U.S. patent application number 14/363266 was filed with the patent office on 2014-11-06 for rotating cutting elements for pdc bits.
This patent application is currently assigned to Smith International, Inc.. The applicant listed for this patent is Smith International, Inc.. Invention is credited to Jibin Shi, Youhe Zhang.
Application Number | 20140326515 14/363266 |
Document ID | / |
Family ID | 48574796 |
Filed Date | 2014-11-06 |
United States Patent
Application |
20140326515 |
Kind Code |
A1 |
Shi; Jibin ; et al. |
November 6, 2014 |
ROTATING CUTTING ELEMENTS FOR PDC BITS
Abstract
A drill bit has a bit body, a plurality of blades extending
radially from the bit body, at least one rolling cutter pocket
disposed on the plurality of blades, and at least one rolling
cutter, wherein each rolling cutter is disposed in one of the
rolling cutter pockets, and wherein a side surface of the rolling
cutter pocket and an outer circumferential surface of the rolling
cutter have at least one mating lip and channel formed therein.
Further, the rolling cutter may include a cavity extending at least
partially along a rotational axis through the rolling cutter, from
a bottom surface of the rolling cutter, and a retention pin
disposed within the cavity.
Inventors: |
Shi; Jibin; (Spring, TX)
; Zhang; Youhe; (Spring, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Smith International, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Smith International, Inc.
Houston
TX
|
Family ID: |
48574796 |
Appl. No.: |
14/363266 |
Filed: |
December 4, 2012 |
PCT Filed: |
December 4, 2012 |
PCT NO: |
PCT/US2012/067685 |
371 Date: |
June 5, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61566859 |
Dec 5, 2011 |
|
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Current U.S.
Class: |
175/365 ;
76/108.4 |
Current CPC
Class: |
E21B 10/08 20130101;
E21B 10/573 20130101; E21B 10/43 20130101; E21B 10/46 20130101;
B23P 15/28 20130101 |
Class at
Publication: |
175/365 ;
76/108.4 |
International
Class: |
E21B 10/08 20060101
E21B010/08; B23P 15/28 20060101 B23P015/28 |
Claims
1. A drill bit, comprising: a bit body; a plurality of blades
extending radially from the bit body; at least one rolling cutter
pocket disposed on the plurality of blades, each rolling cutter
pocket comprising a side surface; at least one rolling cutter,
wherein each rolling cutter is disposed in one of the rolling
cutter pockets, and wherein each rolling cutter comprises: a cavity
extending at least partially along a rotational axis through the
rolling cutter, from a bottom surface of the rolling cutter: and a
retention pin disposed within the cavity; wherein the side surface
of the rolling cutter pocket and an outer circumferential surface
of the rolling cutter comprise at least one mating lip and channel
formed therein.
2. The drill bit of claim 1, wherein the retention pin is integral
with the blade.
3. The drill bit of claim 1, wherein the retention pin further
extends through a hole the blade, from the rolling cutter pocket to
a trailing face of the blade.
4. The drill bit of claim 1, wherein the side surface of the
rolling cutter pocket comprises an arc less than or equal to 180
degrees.
5. The drill bit of claim 1 any of the preceding claims, wherein
the rolling cutter pocket comprises at least one channel formed in
the side surface and the rolling cutter comprises at least one lip
on the outer circumferential surface.
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. The drill bit of claim 1, wherein the rolling cutter pocket
comprises at least one lip on the side surface and the rolling
cutter comprises at least one channel formed in the outer
circumferential surface.
11. The drill bit of claim 1, wherein the cavity extends along the
rotational axis from the bottom surface to a cutting face of the
rolling cutter.
12. The drill bit of claim 11, wherein the retention pin extends
entirely through the cavity from the back face to the cutting
face.
13. The drill bit of claim 11, wherein the retention pin extends
partially through the cavity from the back face of the rolling
cutter.
14. (canceled)
15. (canceled)
16. The drill bit of claim 1, wherein at least a portion of the
side surface of the rolling cutter pocket is formed by a partial
sleeve insert.
17. A method of manufacturing a drill bit, comprising: forming a
bit body comprising a threaded pin end and a cutting end, wherein
at least one blade extends radially from the bit body, and wherein
the blade has at least one rolling cutter pocket formed therein;
and placing a rolling cutter into the rolling cutter pocket,
wherein the rolling cutter comprises an outer circumferential
surface and a cavity extending at least partially along a
rotational axis from a bottom surface of the rolling, cutter
through the rolling cutter; wherein a side surface of the rolling
cutter pocket and the outer circumferential surface of the rolling
cutter comprise at least one mating lip and channel formed therein;
and wherein the rolling cutter is retained in the rolling cutter
pocket by a retention pin disposed within the cavity.
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. The method of claim 17, wherein the rolling cutter is placed in
the rolling cutter pocket prior to inserting the retention pin
within the cavity.
24. The method of claim 23, further comprising attaching the
retention pin to blade by a threaded connection.
25. The method of claim 23, further comprising, inserting the
retention pin through the blade and screwing a bolt to the
retention pin to attach the retention pin to the blade.
26. (canceled)
27. The method of claim 17, wherein the rolling cutter is placed in
a partial sleeve insert prior to placing the rolling cutter with
the partial sleeve insert in the rolling cutter pocket.
28. The method of claim 27, wherein the retention pin is integrally
formed with the rolling cutter pocket.
29. A cutting tool, comprising: a tool body; a plurality of blades
extending from the tool body; at least one cutter pocket formed in
the plurality of blades; at least one cutter assembly disposed in
the at least one cutter pocket, the at least one cutter assembly
comprising: a partial sleeve; a rolling cutter having a groove or
protrusion formed in an outer circumferential surface thereof and
disposed adjacent to a side surface of the partial sleeve; and at
least one component interfacing at least a portion of the groove or
the protrusion to limit axial movement of the rolling cutter with
respect to the partial sleeve, wherein a combination of the partial
sleeve and cutter pocket extends greater than 180 degrees around
the circumference of the rolling cutter to radially retain in the
rolling cutter within the cutter pocket.
30. The cutting tool of claim 29, wherein the at least one
component comprises a channel formed in the side surface of the
partial sleeve, and wherein the rolling cutter comprises at least
one lip on the outer circumferential surface that mates with the
channel.
31. The cutting tool of claim 29, wherein the at least one
component comprises a lip formed on the side surface of the partial
sleeve, and wherein the rolling cutter comprises at least one
channel in the outer circumferential surface that mates with the
lip.
32. (canceled)
33. (canceled)
34. (canceled)
35. The cutting tool of claim 31, wherein the partial sleeve
further comprises at least one channel formed in the side surface
and the rolling cutter further comprises at least one lip in the
outer circumferential surface that mates with the channel.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] Embodiments disclosed herein relate generally to cutting
elements for drill bits or other tools incorporating the same. More
specifically, embodiments disclosed herein relate generally to
rotatable cutting elements for rotary drill bits.
[0003] 2. Background Art
[0004] Drill bits used to drill wellbores through earth formations
generally are made within one of two broad categories of bit
structures. Depending on the application/formation to be drilled,
the appropriate type of drill bit may be selected based on the
cutting action type for the bit and its appropriateness for use in
the particular formation. Drill bits in the first category are
generally known as "roller cone" bits, which include a bit body
having one or more roller cones rotatably mounted to the bit body.
The bit body is typically formed from steel or another high
strength material. The roller cones are also typically formed from
steel or other high strength material and include a plurality of
cutting elements disposed at selected positions about the cones.
The cutting elements may be formed from the same base material as
is the cone. These bits are typically referred to as "milled tooth"
bits. Other roller cone bits include "insert" cutting elements that
are press (interference) fit into holes formed and/or machined into
the roller cones. The inserts may be formed from, for example,
tungsten carbide, natural or synthetic diamond, boron nitride, or
any one or combination of hard or superhard materials.
[0005] Drill bits of the second category are typically referred to
as "fixed cutter" or "drag" bits. Drag bits, include bits that have
cutting elements attached to the bit body, which may be a steel bit
body or a matrix bit body formed from a matrix material such as
tungsten carbide surrounded by a binder material. Drag bits may
generally be defined as bits that have no moving parts. However,
there are different types and methods of forming drag bits that are
known in the art. For example, drag bits having abrasive material,
such as diamond, impregnated into the surface of the material which
forms the bit body are commonly referred to as "impreg" bits. Drag
bits having cutting elements made of an ultra hard cutting surface
layer or "table" (typically made of polycrystalline diamond
material or polycrystalline boron nitride material) deposited onto
or otherwise bonded to a substrate are known in the art as
polycrystalline diamond compact ("PDC") bits.
[0006] PDC bits drill soft formations easily, but they are
frequently used to drill moderately hard or abrasive formations.
They cut rock formations with a shearing action using small cutters
that do not penetrate deeply into the formation. Because the
penetration depth is shallow, high rates of penetration are
achieved through relatively high bit rotational velocities.
[0007] PDC cutters have been used in industrial applications
including rock drilling and metal machining for many years. In PDC
bits, PDC cutters are received within cutter pockets, which are
formed within blades extending from a bit body, and are typically
bonded to the blades by brazing to the inner surfaces of the cutter
pockets. The PDC cutters are positioned along the leading edges of
the bit body blades so that as the bit body is rotated, the PDC
cutters engage and drill the earth formation. In use, high forces
may be exerted on the PDC cutters, particularly in the
forward-to-rear direction. Additionally, the bit and the PDC
cutters may be subjected to substantial abrasive forces. In some
instances, impact, vibration, and erosive forces have caused drill
bit failure due to loss of one or more cutters, or due to breakage
of the blades.
[0008] In a typical PDC cutter, a compact of polycrystalline
diamond ("PCD") (or other superhard material, such as
polycrystalline cubic boron nitride) is bonded to a substrate
material, which is typically a sintered metal-carbide to form a
cutting structure. PCD comprises a polycrystalline mass of diamond
grains or crystals that are bonded together to form an integral,
tough, high-strength mass or lattice. The resulting PCD structure
produces enhanced properties of wear resistance and hardness,
making PCD materials extremely useful in aggressive wear and
cutting applications where high levels of wear resistance and
hardness are desired.
[0009] An example of a prior art PDC bit having a plurality of
cutters with ultra hard working surfaces is shown in FIGS. 1 and 2.
The drill bit 100 includes a bit body 110 having a threaded upper
pin end 111 and a cutting end 115. The cutting end 115 typically
includes a plurality of ribs or blades 120 arranged about the
rotational axis L (also referred to as the longitudinal or central
axis) of the drill bit and extending radially outward from the bit
body 110. Cutting elements, or cutters, 150 are embedded in the
blades 120 at predetermined angular orientations and radial
locations relative to a working surface and with a desired back
rake angle and side rake angle against a formation to be
drilled.
[0010] A plurality of orifices 116 are positioned on the bit body
110 in the areas between the blades 120, which may be referred to
as "gaps" or "fluid courses." The orifices 116 are commonly adapted
to accept nozzles. The orifices 116 allow drilling fluid to be
discharged through the bit in selected directions and at selected
rates of flow between the blades 120 for lubricating and cooling
the drill bit 100, the blades 120 and the cutters 150. The drilling
fluid also cleans and removes the cuttings as the drill bit 100
rotates and penetrates the geological formation. Without proper
flow characteristics, insufficient cooling of the cutters 150 may
result in cutter failure during drilling operations. The fluid
courses are positioned to provide additional flow channels for
drilling fluid and to provide a passage for formation cuttings to
travel past the drill bit 100 toward the surface of a wellbore (not
shown).
[0011] Referring to FIG. 2, a top view of a prior art PDC bit is
shown. The cutting face 118 of the bit shown includes a plurality
of blades 120, wherein each blade has a leading side 122 facing the
direction of bit rotation, a trailing side 124 (opposite from the
leading side), and a top side 126. Each blade includes a plurality
of cutting elements or cutters generally disposed radially from the
center of cutting face 118 to generally form rows. Certain cutters,
although at differing axial positions, may occupy radial positions
that are in similar radial position to other cutters on other
blades.
[0012] Cutters are conventionally attached to a drill bit or other
downhole tool by a brazing process. In the brazing process, a braze
material is positioned between the cutter and the cutter pocket.
The material is melted and, upon subsequent solidification, bonds
(attaches) the cutter in the cutter pocket. Selection of braze
materials depends on their respective melting temperatures, to
avoid excessive thermal exposure (and thermal damage) to the
diamond layer prior to the bit (and cutter) even being used in a
drilling operation. Specifically, alloys suitable for brazing
cutting elements with diamond layers thereon have been limited to
only a couple of alloys which offer low enough brazing temperatures
to avoid damage to the diamond layer and high enough braze strength
to retain cutting elements on drill bits.
[0013] Cracking (and/or formation of micro-cracks) in the bit body
can also occur during the cutter brazing process in the area
surrounding the cutter pockets. The formation and propagation of
cracks in the matrix body during the drilling process may result in
the loss of one or more PDC cutters. A lost cutter may abrade
against the bit, causing further accelerated bit damage.
[0014] A significant factor in determining the longevity of PDC
cutters is the exposure of the cutter to heat. Conventional
polycrystalline diamond is stable at temperatures of up to
700-750.degree. C. in air, above which observed increases in
temperature may result in permanent damage to and structural
failure of polycrystalline diamond. This deterioration in
polycrystalline diamond is due to the significant difference in the
coefficient of thermal expansion of the binder material, cobalt, as
compared to diamond. Upon heating of polycrystalline diamond, the
cobalt and the diamond lattice will expand at different rates,
which may cause cracks to form in the diamond lattice structure and
result in deterioration of the polycrystalline diamond. Damage may
also be due to graphitization at diamond-diamond necks leading to
loss of microstructural integrity and strength loss, at extremely
high temperatures.
[0015] Exposure to heat (through brazing or through frictional heat
generated from the contact of the cutter with the formation) can
cause thermal damage to the diamond table and eventually result in
the formation of cracks (due to differences in thermal expansion
coefficients) which can lead to spalling of the polycrystalline
diamond layer, delamination between the polycrystalline diamond and
substrate, and conversion of the diamond back into graphite causing
rapid abrasive wear. As a cutting element contacts the formation, a
wear flat develops and frictional heat is induced. As the cutting
element is continued to be used, the wear flat will increase in
size and further induce frictional heat. The heat may build-up that
may cause failure of the cutting element due to thermal mis-match
between diamond and catalyst discussed above. This is particularly
true for cutters that are immovably attached to the drill bit, as
conventional in the art.
[0016] Accordingly, there exists a continuing need to develop ways
to extend the life of a cutting element.
SUMMARY OF INVENTION
[0017] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify key or
essential features of the claimed subject matter, nor is it
intended to be used as an aid in limiting the scope of the claimed
subject matter.
[0018] In one aspect, embodiments disclosed herein relate to a
drill bit having a bit body, a plurality of blades extending
radially from the bit body, at least one rolling cutter pocket
disposed on the plurality of blades, and at least one rolling
cutter, wherein each rolling cutter is disposed in one of the
rolling cutter pockets, and wherein a side surface of the rolling
cutter pocket and an outer circumferential surface of the rolling
cutter have at least one mating lip and channel formed therein.
Each rolling cutter includes a cavity extending at least partially
along a rotational axis through the rolling cutter, from a bottom
surface of the rolling cutter, and a retention pin disposed within
the cavity.
[0019] In another aspect, embodiments disclosed herein relate to a
method of manufacturing a drill bit that includes forming a bit
body having a threaded pin end and a cutting end, wherein at least
one blade extends radially from the bit body, and wherein the blade
has at least one rolling cutter pocket formed therein, and placing
a rolling cutter into the rolling cutter pocket, wherein the
rolling cutter has an outer circumferential surface and a cavity
extending at least partially along a rotational axis from a bottom
surface of the rolling cutter through the rolling cutter, wherein a
side surface of the rolling cutter pocket and the outer
circumferential surface of the rolling cutter have at least one
mating lip and channel formed therein, and wherein the rolling
cutter is retained in the rolling cutter pocket by a retention pin
disposed within the cavity.
[0020] Other aspects and advantages of the invention will be
apparent from the following description and the appended
claims.
BRIEF DESCRIPTION OF DRAWINGS
[0021] Embodiments of Rotating Cutting Elements for PDC Bits are
described with reference to the following figures. The same numbers
are used throughout the figures to reference like features and
components.
[0022] FIG. 1 shows a side view of a conventional drag bit.
[0023] FIG. 2 shows a top view of a conventional drag bit.
[0024] FIG. 3 shows a rolling cutter, a rolling cutter pocket, and
a retention pin according to embodiments of the present
disclosure.
[0025] FIG. 4 shows a rolling cutter assembled to a rolling cutter
pocket according to embodiments of the present disclosure.
[0026] FIG. 5 shows a rolling cutter pocket according to
embodiments of the present disclosure.
[0027] FIG. 6 shows a rolling cutter and a rolling cutter pocket
according to embodiments of the present disclosure.
[0028] FIG. 7 shows a cross-sectional view of a rolling cutter and
a rolling cutter pocket according to embodiments of the present
disclosure.
[0029] FIG. 8 shows a rolling cutter, a rolling cutter pocket, and
a retention pin according to embodiments of the present
disclosure.
[0030] FIG. 9 shows a rolling cutter assembled to a rolling cutter
pocket according to embodiments of the present disclosure.
[0031] FIG. 10 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0032] FIG. 11 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0033] FIG. 12 shows a rolling cutter, a rolling cutter pocket, and
a retention pin according to embodiments of the present
disclosure.
[0034] FIG. 13 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0035] FIG. 14 shows a rolling cutter assembled to a rolling cutter
pocket according to embodiments of the present disclosure.
[0036] FIG. 15 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0037] FIG. 16 shows a rolling cutter pocket according to
embodiments of the present disclosure.
[0038] FIG. 17 shows a rolling cutter assembled to a rolling cutter
pocket according to embodiments of the present disclosure.
[0039] FIG. 18 shows a rolling cutter, a rolling cutter pocket, and
a retention pin according to embodiments of the present
disclosure.
[0040] FIG. 19 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0041] FIG. 20 shows a rolling cutter assembled to a rolling cutter
pocket according to embodiments of the present disclosure.
[0042] FIG. 21 shows a rolling cutter and a rolling cutter pocket
according to embodiments of the present disclosure.
[0043] FIG. 22 shows a cross-sectional view of a rolling cutter
assembled to a rolling cutter pocket according to embodiments of
the present disclosure.
[0044] FIG. 23 shows a partial sleeve according to embodiments of
the present disclosure.
[0045] FIG. 24 shows a partial sleeve according to embodiments of
the present disclosure.
DETAILED DESCRIPTION
[0046] In one aspect, embodiments disclosed herein relate to
rolling cutters and methods of retaining such rolling cutters on a
drill bit or other cutting tools. In some embodiments, rolling
cutters may be retained on a fixed cutter drill bit by a retention
pin or a WC sleeve and the side surface of a rolling cutter pocket,
thus allowing the entire cutting face of a rolling cutter to be
exposed. According to other embodiments, rolling cutters may be
retained on a fixed cutter drill bit by only the side surface of a
rolling cutter pocket.
[0047] Generally, cutting elements described herein allow at least
one surface or portion of the cutting element to rotate as the
cutting elements contact a formation. As the cutting element
contacts the formation, the cutting action may allow portion of the
cutting element to rotate around a cutting element rotational axis
extending through the cutting element. Rotation of the cutting
structure may allow for a cutting surface to cut the formation
using the entire outer edge of the cutting surface, rather than the
same section of the outer edge, as observed in a conventional
cutting element.
[0048] Referring to FIG. 3, a segment of a cutting tool 300 having
a rolling cutter pocket 310 is shown. The rolling cutter pocket 310
has a back surface 312 and a side surface 314. Further, a lip 316
(protrusion) may be disposed on the side surface 314 of the rolling
cutter pocket 310. The lip 316 may be integrally formed with the
rolling cutter pocket, or the lip 316 may be attached to the side
surface of the rolling cutter pocket. A rolling cutter 320 may be
disposed within the rolling cutter pocket 310, wherein the rolling
cutter 320 has a cutting face 322, a bottom surface 323 opposite
from the cutting face 322, an outer circumferential surface 324, a
circumferential channel 326 formed within the outer circumferential
surface 324, and a cavity 328 extending at least partially along a
rotational axis R through the rolling cutter 320 from the bottom
surface 323 of the rolling cutter 320. The circumferential channel
326 may be formed around the outer circumferential surface 324 of
the rolling cutter 320, for example, during formation of the
rolling cutter (such as in a mold) or after formation of the
rolling cutter (such as by machining) depending on the material of
the rolling cutter. Likewise, the cavity 328 may be formed, for
example, during formation of the rolling cutter or after formation
of the rolling cutter (such as by plunge EDM (Electrical Discharge
Machining) or laser cutting), depending on the depth of the cavity
and the material of the rolling cutter. A retention pin 330 may be
disposed within the cavity 328 of the rolling cutter 320. FIG. 4
shows the rolling cutter 320 and the retention pin 330 shown in
FIG. 3 assembled within the rolling cutter pocket 310 formed in the
cutting tool 300, wherein the circumferential channel 326 mates
with the lip 316. The cross section of the lip 316 is a half
circle, which may have a radius ranging from 0.030'' to 0.150''.
The cross section of the channel 326 is a slightly larger half
circle, which may have a radius of 0.001'' to 0.010'' greater than
the lip. In order to help rotation, diamond like carbon coating
(DLC) may be applied on rolling cutter pocket surfaces in order to
reduce friction and improve wear resistance.
[0049] According to some embodiments of the present disclosure, a
rolling cutter pocket may have a channel formed in the side surface
of the rolling cutter pocket, and a rolling cutter may have a
corresponding lip formed around the outer circumferential surface
of the rolling cutter. The rolling cutter may be assembled within
the rolling cutter pocket such that the channel formed in the
rolling cutter pocket mates with the lip formed around the outer
circumferential surface of the rolling cutter. In other
embodiments, more than one mating pairs of a lip and channel may be
formed in a rolling cutter assembled to a rolling cutter pocket.
For example, a rolling cutter may have a lip and a channel formed
around the outer circumferential surface of the rolling cutter. The
rolling cutter having both a lip and a channel may be assembled to
a rolling cutter pocket having a corresponding channel and a
corresponding lip formed within the side surface of the rolling
cutter pocket. However, it is within the scope of the present
disclosure that embodiments may have different combinations of one
or more mating pairs of a lip and a channel formed in a rolling
cutter assembled to a rolling cutter pocket.
[0050] Further, cutting tools having a rolling cutter pocket formed
therein may include, for example, a drill bit, a reamer, or a
hybrid bit. For example, a drill bit may have a bit body and a
plurality of blades extending radially from the bit body, wherein
each blade has a leading face, a trailing face, and a top face. At
least one rolling cutter pocket may be disposed on one or more of
the bit blades at the leading face of each blade. For example, a
rolling cutter pocket may be formed at the leading face of a blade,
such that when a rolling cutter is disposed therein, the rolling
cutter is exposed at the leading face and the top face of the
blade.
[0051] Rolling cutter pockets according to embodiments of the
present disclosure may have a side surface that forms a partial
cylindrical shape, or an arc profile. The arc defined by a rolling
cutter pocket side surface may extend 180 degrees or less. For
example, FIG. 5 shows a rolling cutter pocket 510 according to
embodiments of the present disclosure having a back surface 512 and
a side surface 514. As shown, the side surface 514 forms an arc A
equal to about 180 degrees. However, other embodiments may have a
side surface forming an arc equal to less than 180 degrees.
Advantageously, in some embodiments having a side surface extending
180 degrees or less, a rolling cutter may be loaded into the
rolling cutter pocket from the top face of the pocket (top loading)
as opposed to loading the rolling cutter into the pocket from the
leading face of the pocket (i.e., the opening in the pocket that
faces the leading side of a cutting tool, such as a bit blade, in
the direction of cutting). Further, in some embodiments having a
side surface extending 180 degrees or less, a larger portion of the
rolling cutter may be exposed to the formation being drilled when
compared to, for example, cutting elements disposed in cutter
pockets with side surfaces extending more than 180 degrees.
[0052] Referring still to FIG. 5, a lip 516 may be formed along the
side surface 514 of the rolling cutter pocket 510 such that the lip
516 is substantially parallel with and a distance from the back
surface 512 of the rolling cutter pocket 510. The lip 516 may
extend partially along the arc A of the side surface 514 (as shown
in FIG. 5), or the lip may extend along the entire arc A of the
side surface (as shown in FIGS. 3 and 6). The arc angle of the lip
may be less than or equal to 180 degrees and greater than 60
degrees.
[0053] Referring now to FIGS. 6 and 7, a rolling cutter 620 and a
rolling cutter pocket 610 according to embodiments of the present
disclosure are shown. The rolling cutter pocket 610 may be disposed
on a bit blade 600 having a leading face 602, a trailing face 604,
and a top face 606, wherein the rolling cutter pocket 610 is formed
at the leading face 602 of the blade 600. The rolling cutter pocket
610 has a back surface 612 and a side surface 614. Further, a lip
616 may be disposed on the side surface 614 of the rolling cutter
pocket 610. The lip 616 may be integrally formed with the rolling
cutter pocket, or the lip 616 may be attached to the side surface
of the rolling cutter pocket. A rolling cutter 620 may be disposed
within the rolling cutter pocket 610, wherein the rolling cutter
620 has a cutting face 622, a bottom surface 623 opposite from the
cutting face 622, an outer circumferential surface 624, a
circumferential channel 626 formed within the outer circumferential
surface 624, and a cavity 628 extending at least partially along a
rotational axis R through the rolling cutter 620 from the bottom
surface 623 of the rolling cutter.
[0054] A retention pin 630 may be disposed within the cavity 628 of
the rolling cutter 620 and extend through the blade 600, from the
rolling cutter pocket back surface 612 to the trailing face 604 of
the blade 600. The retention pin 630 may be attached to the blade
600 so that the retention pin 630 is fixed to the blade and the
rolling cutter 620 rotates about the retention pin 630. For
example, a bolt 640 may be used to attach the retention pin 630 to
the blade 600, wherein the bolt 640 is threaded to the retention
pin 630 at the trailing face of the blade 600. The bolt 640 and/or
retention pin 630 may be fixed to the blade 600 such as by
interference fitting the retention pin 630 within the blade or by
welding, for example. A retention pin may also be attached to a
blade by other means known in the art, or may be formed integrally
with the blade. Further, a retention pin may be prevented from
rotating (so that a rolling cutter rotates about a fixed retention
pin) by forming non-cylindrical mating portions of the retention
pin and blade. For example, a retention pin may have a
non-cylindrical portion formed at the portion of the retention pin
positioned proximate to the trailing face of the blade. A hole
formed in the blade to receive the retention pin may have a mating
non-cylindrical portion formed proximate to the trailing face of
the blade. In such embodiments, the retention pin may be inserted
through the trailing face of the blade into the blade hole and
rolling cutter cavity, such that the mating non-cylindrical
portions of the retention pin and the blade hole prevent retention
pin rotation while at the same time, the remaining cylindrical
portions of the retention pin allow for a rolling cutter to rotate
about the retention pin. FIG. 7 shows the rolling cutter 620 and
the retention pin 630 shown in FIG. 6 assembled within the rolling
cutter pocket 610 formed in a bit blade 600, wherein the
circumferential channel 626 mates with the lip 616.
[0055] Rolling cutters according to embodiments of the present
disclosure may be retained within a rolling cutter pocket by the
rolling cutter pocket side surface and a retention pin. The side
surface retention mechanism (mating lip and circumferential
channel) may retain the rolling cutter axially within the rolling
cutter pocket, while the retention pin may inhibit the rolling
cutter from being dislodged (pulled out from the top face) from the
rolling cutter pocket. Advantageously, by using a retention pin to
retain a rolling cutter within a rolling cutter pocket, the entire
cutting face of the rolling cutter may be exposed to the formation
being drilled, as opposed to cutting elements that have a retention
system that covers part of the cutting face of the cutter.
[0056] FIGS. 8-10 show a segment of a bit blade 800 having a
rolling cutter pocket 810 formed therein. The rolling cutter pocket
810 has a back surface 812 and a side surface 814. Further, a lip
816 may be disposed on the side surface 814 of the rolling cutter
pocket 810. The lip 816 may be integrally formed with the rolling
cutter pocket, or the lip 816 may be attached, such as by brazing,
to the side surface of the rolling cutter pocket. A rolling cutter
820 may be disposed within the rolling cutter pocket 810, wherein
the rolling cutter 820 has a cutting face 822, a bottom surface 823
opposite the cutting face 822, an outer circumferential surface
824, a circumferential channel 826 formed within the outer
circumferential surface 824, and a cavity 828 extending at least
partially along a rotational axis R, from the bottom surface 823
through the rolling cutter 820. A retention pin 830 may be disposed
within the cavity 828 of the rolling cutter 820 and attached to the
blade 800 by a threaded connection. FIG. 9 shows the rolling cutter
820 and the retention pin 830 shown in FIG. 8 assembled within the
rolling cutter pocket 810 formed in the cutting tool 800, wherein
the circumferential channel 826 mates with the lip 816.
[0057] FIG. 10 shows a cross-sectional view of the rolling cutter
820 and the retention pin 830 shown in FIG. 8 assembled within the
rolling cutter pocket 810. As shown, the cavity 828 extends along
the rotational axis from the cutting face 822 to a back face 823 of
the rolling cutter 820. The retention pin 830 may extend entirely
through the cavity from the back face 823 to the cutting face 822,
such that the portion of the retention pin 830 exposed at the
cutting face side of the cavity 828 is flush with the cutting face
822. According to other embodiments, the retention pin may extend
partially through the cavity from the back face of the rolling
cutter, such that the retention pin is not flush with the cutting
face (see, for example, FIGS. 13 and 19, described below).
[0058] Rolling cutters according to embodiments of the present
disclosure may have at least one ultrahard material included
therein. Such ultra hard materials may include a conventional
polycrystalline diamond table (a table of interconnected diamond
particles having interstitial spaces therebetween in which a metal
component (such as a metal catalyst) may reside), a thermally
stable diamond layer (i.e., having a thermal stability greater than
that of conventional polycrystalline diamond, 750.degree. C.)
formed, for example, by removing substantially all metal from the
interstitial spaces between interconnected diamond particles or
from a diamond/silicon carbide composite, or other ultra hard
material such as a cubic boron nitride. An ultrahard material layer
may be formed on or attached to a substrate, which may be made of a
metallic carbide material, such as a cemented or sintered carbide
of one of the Group IVB, VB, and VIB metals, e.g., tungsten
carbide, tantalum carbide, or titanium carbide, pressed or sintered
in the presence of a binder, such as cobalt, nickel, iron, alloys
thereof, or mixtures thereof.
[0059] Further, in particular embodiments, the rolling cutter may
be formed entirely of ultrahard material(s), but the rolling cutter
may include a plurality of diamond grades used, for example, to
form a gradient structure (with a smooth or non-smooth transition
between the grades). In a particular embodiment, a first diamond
grade having smaller particle sizes and/or a higher diamond density
may be used to form the upper portion of the rolling cutter (that
forms the cutting edge when installed on a bit or other tool),
while a second diamond grade having larger particle sizes and/or a
higher metal content may be used to form the lower, non-cutting
portion of the cutting element. Further, it is also within the
scope of the present disclosure that more than two diamond grades
may be used.
[0060] As known in the art, thermally stable diamond may be formed
in various manners. A typical polycrystalline diamond layer
includes individual diamond "crystals" that are interconnected. The
individual diamond crystals thus form a lattice structure. A metal
catalyst, such as cobalt, may be used to promote recrystallization
of the diamond particles and formation of the lattice structure.
Thus, cobalt particles are typically found within the interstitial
spaces in the diamond lattice structure. Cobalt has a significantly
different coefficient of thermal expansion as compared to diamond.
Therefore, upon heating of a diamond table, the cobalt and the
diamond lattice will expand at different rates, causing cracks to
form in the lattice structure and resulting in deterioration of the
diamond table.
[0061] To obviate this problem, strong acids may be used to "leach"
the cobalt from a polycrystalline diamond lattice structure (either
a thin volume or entire tablet) to at least reduce the damage
experienced from heating diamond-cobalt composite at different
rates upon heating. Examples of "leaching" processes can be found,
for example, in U.S. Pat. Nos. 4,288,248 and 4,104,344. Briefly, a
strong acid, typically hydrofluoric acid or combinations of several
strong acids may be used to treat the diamond table, removing at
least a portion of the co-catalyst from the PDC composite. Suitable
acids include nitric acid, hydrofluoric acid, hydrochloric acid,
sulfuric acid, phosphoric acid, or perchloric acid, or combinations
of these acids. In addition, caustics, such as sodium hydroxide and
potassium hydroxide, have been used to the carbide industry to
digest metallic elements from carbide composites. In addition,
other acidic and basic leaching agents may be used as desired.
Those having ordinary skill in the art will appreciate that the
molarity of the leaching agent may be adjusted depending on the
time desired to leach, concerns about hazards, etc.
[0062] By leaching out the cobalt, thermally stable polycrystalline
(TSP) diamond may be formed. In certain embodiments, only a select
portion of a diamond composite is leached, in order to gain thermal
stability without losing impact resistance. As used herein, the
term TSP includes both of the above (i.e., partially and completely
leached) compounds. Interstitial volumes remaining after leaching
may be reduced by either furthering consolidation or by filling the
volume with a secondary material, such by processes known in the
art and described in U.S. Pat. No. 5,127,923, which is herein
incorporated by reference in its entirety.
[0063] Alternatively, TSP may be formed by forming the diamond
layer in a press using a binder other than cobalt, one such as
silicon, which has a coefficient of thermal expansion more similar
to that of diamond than cobalt has. During the manufacturing
process, a large portion, 80 to 100 volume percent, of the silicon
reacts with the diamond lattice to form silicon carbide which also
has a thermal expansion similar to diamond. Upon heating, any
remaining silicon, silicon carbide, and the diamond lattice will
expand at more similar rates as compared to rates of expansion for
cobalt and diamond, resulting in a more thermally stable layer. PDC
cutters having a TSP cutting layer have relatively low wear rates,
even as cutter temperatures reach 1200.degree. C. However, one of
ordinary skill in the art would recognize that a thermally stable
diamond layer may be formed by other methods known in the art,
including, for example, by altering processing conditions in the
formation of the diamond layer.
[0064] The substrate on which the cutting face is disposed may be
formed of a variety of hard or ultra hard particles. In one
embodiment, the substrate may be formed from a suitable material
such as tungsten carbide, tantalum carbide, or titanium carbide.
Additionally, various binding metals may be included in the
substrate, such as cobalt, nickel, iron, metal alloys, or mixtures
thereof. In the substrate, the metal carbide grains are supported
within the metallic binder, such as cobalt. Additionally, the
substrate may be formed of a sintered tungsten carbide composite
structure. It is well known that various metal carbide compositions
and binders may be used, in addition to tungsten carbide and
cobalt. Thus, references to the use of tungsten carbide and cobalt
are for illustrative purposes only, and no limitation on the type
substrate or binder used is intended. In another embodiment, the
substrate may also be formed from a diamond ultra hard material
such as polycrystalline diamond and thermally stable diamond.
[0065] Referring to FIG. 11, a cross-sectional view of a rolling
cutter 1120 and a retention pin 1130 assembled within a rolling
cutter pocket 1110 according to embodiments of the present
disclosure are shown. The rolling cutter 1120 has an ultrahard
material table 1125, which forms the cutting face 1122, disposed on
a substrate 1127. The ultrahard material table 1125 may be formed
of ultrahard material described above, such as diamond, TSP, or
cubic boron nitride, and the substrate 1127 may be formed of
substrate material described above, such as metal carbides. While
the illustrated embodiment shows the cutting face and substrate as
two distinct pieces, one of skill in the art should appreciate that
it is within the scope of the present disclosure the cutting face
and substrate are integral, identical compositions. In such an
embodiment, it may be preferable to have a single diamond composite
forming the cutting face and substrate or distinct layers.
[0066] Referring now to FIGS. 12 and 13, a segment of a bit blade
1200 having a rolling cutter pocket 1210 formed therein is shown.
The rolling cutter pocket 1210 has a back surface 1212 and a side
surface 1214. Further, a lip 1216 may be disposed on the side
surface 1214 of the rolling cutter pocket 1210. The lip 1216 may be
integrally formed with the rolling cutter pocket, or the lip 1216
may be attached, such as by brazing, to the side surface of the
rolling cutter pocket. A rolling cutter 1220 may be disposed within
the rolling cutter pocket 1210, wherein the rolling cutter 1220 has
a cutting face 1222, a back face 1223, an outer circumferential
surface 1224, a circumferential channel 1226 formed within the
outer circumferential surface 1224, and a cavity 1228 extending at
least partially from the back face 1223, along a rotational axis R
through the rolling cutter 1220. Further, the rolling cutter 1220
has an ultrahard material table 1225 formed on a substrate 1227,
wherein the ultrahard material table 1225 forms the cutting face
1222 of the rolling cutter 1220. A retention pin 1230 may be
disposed within the cavity 1228 of the rolling cutter 1220 and
attached to the blade 1200 by a threaded connection.
[0067] FIG. 13 shows the rolling cutter 1220 and the retention pin
1230 shown in FIG. 12 assembled within the rolling cutter pocket
1210 formed in the cutting tool 1200, wherein the circumferential
channel 1226 mates with the lip 1216. As shown, the retention pin
1230 extends partially through the cavity 1228 from a back face
1223 of the rolling cutter 1220 to the ultrahard material table
1225. According to embodiments of the present disclosure, a cavity
may extend along the rotational axis of a rolling cutter a distance
of at least 50 percent of the length of the rolling cutter from the
back face of the rolling cutter, and up to the entire length of the
rolling cutter. Further, a retention pin may extend a distance less
than or equal to the length of the cavity. For example, in
embodiments having a cavity extending the entire length of the
rolling cutter (from the back face to the cutting face of the
rolling cutter) along the rolling cutter rotational axis, a
retention pin may also extend the entire length of the rolling
cutter, such that an end of the retention pin is flush with the
cutting face of the rolling cutter. Alternatively, in embodiments
having a cavity extending the entire length of the rolling cutter
(from the back face to the cutting face of the rolling cutter)
along the rolling cutter rotational axis, a retention pin may
extend a partial length of the rolling cutter from the back face,
such that a portion of the cavity is exposed at the cutting face of
the rolling cutter (e.g., shown in FIG. 19). In embodiments having
a cavity extending a partial length of the rolling cutter from the
rolling cutter back face, a retention pin may extend substantially
the distance of the cavity, such that the retention pin and cavity
terminate adjacent to each other. Alternatively, in embodiments
having a cavity extending a partial length of the rolling cutter
from the rolling cutter back face, a retention pin may extend a
distance less than the length of the cavity, such that a gap is
formed between where the retention pin and the cavity terminate.
Additionally, retention pins and/or cavities of the present
disclosure may include diamond or other low-friction material to
provide bearing surfaces between a retention pin and rolling
cutter. Further, the diameter of the pin may range from 0.100
inches to 0.3 inches.
[0068] According to embodiments of the present disclosure, a
rolling cutter pocket may be formed in a cutting tool, such as in a
blade of a drag bit. Drill bits formed from a matrix material may
have the rolling cutter pockets formed in the blade by positioning
rolling cutter place holders (displacements) into a bit mold, and
then pouring the bit matrix material in the mold around the
displacements. The displacements may have a circumferential channel
formed therein to provide a mold of a lip for the rolling cutter
pockets. Alternatively, the rolling cutter displacements may have
no circumferential channel, and a lip may be added to the rolling
cutter pockets after formation of the bit. Matrix material may
include a mixture of a carbide compounds and/or a metal alloy using
any technique known to those skilled in the art. For example,
matrix materials may include at least one of macrocrystalline
tungsten carbide particles, carburized tungsten carbide particles,
cast tungsten carbide particles, sintered tungsten carbide
particles, and unsintered or pre-sintered tungsten monocarbide. In
other embodiments non-tungsten carbides of vanadium, chromium,
titanium, tantalum, niobium, silicon, aluminum or other transition
metal carbides may be used. In yet other embodiments, carbides,
oxides, and nitrides of Group IVA, VA, or VIA metals may be used.
Typically, a binder phase may be formed from a powder component
and/or an infiltrating component. In some embodiments of the
present invention, hard particles may be used in combination with a
powder binder such as cobalt, nickel, iron, chromium, copper,
molybdenum and their alloys, and combinations thereof Once the bit
is formed and the place holders removed, rolling cutters may then
be placed into the rolling cutter pockets. Alternatively, drill
bits formed from a steel bit body may have the rolling cutter
pockets machined into the blades.
[0069] In embodiments having a lip formed on the rolling cutter
pockets after manufacturing the cutting tool, the lip may be
attached within a groove formed in the rolling cutter pocket. For
example, referring to FIGS. 14-16, a segment of a bit blade 1400
has rolling cutter 1420 assembled within a rolling cutter pocket
1410 using a retention pin 1430, wherein the rolling cutter 1420
and the rolling cutter pocket 1410 have a mating circumferential
channel 1426 and lip 1416, respectively. Particularly, the rolling
cutter 1420 has a cutting face 1422, an outer circumferential
surface 1424, a circumferential channel 1426 formed within the
outer circumferential surface 1424, and a cavity 1428 extending at
least partially along a rotational axis through the rolling cutter
1420. The rolling cutter pocket 1410 has a back surface 1412, a
side surface 1414, and a lip 1416 disposed within a groove 1418
formed in the side surface 1414, wherein the lip 1416 is parallel
with and a distance from the back surface 1412. The lip 1416 may be
attached in the groove 1418 to the side surface 1414 of the rolling
cutter pocket 1410 by brazing, for example. Further, the lip 1416
may extend partially around the side surface 1414 or entirely
around the side surface (such that the lip intersects with the top
face of the blade). The lip may be formed of the same or different
material used to make the rolling cutter pocket, including, for
example, a metal carbide or steel material. A retention pin 1430
may be disposed within the cavity 1428 of the rolling cutter 1420
and attached to the blade 1400 by a threaded connection.
[0070] Methods of manufacturing a drill bit according to
embodiments disclosed here may include forming a bit body, as
described above, wherein the bit body has a threaded pin end and a
cutting end, and at least one blade extends radially from the
cutting end of the bit body. A bit blade may have at least one
rolling cutter pocket formed therein during the bit formation, or
at least one rolling cutter pocket may be formed in a blade after
bit formation. A rolling cutter may then be placed into each
rolling cutter pocket, wherein the rolling cutter has a cutting
face, an outer circumferential surface, a circumferential channel
formed within the outer circumferential surface, and a cavity
extending at least partially along a rotational axis through the
rolling cutter. The rolling cutter may be retained in the rolling
cutter pocket by a retention pin disposed within the cavity. In
embodiments disclosed herein, a rolling cutter may also be retained
in a rolling cutter pocket using a side wall retention mechanism.
Such side wall retention mechanism may include mating a lip
disposed within a side surface of the rolling cutter pocket with a
circumferential channel formed within the outer circumferential
surface of the rolling cutter. The lip may be attached to the
rolling cutter pocket (such as by brazing) or integrally formed
with the rolling cutter pocket.
[0071] According to some embodiments, a rolling cutter may be
placed in a rolling cutter pocket prior to inserting the retention
pin within the rolling cutter cavity. The retention pin may then be
attached to the blade by a threaded connection. For example, in
some embodiments, a threaded blind hole may be machined in a back
surface of the rolling cutter pocket, and once the rolling cutter
is placed in the rolling cutter pocket, a retention pin may be
inserted through the rolling cutter cavity and threaded within the
threaded blind hole (such that the retention pin is positioned
within the cavity and the blind hole). In other embodiments, a
threaded hole may be drilled entirely through the blade (or other
cutting tool), such that a retention pin may be threaded through
the blade and into the back side of a rolling cutter. For example,
as shown in FIG. 15, a threaded hole 1408 may be machined through a
blade 1400, extending from a trailing side 1404 of the blade to a
back surface 1412 of a rolling cutter pocket 1410. A rolling cutter
1420 may then be placed within the rolling cutter pocket 1410. A
retention pin 1430 may be threaded through the threaded hole 1408,
such that the retention pin 1430 also extends into a cavity 1428 of
the rolling cutter 1420.
[0072] According to other embodiments, a rolling cutter may be
placed in a rolling cutter pocket that has a retention pin
integrally formed therein. The retention pin may be integrally
formed with a blade or other cutting tool at a back surface of a
rolling cutter pocket. In such embodiments, a partial sleeve may be
assembled with the rolling cutter before placing the assembly
within the rolling cutter pocket and around the retention pin.
[0073] For example, referring to FIGS. 17-19, a segment of a bit
blade 1700 has rolling cutter 1720 assembled within a rolling
cutter pocket 1710 using a retention pin 1730. Particularly, the
rolling cutter 1720 has a cutting face 1722, an outer
circumferential surface 1724, a circumferential channel 1726 formed
within the outer circumferential surface 1724, and a cavity 1728
extending at least partially along a rotational axis through the
rolling cutter 1720. The rolling cutter pocket 1710 has a back
surface 1712 and a side surface 1714, wherein a receptacle 1715
(represented by the shaded area) is formed within the side surface
1714 to receive a partial sleeve 1740. The receptacle 1715 extends
from the leading side 1702 of the blade 1700 a distance along the
length of the rolling cutter pocket 1710 and a radial distance
around the side surface of the rolling cutter pocket 1710. A
partial sleeve 1740 may be positioned adjacent to the rolling
cutter 1720, such that the partial sleeve 1740 extends partially
around the outer circumferential surface 1724 of the rolling cutter
1720. Further, the partial sleeve 1740 may have a lip 1746 formed
thereon that mates with the circumferential channel 1726 of the
rolling cutter 1720. The rolling cutter 1720 and the partial sleeve
1740 may then be inserted into the rolling cutter pocket 1710,
around a retention pin 1730 integrally formed with the rolling
cutter pocket 1710. Particularly, the retention pin 1730 extends
from the back surface 1712 of the rolling cutter pocket 1710 and at
least partially through the cavity 1728 of the rolling cutter 1720.
The partial sleeve 1740 may be attached within the receptacle 1715
within the rolling cutter pocket 1710 to form part of the rolling
cutter pocket side surface 1714, wherein the rolling cutter 1720
may rotate within the rolling cutter pocket 1710 and partial sleeve
1740.
[0074] Further, the shape of a partial sleeve and a corresponding
receptacle may vary. For example, as shown in FIGS. 23 and 24, two
partial sleeves according to embodiments of the present disclosure
are shown. A partial sleeve 2340 has a lower surface 2341 and an
upper surface 2342, wherein the upper surface 2342 is positioned
adjacent to a rolling cutter and forms at least part of the side
surface of a rolling cutter pocket once inserted into a rolling
cutter pocket receptacle. Particularly, the upper surface 2342 of a
partial sleeve 2340 may have an arc shape, which extends around
part of the circumference of a rolling cutter once the partial
sleeve 2340 is assembled with a rolling cutter. Further, as
described above, the upper surface 2342 of a partial sleeve 2340
may have at least one lip 2346 (and/or at least one channel) formed
thereon. The shape of a partial sleeve may be described with
reference to its width W (the distance the partial sleeve extends
from a leading face of a blade into the rolling cutter pocket),
depth D (the distance between the upper surface of the partial
sleeve to the lower surface of the partial sleeve), and arc length
L (the distance around the arc of the upper surface). As shown in
FIG. 23, the depth D of the partial sleeve 2340 may extend a
constant distance from the upper surface 2342 to the lower surface
2341 of the partial sleeve 2340, as measured around the arc length
L. Thus, in such embodiments, the cross-sectional shape along the
length of the partial sleeve 1740 may be an arc, or
partial-circular shape. Alternatively, as shown in FIG. 24, the
depth D of the partial sleeve 2340 may extend a varying distance
from the upper surface 2342 to the lower surface 2341 of the
partial sleeve 2340, as measured around the arc length L. In such
embodiments, the cross-sectional shape along the length of the
partial sleeve may be irregular shapes. Additionally, the width W
of a partial sleeve 2340 may constant or varying, as measured
around the arc length L. One skilled in the art may appreciate that
receptacles according to embodiments of the present disclosure may
have corresponding shapes to the partial sleeve shapes described
above. Particularly, a receptacle may have a negative shape (i.e.,
the shape of the void, or empty space) that mates with a
corresponding partial sleeve.
[0075] Partial sleeves may be formed of a carbide material, such as
tungsten carbide, or high strength tool steel alloys. In some
embodiments, a partial sleeve may be formed of the same material as
the cutter pocket, while in other embodiments, a partial sleeve may
be formed of a different material than the cutter pocket.
[0076] According to yet other embodiments, a rolling cutter may be
retained in a rolling cutter pocket without the use of a retention
pin. For example, referring to FIGS. 20-22, a segment of a bit
blade 2000 has a rolling cutter 2020 assembled within a rolling
cutter pocket 2010. Particularly, the rolling cutter 2020 has a
cutting face 2022, an outer circumferential surface 2024, and a
circumferential channel 2026 formed within the outer
circumferential surface 2024. The rolling cutter pocket 2010 has a
back surface 2012 and a side surface 2014, wherein a receptacle
2015 (represented by the shaded area) is formed within the side
surface 2014 to receive a partial sleeve 2040. The receptacle 2015
extends from the leading side 2002 of the blade 2000 a distance D
along the length of the rolling cutter pocket 2010 and a radial
distance around the side surface of the rolling cutter pocket 2010.
A partial sleeve 2040 may be positioned adjacent to the rolling
cutter 2020, such that the partial sleeve 2040 extends partially
around the outer circumferential surface 2024 of the rolling cutter
2020. Further, the partial sleeve 2040 may have a lip 2046 formed
thereon that mates with the circumferential channel 2026 of the
rolling cutter 2020. The rolling cutter 2020 and the partial sleeve
2040 may then be inserted into the rolling cutter pocket 2010. The
partial sleeve 2040 may be attached to the rolling cutter pocket
2010 to form part of the rolling cutter pocket side surface,
wherein the rolling cutter 2020 may rotate within the rolling
cutter pocket 2010 and partial sleeve 2040. Methods of attaching
the partial sleeve 2040 to the rolling cutter pocket 2010 may
include, for example, brazing, welding, mechanical locking, or
other means known in the art.
[0077] As shown, the partial sleeve 2040 and the rolling cutter
pocket side surface 2014 may form an arc A. The arc may extend
around the rolling cutter 2020 greater than 180 degrees.
Advantageously, in some embodiments having an arc extending greater
than 180 degrees, a rolling cutter may be retained within a rolling
cutter pocket using only the side wall of the rolling cutter
pocket. For example, a side wall retention mechanism (the mating
lip formed along the rolling cutter pocket side wall and
circumferential channel formed within the rolling cutter) may
retain the rolling cutter axially within the rolling cutter pocket,
while the extension of the rolling cutter pocket side wall greater
than 180 degrees may inhibit the rolling cutter from being
dislodged (pulled out from the top face) from the rolling cutter
pocket.
[0078] Further, design modifications including, for example, side
rake and back rake may be included in various combinations not
limited to those described above in the rolling cutters of the
present disclosure. In one embodiment, a cutter may have a side
rake ranging from 0 to .+-.45 degrees. In another embodiment, a
cutter may have a back rake ranging from about 5 to 35 degrees. A
rolling cutter may be positioned on a blade with a selected back
rake to assist in removing drill cuttings and increasing rate of
penetration. A cutter disposed on a drill bit with side rake may be
forced forward in a radial and tangential direction when the bit
rotates. In some embodiments, because the radial direction may
assist the movement of rolling cutters, such rotation may allow
greater drill cuttings removal and provide an improved rate of
penetration. As a cutting element contacts formation, the rotating
motion of the cutting element may be continuous or discontinuous.
For example, when the cutting element is mounted with a determined
side rake and/or back rake, the cutting force may be generally
pointed in one direction. Providing a directional cutting force may
allow the cutting element to have a continuous rotating motion,
further enhancing drilling efficiency.
[0079] Although only a few example embodiments have been described
in detail above, those skilled in the art will readily appreciate
that many modifications are possible in the example embodiments
without materially departing from this invention. Accordingly, all
such modifications are intended to be included within the scope of
this disclosure as defined in the following claims.
* * * * *