U.S. patent application number 14/334287 was filed with the patent office on 2016-01-21 for precision polycrystalline diamond compact (pdc) pockets.
The applicant listed for this patent is Superior Drilling Products, Inc.. Invention is credited to Joseph Aschenbrenner, Cameron Dick, Gilbert Troy Meier, James D. Osterloh, Joshua J. Smith.
Application Number | 20160017668 14/334287 |
Document ID | / |
Family ID | 55074154 |
Filed Date | 2016-01-21 |
United States Patent
Application |
20160017668 |
Kind Code |
A1 |
Meier; Gilbert Troy ; et
al. |
January 21, 2016 |
PRECISION POLYCRYSTALLINE DIAMOND COMPACT (PDC) POCKETS
Abstract
Method of manufacturing and remanufacturing wellbore drill bits
and wellbore drill bit manufactured or remanufactured by the
methods are disclosed. The manufacturing method comprises providing
a drill bit having at least one blade, providing at least one
cutter pocket in each blade, providing a registration device in
each cutter pocket, and positioning a cutting surface within each
cutter pocket and in engagement with each the registration device
therein.
Inventors: |
Meier; Gilbert Troy;
(Vernal, UT) ; Osterloh; James D.; (West Richland,
WA) ; Smith; Joshua J.; (Vernal, UT) ; Dick;
Cameron; (Vernal, UT) ; Aschenbrenner; Joseph;
(Blackfoot, ID) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Superior Drilling Products, Inc. |
Vernal |
UT |
US |
|
|
Family ID: |
55074154 |
Appl. No.: |
14/334287 |
Filed: |
July 17, 2014 |
Current U.S.
Class: |
175/428 ;
51/307 |
Current CPC
Class: |
B24D 18/00 20130101;
E21B 10/56 20130101 |
International
Class: |
E21B 10/56 20060101
E21B010/56; B24D 18/00 20060101 B24D018/00 |
Claims
1. A method of manufacturing a wellbore drill bit, comprising:
providing a drill bit having at least one blade; providing at least
one cutter pocket in each blade; providing a registration device in
each cutter pocket; and positioning a cutting surface within each
cutter pocket and in engagement with each the registration device
therein.
2. The method of claim 1, wherein each cutting surface is a
polycrystalline diamond compact (PDC).
3. The method of claim 1, wherein a registration device is milled
into each cutter pocket.
4. The method of claim 1, wherein the registration device aligns
the cutting surface within the cutter pocket.
5. The method of claim 4, wherein the alignment comprises coaxially
aligning the cutting surface with the cutter pocket.
6. The method of claim 4, wherein the alignment occurs
automatically.
7. The method of claim 1, wherein each cutting surface is
positioned within the associated cutter pocket with a constant
peripheral brazed joint of between 0.004'' and 0.006'' between the
cutting surface and the cutter pocket.
8. The method of claim 1, wherein the cutting surface is brazed
into the cutter pocket.
9. A method of remanufacturing a wellbore drill bit, comprising:
providing a drill bit having at least one blade; providing at least
one cutter pocket in each blade; providing a registration device in
each cutter pocket; positioning a cutting surface within each
cutter pocket and in engagement with each the registration device
therein; distributing the drill bit for use; receiving the drill
bit after use; assessing each cutting surface; removing damaged
cutting surfaces; and replacing the damaged cutting surfaces with
new cutting surfaces within each cutter pocket and in engagement
with each the registration device therein.
10. The method of claim 9, wherein each cutting surface is a
polycrystalline diamond compact (PDC).
11. The method of claim 9, wherein a registration device is milled
into each cutter pocket.
12. The method of claim 9, wherein the registration device aligns
the cutting surface within the cutter pocket.
13. The method of claim 12, wherein the alignment comprises
coaxially aligning the cutting surface with the cutter pocket.
14. The method of claim 12, wherein the alignment occurs
automatically.
15. The method of claim 9, wherein each cutting surface is
positioned within the associated cutter pocket with a constant
peripheral brazed joint of between 0.004'' and 0.006'' between the
cutting surface and the cutter pocket.
16. The method of claim 15, wherein the new cutting surfaces have
the same tolerances as the replaced cutting surfaces.
17. The method of claim 9, wherein the step of removing damaged
cutting surfaces occurs without damaging the registration
devices.
18. The method of claim 9, wherein the use is drilling a
wellbore.
19. A wellbore drill bit manufactured by the method of claim 1.
20. A wellbore drill bit remanufactured by the method of claim 9.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The invention is directed to methods and devices for
manufacturing and refurbishing drill bits. Specifically, the
invention is directed to methods and devices for inserting and
replacing polycrystalline diamond compacts (PDCs) in drill
bits.
[0003] 2. Background of the Invention
[0004] Wellbore drilling is the process of drilling one or more
holes into the ground for the extraction of water, brine, natural
gas, petroleum, or other natural resources. One of the main
components for wellbore drilling is the drill bit. Drill bits
typically comprise a solid metal or composite matrix-type metal
body having a lower cutting face region and an upper shank region
for connection to the bottom hole assembly of a drill string formed
of jointed tubular members which are then rotated as a single unit
by a rotary table or top drive drilling rig, or by a downhole motor
selectively in combination with the surface equipment.
Alternatively, rotary drill bits may be attached to a bottom hole
assembly, including a downhole motor assembly, which is, in turn,
connected to a drill string wherein the downhole motor assembly
rotates the drill bit. The bit body may have one or more internal
passages for introducing drilling fluid, or mud, to the cutting
face of the drill bit to cool cutters provided thereon and to
facilitate formation chip and formation fines removal. The sides of
the drill bit typically may include a plurality of radially or
laterally extending blades that have an outermost surface of a
substantially constant diameter and generally parallel to the
central longitudinal axis of the drill bit, commonly known as gage
pads. The gage pads generally contact the wall of the borehole
being drilled in order to support and provide guidance to the drill
bit as it advances along a desired cutting path or trajectory.
[0005] Fixed cutter drill bits have no moving parts. Instead,
drilling occurs due to percussion or rotation of the drill string.
Fixed cutter bits can be polycrystalline diamond compact (PDC),
grit hotpressed inserts (GHI), or other hard materials. PDCs are
aggregate tiny, inexpensive, manmade diamonds into relatively
large, intergrown masses of randomly oriented crystals that can be
formed into useful shapes called diamond tables. Diamond tables are
the part of a cutter that contacts a formation. Besides their
hardness, PDC diamond tables efficiently bond with tungsten carbide
materials that can be brazed (attached) to bit bodies. Diamonds, by
themselves, will not bond together, nor can they be attached by
brazing. Under the high temperature, high stress, high impact,
and/or corrosive conditions that the PDCs are subjected to, the
PDCs often chip, crack, become loose, or otherwise degrade. While
the PDCs may become less effective, the drill bit body may still be
useable. Therefore, a process to remanufacture (or repair) drill
bits has been developed over the years. The process involves
removing broken or problematic PDCs and replacing them with new
PDCs. However, during initial fabrication and replacement, the PDCs
may not be properly centered or positioned. Therefore, there is a
desire for a method and system to properly position PDCs in drill
bits.
SUMMARY OF THE INVENTION
[0006] The present invention overcomes the problems and
disadvantages associated with current strategies and designs and
provides new tools and methods of manufacturing and remanufacturing
drill bits.
[0007] One embodiment of the invention is directed to a method of
manufacturing a wellbore drill bit. The method comprises providing
a drill bit having at least one blade, providing at least one
cutter pocket in each blade, providing a registration device in
each cutter pocket, and positioning a cutting surface within each
cutter pocket and in engagement with each the registration device
therein.
[0008] Preferably, each cutting surface is a polycrystalline
diamond compact (PDC). In a preferred embodiment, a registration
device is milled into each cutter pocket. Preferably, the
registration device aligns the cutting surface within the cutter
pocket. The alignment preferably comprises coaxially aligning the
cutting surface with the cutter pocket. Preferably, the alignment
occurs automatically. In a preferred embodiment, each cutting
surface is positioned within the associated cutter pocket with a
constant peripheral brazed joint of between 0.004'' and 0.006''
between the cutting surface and the cutter pocket. Preferably, the
cutting surface is brazed into the cutter pocket.
[0009] Another embodiment of the invention is directed to a method
of remanufacturing a wellbore drill bit. The method comprises,
providing a drill bit having at least one blade, providing at least
one cutter pocket in each blade, providing a registration device in
each cutter pocket, positioning a cutting surface within each
cutter pocket and in engagement with each the registration device
therein, distributing the drill bit for use, receiving the drill
bit after use, assessing each cutting surface, removing damaged
cutting surfaces, and replacing the damaged cutting surfaces with
new cutting surfaces within each cutter pocket and in engagement
with each the registration device therein.
[0010] Preferably each cutting surface is a polycrystalline diamond
compact (PDC). In a preferred embodiment, a registration device is
milled into each cutter pocket. Preferably, the registration device
aligns the cutting surface within the cutter pocket. The alignment
preferably comprises coaxially aligning the cutting surface with
the cutter pocket. Preferably, the alignment occurs automatically.
In a preferred embodiment, each cutting surface is positioned
within the associated cutter pocket with a constant peripheral
brazed joint of between 0.004'' and 0.006'' between the cutting
surface and the cutter pocket. Preferably, the new cutting surfaces
have the same tolerances as the replaced cutting surfaces.
Preferably, the step of removing damaged cutting surfaces occurs
without damaging the registration devices. The use is preferably
drilling a wellbore.
[0011] Another embodiment of the invention is directed to wellbore
drill bits manufactured by the methods disclosed herein.
[0012] Other embodiments and advantages of the invention are set
forth in part in the description, which follows, and in part, may
be obvious from this description, or may be learned from the
practice of the invention.
DESCRIPTION OF THE DRAWING
[0013] The invention is described in greater detail by way of
example only and with reference to the attached drawing, in
which:
[0014] FIG. 1 is a schematic depicting the existing process of
inserting PDCs into a drill bit.
[0015] FIG. 2 is a schematic depicting the inventive method of
inserting PDCs into a drill bit.
DESCRIPTION OF THE INVENTION
[0016] As embodied and broadly described herein, the disclosures
herein provide detailed embodiments of the invention. However, the
disclosed embodiments are merely exemplary of the invention that
may be embodied in various and alternative forms. Therefore, there
is no intent that specific structural and functional details should
be limiting, but rather the intention is that they provide a basis
for the claims and as a representative basis for teaching one
skilled in the art to variously employ the present invention
[0017] FIG. 1 depicts the current method of installing and
replacing polycrystalline diamond compacts (PDCs) in drill bits.
While the invention is described with reference to PDCs and drill
bits, the cutting surfaces can be grit hotpressed inserts (GHIs),
aluminum oxide, silicon carbide, cubic boron nitride or another
material with a high
[0018] Young's Modulus and the housing can be a router or another
drilling, grinding, or cutting device.
[0019] As can be seen in FIG. 1, in order for a PDC 110 to fit
within a cutter pocket 105 (or cavity in the drill bit for the PDC
110), the cutter pocket's interior dimensions must be larger than
the PDC's exterior dimensions. Ideally, there is between a 0.004''
and 0.006'' gap 115 between the outer surface of the PDC 110 and
the inner surface of the cutter pocket. This gap 115 allows for the
brazing material (e.g. molten silver solder) to be inserted between
the PDC 110 and cutter pocket 105 to couple the PDC 110 to the
drill bit 120. However, in practice, the gap 115 can range between,
for example, no gap at all (as shown in dashed lines 125) and a
0.012'' gap (as shown in dotted lines 130).
[0020] The variation in the size 135 of the gap 115 can cause the
PDC 110 to be seated improperly. Such variations can cause the PDC
110 not to extend the proper distance proud of the drill bit 120
body, be off center, or improperly angled.
[0021] During the remanufacturing process, the drill bit is heated
to at or above 375.degree. C. so that the damaged PDCs are easily
removable. Once the PDCs are removed, the cutter pocket is
conditioned by removing any excess material and sized to receive a
new PDC.
[0022] The new PDC is then placed in the cutter pocket and brazed
to affix the PDC to the drill bit. During this process, the cutter
pocket can become irregularly shaped, enlarged, or otherwise
degraded.
[0023] FIG. 2 depicts a schematic of an embodiment of the inventive
method of positioning a PDC 210 in a cutter pocket 205. As can be
seen in the figure, a registration device 240 is added to the
cutter pocket 205 prior to insertion of the PDC 210. The
registration device 240 preferably aligns or properly positions the
PDC 210 relative to the cutter pocket 205. Preferably, the
registration device 240 is machined directly into base material
(for example the registration device can be milled, ground, or
molded into the cutter pocket 205). The registration device 240 can
be a rod, ball, hemisphere, triangular, a prism, or another shape.
However, the registration device 240 may be affixed to the interior
surface of the cutter pocket 205. For example, recesses can be
machined to receive a registration device 240 or one or more
registration devices 240 to be affixed to the interior surface of
the cutter pocket 205 during manufacturing of the drill bit 220.
For example, three, four, or five registration devices 240 can be
affixed to the interior surface of the cutter pocket 205. The
registration device(s) 240 can be steel, bronze, a PDC, or another
material. The registration device(s) 240 can be affixed with
adhesive, solder, brazing, a mechanical coupling, friction, or
another fixation method.
[0024] The PDC 210 is then placed into the cutter pocket 205 and
into engagement with the registration device 240. Preferably, the
registration device 240 automatically aligns the PDC 210 within the
cutter pocket 205 such that the center of the PDC 210 is coaxial
with the center of the cutter pocket 205 and the PDC 210 extends
proud of the drill bit 220 the desired distance without the need
for grinding the full diameter PDCs (gage). Preferably the
registration device 240 allows the brazer to exert pressure on the
PDC 210 without dislocating the PDC 210 from its ideal position.
Furthermore, the registration device 240 preferably provides a
constant peripheral brazed joint of between 0.004'' and 0.006''
between the PDC 210 and the cutter pocket 205.
[0025] After the drill bit returns from the oil fields or other
use, any damaged PDCs 210 can be removed, preferably without
damaging the registration device 240 and new PDCs 210 can
preferably be inserted into the cutter pocket 205 and into
engagement with the registration device 240 in the same manner as
the original PDCs 210. Preferably, the new PDCs 210 have the same
tolerances as the original PDCs 210.
[0026] Other embodiments and uses of the invention will be apparent
to those skilled in the art from consideration of the specification
and practice of the invention disclosed herein. All references
cited herein, including all publications, U.S. and foreign patents
and patent applications, are specifically and entirely incorporated
by reference. It is intended that the specification and examples be
considered exemplary only with the true scope and spirit of the
invention indicated by the following claims. Furthermore, the term
"comprising of" includes the terms "consisting of" and "consisting
essentially of."
* * * * *