one contingency contoured cutting element in operable
communication with the first contoured cutting element and the
body. A contour of the at least one contingency contoured cutting
element substantially matches a contour of the first contoured
cutting element, and the at least one contingency contoured cutting
element is maintainable in reserve and positioned to substitute for
the first contoured cutting element if the first contoured cutting
element becomes detached.
Inventors: |
Ponder; Andrew D.; (Houston,
TX) ; Stowe, II; Calvin J.; (Bellaire, TX) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
42130057 |
Appl. No.: |
12/262690 |
Filed: |
October 31, 2008 |
Current U.S.
Class: |
175/428 ;
175/421; 175/426; 175/435; 76/108.4 |
Current CPC
Class: |
E21B 10/006
20130101 |
Class at
Publication: |
175/428 ;
76/108.4; 175/435; 175/426; 175/421 |
International
Class: |
E21B 10/55 20060101
E21B010/55; E21B 10/42 20060101 E21B010/42 |
Claims
1. A downhole cutting tool comprising: a body; a first contoured
cutting element in operable communication with the body; and at
least one contingency contoured cutting element in operable
communication with the first contoured cutting element and the
body, a contour of the at least one contingency contoured cutting
element substantially matching a contour of the first contoured
cutting element, the at least one contingency contoured cutting
element being maintainable in reserve and positioned to trail
rotationally behind the first contoured cutting element while
cutting to substitute for the first contoured cutting element if
the first contoured cutting element becomes detached.
2. The downhole cutting tool of claim 1, wherein the first
contoured cutting element is attached to at least one of the body
and the at least one contingency contoured cutting element.
3. The downhole cutting tool of claim 2, wherein attachment of the
first contoured cutting element to the at least one of the body and
the at least one contingency contoured cutting element is by one of
bonding, brazing, welding and gluing.
4. The downhole cutting tool of claim 2, wherein material employed
to attach the first contoured cutting element to the at least one
of the body and the at least one contingency contoured cutting
element is more ductile than at least one of the first contoured
cutting element and the at least one contingency contoured cutting
element.
5. The downhole cutting tool of claim 2, wherein attachment of the
first contoured cutting element to at least one of the body and the
at least one contingency contoured cutting element is configured to
fail prior to fracture of the first contoured cutting element.
6. The downhole cutting tool of claim 2, wherein detachment of the
first contoured cutting element from at least the body and the at
least one contingency contoured cutting element stops a fracture in
the first contoured cutting element from propagating into the at
least one contingency contoured cutting element.
7. The downhole cutting tool of claim 1, wherein the at least one
contingency contoured cutting element is attached to the body.
8. The downhole cutting tool of claim 1, wherein the first
contoured cutting element and the at least one contingency
contoured cutting element are oriented in at least one stack.
9. The downhole cutting tool of claim 1, wherein a size of the
first contoured cutting element limits a loss of volume of the
downhole cutting tool associated with each detachment event.
10. The downhole cutting tool of claim 1, wherein the first
contoured cutting element includes a contoured cutting edge.
11. The downhole cutting tool of claim 1, wherein the at least one
of the first contoured cutting element and the at least one
contingency cutting element are one of hard metal, ceramic and
diamond.
12. The downhole cutting tool of claim 11, wherein the hard metal
is carbide.
13. (canceled)
14. A method of making a downhole cutter device comprising:
substantially matching a contoured cutting edge of at least one
contingency contoured cutting element with a contoured cutting edge
of a first contoured cutting element; and attaching the at least
one contingency contoured cutting element adjacent the first
contoured cutting element positioned to trail rotationally behind
the first contoured cutting element while cutting such that the at
least one contingency contoured cutting element substitutes for the
first contoured cutting element if the first contoured cutting
element becomes detached.
15. The method of making a downhole cutter device of claim 14,
wherein the attaching is by one of bonding, brazing, welding and
gluing.
16. The method of making a downhole cutter device of claim 14,
wherein the attaching is designed to fail at loads less than would
cause fracture of the first contoured cutting element.
17. A downhole cutter comprising: a plurality of cutting elements
having substantially matched contoured cutting edges positioned
perimetrically adjacent to one another; and a bonding material
having greater ductility than the plurality of cutting elements
bonding the plurality of cutting elements to one another in an
arrangement such that detachment of one of the plurality of cutting
elements reveals another of the substantially matched contoured
cutting edges that substitutes for a contoured cutting edge of the
detached cutting element.
18. The downhole cutter of claim 17, wherein the downhole cutter is
configured to allow detachment of one of the plurality of cutting
elements under load prior to fracture of the one of the plurality
of cutting elements.
19. (canceled)
20. The downhole cutting tool of claim 1, further comprising: a
second contoured cutting element in operable communication with the
body; and at least one contingency contoured cutting element in
operable communication with the second contoured cutting element
and the body, a contour of the at least one contingency contoured
cutting element substantially matching a contour of the second
contoured cutting element, the at least one contingency contoured
cutting element being maintainable in reserve and positioned and
displaced from the second contoured cutting element in a rotational
direction of motion of the cutting elements while cutting to
substitute for the second contoured cutting element if the second
contoured cutting element becomes detached, and the detachability
of the first contoured cutting element and the second contoured
cutting element are independent from one another.
21. The downhole cutting tool of claim 20, wherein independent
detachment of the first contoured cutting element from the second
contoured cutting element limits a volume of the downhole cutting
tool that becomes detached during a detachment event.
Description
BACKGROUND
[0001] Downhole cutting tools commonly employ carbide cutters made
of a solid piece of carbide. Although such cutters are effective at
cutting the downhole materials they are designed to cut, their
cutting efficiency, and effective lifespan, can be significantly
reduced due to fracturing or chipping of the cutter. Fracturing and
chipping can remove all or a portion of a cutting edge of the
carbide cutter resulting in a dull and inefficient cutting tool.
Well operators will therefore be receptive to tools and methods to
increase the longevity of downhole cutters.
BRIEF DESCRIPTION
[0002] Disclosed herein is a downhole cutting tool. The tool
includes, a body, a first contoured cutting element in operable
communication with the body, and at least one contingency contoured
cutting element in operable communication with the first contoured
cutting element and the body. And a contour of the at least one
contingency contoured cutting element substantially matching a
contour of the first contoured cutting element, the at least one
contingency contoured cutting element being maintainable in reserve
and positioned to substitute for the first contoured cutting
element if the first contoured cutting element becomes
detached.
[0003] Further disclosed herein is a method of making a downhole
cutter. The method includes, substantially matching a contoured
cutting edge of at least one contingency contoured cutting element
with a contoured cutting edge of a first contoured cutting element,
and attaching the at least one contingency contoured cutting
element adjacent the first contoured cutting element such that the
at least one contingency contoured cutting element substitutes for
the first contoured cutting element if the first contoured cutting
element becomes detached.
[0004] Further disclosed herein is a downhole cutter. The cutter
includes, a plurality of cutting elements having substantially
matched contoured cutting edges, and a bonding material having
greater ductility than the plurality of cutting elements bonding
the plurality of cutting elements to one another in an arrangement
such that detachment of one of the plurality of cutting elements
reveals another of the substantially matched contoured cutting
edges that substitutes for a contoured cutting edge of the detached
cutting element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0006] FIG. 1 depicts a perspective view of a downhole cutting tool
disclosed herein;
[0007] FIG. 2 depicts an enlarged perspective view of a portion of
the downhole cutting tool of FIG. 1; and
[0008] FIG. 3 depicts an enlarged perspective view of a plurality
of carbide cutting elements shown in FIG. 2.
DETAILED DESCRIPTION
[0009] A detailed description of one or more embodiments of the
disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0010] Referring to FIG. 1, an embodiment of a downhole cutting
tool 10 having a plurality of cutters 12 disclosed herein is
illustrated. The tool 10 is just one embodiment of the invention to
facilitate illustration of a break away construction of the cutter
12 that leaves a new cutting edge as will be disclosed in detail
hereunder. In addition to the cutters 12, the cutting tool 10
includes, a tubular 14 and a plurality of articulatable bodies 18,
also commonly referred to as arms or shanks. Each of the cutters 12
includes a plurality of contoured cutting elements 22A-22D attached
thereto. The cutting tool 10 is positionable in a downhole wellbore
via a drill string (not shown), for example, where it can be used
to cut metal, earth or other materials whose removal is desired.
The tool 10 can also be used to cut windows in walls of a wellbore,
for example, to create a lateral wellbore from a primary wellbore.
The plurality of contoured cutting elements 22A-22D are configured
on the cutter 12 to break away from the cutter 12 in full elements
22A-22D, thereby limiting the extend of a fracture to a single
element 22A-22D. In so doing, each time an element 22A-22C breaks
free from the tool 10, a new (contingent) element 22B-22D becomes
exposed with a new cutting edge that substitutes for the cutting
edge of the detached element 22A-22C.
[0011] In this particular embodiment, the bodies 18 can articulate
from a position wherein the cutters 12 are positioned radially
inwardly of a diameter 26 that defines the tubular 14, to a
position wherein the cutters 12 (during rotation of the cutting
tool 10) trace out a diameter 30 that is substantially larger than
the diameter 26. It should be noted that alternate embodiments of
the cutting tool 10 could have fixed bodies 18 as well. A
characteristic of any embodiment of the cutting tool 10 is that the
tool 10 can move in such a way as to force the cutter 12 and
cutting elements 22A-22D, attached to the body 18, to contact and
thereby cut into a material intended to be removed.
[0012] Referring to FIGS. 2 and 3, the body 18, cutter 12 and
contoured cutting elements 22A-22D are shown at greater
magnification. This embodiment includes three stacks 34 of the
contoured cutting elements 22A-22D that are attached at a distal
end 38 of the body 18. Alternate embodiments could have a single
stack 34 or more than three stacks 34. A first contoured element
22A in one of the stacks 34 has an exposed edge 46A that defines a
first cutting contour 50A. The additional elements 22B, 22C and
22D, in any particular stack 34, have cutting contours 50B-50D that
substantially match the first cutting contour 50A. The first
cutting contour 50A can be formed to any desired shape practical by
such methods as wire EDM, cutting with a diamond saw or by
sintering, for example. Each of the elements 22A-22D are brazed,
bonded, glued or welded to one another or to the body 18 with a
bonding material 54.
[0013] Regardless of the bonding method used, the elements 22A-22D
disclosed herein are made of a hard metal material such as tungsten
carbide, titanium carbide or tantalum carbide, for example, or
other hard material such as a ceramic (cubic boron nitride) or
diamond. In embodiments disclosed herein the elements 22A-22D are
made of tungsten carbide, also referred to as carbide. Carbide has
exceptional hardness, a high melting point, and excellent wear
characteristics when used as a cutting tool for cutting metal and
earth formation materials. The elements 22A-22D, by design, are
harder and more brittle than the bonding materials 54 employed and
than the material of the body 18, which is made of a strong rigid
material such as steel, for example. With the foregoing
construction the more ductile bonding materials 54 and the body 18
will absorb much of the shock incurred while cutting. Should a load
incurred be so great as to cause detachment of a portion of the
cutter 12 the bonding material 54 should fail prior to fracture of
one of the elements 22A-22D, thereby limiting the loss of a piece
of the cutter 12 to that of an individual element 22A-22D. The
foregoing construction thereby limits the loss of carbide volume
from the cutter 12 due to each excessive load in comparison to a
single solid piece cutter 12, for example. Additionally, should a
fracture of an element 22A-22D occur the ductile bonding material
54 would prevent the fracture from propagating to an adjacent
element 22A-22D, again limiting the size of a fracture chip to the
size of an individual element 22A-22D.
[0014] Further, when, for example, the first element 22A of a stack
34 is detached at a bonding interface the contingent element 22B
becomes exposed. And since the contingent element 22B has a contour
50B that substantially matches the contour 50A of the first element
22A, the contingent element 22B is positioned to substitute for and
continue cutting of the target material. This substitution effect
is possible because the first element 22A is displaced from the
contingent element 22B in a direction according to arrow 58 (FIG.
1), defined by motion of the cutter 12 while cutting. Also, since
the contour 50B of the contingent element 22B matches that of the
first element 22A the desired original cutting profile can be
maintained. A newly exposed contoured cutting edge 46B on element
22B having been formed in a similar fashion as the first contoured
cutting edge 46A will be just as well suited for cutting and will
be more durable and less susceptible to fracture than an edge
randomly formed from a chip broken from a cutter 12 made of a
single solid piece of carbide, for example.
[0015] Since each of the stacks 34 can have multiple contingent
elements 22B-22D, with three contingent elements 22B-22D being
illustrated in this embodiment, a new cutting edge 46B-46D can be
reestablished several times without having to retrieve the tool
10.
[0016] While the invention has been described with reference to an
exemplary embodiment or embodiments, it will be understood by those
skilled in the art that various changes may be made and equivalents
may be substituted for elements thereof without departing from the
scope of the invention. In addition, many modifications may be made
to adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the claims. Also, in
the drawings and the description, there have been disclosed
exemplary embodiments of the invention and, although specific terms
may have been employed, they are unless otherwise stated used in a
generic and descriptive sense only and not for purposes of
limitation, the scope of the invention therefore not being so
limited. Moreover, the use of the terms first, second, etc. do not
denote any order or importance, but rather the terms first, second,
etc. are used to distinguish one element from another. Furthermore,
the use of the terms a, an, etc. do not denote a limitation of
quantity, but rather denote the presence of at least one of the
referenced item.
* * * * *