Earth-boring tools including selectively actuatable cutting elements and related methods

• US 10,214,968 B2
• Filed: 12/02/2015
• Issued: 02/26/2019
• Est. Priority Date: 12/02/2015
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Evans, Kenneth R., Sullivan, Eric C., Makkar, Navish
• Primary Examiner(s): Harcourt, Brad
• Assistant Examiner(s): Carroll, David
• Application Number:
  US14/957,203
• Publication Number:
  US 20170159370A1
• Time in Patent Office: 1,182 Days
• CPC Class Codes: E21B 10/605 the bit being a core-bit
• CPC Class Codes: E21B 10/62 characterised by parts, e.g. cutting elements, which are detachable or adjustable E21B10/64 takes precedence; for roller bits E21B10/20; for augers E21B10/44
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems

Abstract

Methods of operating earth-boring tools may involve extending a selectively actuatable cutting element outward from a face of the earth-boring tool. A portion of an underlying earth formation may be crushed by a crushing cutting action utilizing the selectively actuatable cutting element in response to extension of the cutting element. The selectively actuatable cutting element may subsequently be retracted. Earth-boring tools may include a selectively actuatable cutting element mounted to a blade, the selectively actuatable cutting element configured to move between a retracted state in which the selectively actuatable cutting element does not engage with an underlying earth formation and an extended state in which the selectively actuatable cutting element engages with the underlying earth formation. The selectively actuatable cutting element may be configured to perform a gouging or crushing cutting action at least upon initial positioning into the extended state.

Claims

1. A method of operating an earth-boring tool, comprising:

extending a selectively actuatable cutting element from a first, retracted position in which the selectively actuatable cutting element is underexposed relative to a rotationally leading shearing cutting element, outward from a face of the earth-boring tool, to a second, extended position in which the selectively actuatable cutting element is overexposed relative to the shearing cutting element;

at least one of gouging or crushing a portion of an underlying earth formation by a cutting action utilizing the selectively actuatable cutting element in response to extension of the cutting element to the second, extended position;

subsequently retracting the selectively actuatable cutting element from the second, extended position to the first, retracted position; and

cycling the selectively actuatable cutting element between the first, retracted position and the second, extended position at least once per second.

2. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises crushing the portion of the underlying earth formation by contacting the underlying earth formation with a nonplanar surface of the selectively actuatable cutting element.

3. The method of claim 2, wherein at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with the nonplanar surface of the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with a hemispherical surface of the selectively actuatable cutting element.

4. The method of claim 2, wherein at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with the nonplanar surface of the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with a chisel-shaped surface of the selectively actuatable cutting element.

5. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises gouging the portion of the underlying earth formation by contacting the underlying earth formation with a planar surface of the selectively actuatable cutting element.

6. The method of claim 5, wherein gouging the portion of the underlying earth formation by contacting the underlying earth formation with the planar surface of the selectively actuatable cutting element comprises gouging the portion of the underlying earth formation by contacting the underlying earth formation with the planar surface of an at least substantially cylindrical selectively actuatable cutting element.

7. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with a polycrystalline diamond material of the selectively actuatable cutting element.

8. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with a tungsten carbide material of the selectively actuatable cutting element.

9. The method of claim 8, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with a diamond-impregnated tungsten carbide material of the selectively actuatable cutting element.

10. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with the selectively actuatable cutting element in a nose region of the face of the earth-boring tool.

11. The method of claim 1, wherein at least one of gouging or crushing the portion of the underlying earth formation by the cutting action utilizing the selectively actuatable cutting element comprises at least one of gouging or crushing the portion of the underlying earth formation by contacting the underlying earth formation with the selectively actuatable cutting element in a shoulder region of the face of the earth-boring tool.

12. The method of claim 1, wherein extending the selectively actuatable cutting element outward from the face of the earth-boring tool comprises extending the selectively actuatable cutting element outward from the face of the earth-boring tool when a temperature detected by a temperature sensor operatively connected to the selectively actuatable cutting element exceeds a threshold amount, when a rate of penetration of the earth-boring tool descends below a threshold amount, when a torque on the earth-boring tool exceeds a threshold amount, when a predetermined formation type is encountered, when a formation hardness exceeds a threshold amount, when a depth of cut of a shearing cutting element mounted to the earth-boring tool descends below a threshold amount, when a pressure of a drilling fluid exceeds a threshold amount, or when a vibration of the earth-boring tool exceeds a threshold amount.

13. The method of claim 1, further comprising leaving another selectively actuatable cutting element mounted to the earth-boring tool in a retracted state when extending the selectively actuatable cutting element outward from the face of the earth-boring tool.

14. The method of claim 1, further comprising cycling the selectively actuatable cutting element between the first, retracted position and the second, extended position at least three times per second.

15. The method of claim 1, further comprising extending another selectively actuatable cutting element to an extended state and leaving the other selectively actuatable cutting element in the extended state for at least one minute before retracting the other selectively actuatable cutting element.

16. The method of claim 15, further comprising shearing a portion of the underlying earth formation different from the portion of the underlying earth formation gouged or crushed by the selectively actuatable cutting element by a shearing cutting action utilizing the shearing cutting element after retracting the selectively actuatable cutting element.

17. An earth-boring tool, comprising:

a body;

blades extending outward from the body to a face;

shearing cutting elements mounted to the blades proximate rotationally leading surfaces of the blades; and

a selectively actuatable cutting element mounted to a blade, the selectively actuatable cutting element configured to cycle between a retracted state in which the selectively actuatable cutting element does not engage with an underlying earth formation and is underexposed relative to the shearing cutting elements and an extended state in which the selectively actuatable cutting element engages with the underlying earth formation and is overexposed relative to the shearing cutting elements at least once per second, the selectively actuatable cutting element configured to perform at least one of a gouging or crushing cutting action at least upon initial positioning into the extended state.

18. The earth-boring tool of claim 17, wherein the selectively actuatable cutting element comprises a nonplanar cutting face positioned and oriented to engage with the underlying earth formation when the selectively actuatable cutting element is in the extended position.

19. The earth-boring tool of claim 17, wherein the selectively actuatable cutting element is located in one of a nose region and a cone region of the face.

20. The earth-boring tool of claim 17, wherein the selectively actuatable cutting element is configured to move from the retracted position to the extended position when a temperature detected by a temperature sensor operatively connected to the selectively actuatable cutting element exceeds a threshold amount, when a rate of penetration of the earth-boring tool descends below a threshold amount, when a torque on the earth-boring tool exceeds a threshold amount, when a predetermined formation type is encountered, when a formation hardness exceeds a threshold amount, when a depth of cut of a shearing cutting element mounted to the earth-boring tool descends below a threshold amount, when a pressure of a drilling fluid exceeds a threshold amount, or when a vibration of the earth-boring tool exceeds a threshold amount.