Mosaic diamond drag bit cutter having a nonuniform wear pattern
AssigneeBaker Hughes Incorporated
InventorsGordon A. Tibbitts, Kenneth Johns
Life of this patent
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Abstract
A cutter for a rotating drag bit which has a cutting face formed from a plurality of polycrystalline diamond compact (PCD) elements. The elements can be of varying thickness and/or varying hardness to provide a cutting edge having a nonuniform wear pattern. Also provided is a cutter which includes two layers of PCD elements. The PCD elements can be of varying thickness and/or hardness to provide a cutter which presents a cutting edge having a wear ratio which varies with cutter wear. Also provided is an impact cutter having a cutting surface formed from one or more layers of PCD elements.
Claims38
A cutter in a rotating drag bit comprising:
- a cutting face;
- a first group of cutting elements each having at least one end surface and being subject to wear at a first rate, said end surfaces being exposed on said cutting face;
- a second group of cutting elements each having at least one end surface and being subject to wear at a second rate different from said first rate, said second group end surfaces also being exposed on said cutting face;
- and
- a cutting slug formed of matrix material and having said first and second groups of cutting elements disposed therein, said cutting face being defined by a plurality of said end surfaces exposed on said cutting face.
A diamond cutter in a rotating drag bit comprising:
- a plurality of thermally stable, prefabricated polycrystalline diamond synthetic elements each having at least one end surface;
- a cutting slug formed of matrix material, said plurality of elements disposed within said cutting slug and said matrix material filling between said plurality of elements;
- a cutting face formed on said cutting slug and defined by a plurality of said end surfaces exposed on said cutting face;
- and
- a cutting edge formed on one side of said cutting face and including side surfaces presented by said polycrystalline diamond elements, said cutting edge including elements which wear at different rates thereby forming a cutting edge having a profile dependent upon the wear rate of the elements comprising said cutting edge.
A rotating drag bit comprising:
- a plurality of cutters, including at least two cutters of the type made from cutting elements embedded in a matrix material and presenting a plurality of end surfaces which define a cutting face;
- a first one of such cutters having elements which wear at a first rate;
- and
- a second one of such cutters having cutting elements which wear at a second rate different from said first rate.
A method of precussive drilling comprising the steps of:
- bonding a first layer of cutting elements to a precussive drill bit;
- bonding a second layer of such elements to said first layer;
- operating the precussive drill bit;
- orienting the bit to effect repeated striking of the cutting elements against an earth formation in a manner which compresses the cutting elements each time it strikes the formation.
A precussive drill bit comprising:
- a bit body having a working surface profile of a type suitable for precussive drilling wherein a working surface on said bit body repeatedly strikes an earth formation;
- and
- a layer of polycrystalline diamond bonded to said bit body and having a surface which defines substantially all of said working surface.
Dependencies are inferred from the claim text.