Multiple diameter cutting elements and bits incorporating the same

• US 20050082093A1
• Filed: 08/17/2004
• Published: 04/21/2005
• Est. Priority Date: 08/21/2003
• Status: Active Grant

• Current Assignee: Smith International Incorporated (Schlumberger NV)
• Original Assignee: Smith International Incorporated (Schlumberger NV)
• Inventors: Keshavan, Madapusi K., Azar, Michael G., Truax, David K.
• Granted Patent: US 7,461,709 B2
• Time in Patent Office: Days
• US Class Current: 175/374
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts

Abstract

Cutting elements are provided having multiple diameter sections. Also provided are bits incorporating such cutting elements.

Claims

1. A cutting element comprising:

a body comprising a longitudinal axis and a periphery comprising at least two single curvature sections, each section having a single radius of curvature along a plane generally perpendicular to the longitudinal axis, wherein each section has a different radius of curvature from an adjacent section, said single curvature sections defining the entire periphery; and

an ultra hard material layer formed over the body, the ultra hard material layer having a periphery, wherein the ultra hard material layer periphery comprises at least two single curvature sections along a plane generally perpendicular to the longitudinal axis.

2. A cutting element as recited in claim 1 wherein the body and the ultra hard material layer peripheries each comprise three single curvature sections wherein each body periphery section abuts two adjacent body periphery sections and wherein each of the ultra hard material periphery section abuts two adjacent ultra hard material periphery sections.

3. A cutting element as recited in claim 2 wherein each section has a different radius of curvature than an abutting section.

4. A cutting element as recited in claim 3 wherein two abutting sections have the same radius of curvature.

5. A cutting element as recited in claim 1 wherein the body and the ultra hard material layer peripheries each consist of two sections, wherein the two body periphery sections abut each other and wherein the two ultra hard material layer periphery sections abut each other.

6. A cutting element as recited in claim 1 wherein each ultra hard material periphery section is aligned with a corresponding body periphery section and wherein corresponding ultra hard material periphery and body periphery sections have the same radii of curvature.

7. A cutting element as recited in claim 1 wherein said ultra hard material sections define the entire periphery of the ultra hard material layer.

8. A cutting element as recited in claim 1 wherein each of said body and ultra hard material layer peripheries comprise at least two but no more than three single curvature sections along a plane generally perpendicular to the longitudinal axis.

9. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is the same as the diameter of the first pocket;

a first cutting element mounted on the first pocket, the first cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second diameter portions have diameters different from the diameters of the first diameter portions, wherein the body first diameter portion is brazed to the first pocket; and

a second cutting element mounted on the second pocket, the second cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second cutting element second diameter portions have diameters different from the diameters of the second cutting element first diameter portions, wherein the second cutting element body first diameter portion is brazed to the second pocket, and wherein the diameter of the second diameter portion of the second cutting element is greater than the diameter of the second diameter portion of the first cutting element.

10. The bit body as recited in claim 9 wherein the first cutting element second diameter portions have diameters greater than the first cutting element first diameter portions.

11. The bit body as recited in claim 10 wherein the second cutting element second diameter portions have diameters greater than the second cutting element first diameter portions.

12. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is the same as the diameter of the first pocket;

a first cutting element mounted on the first pocket; and

a second cutting element mounted on the second pocket, wherein each cutting element comprises a curved surface for contacting earth formations during drilling, wherein the curved surface of the first cutting element has a diameter that is different from a diameter of the curved surface of the second cutting element.

13. A bit body comprising:

a bit body having a pocket; and

a cutting element having a longitudinal axis and mounted on the pocket, the cutting element comprising,

a cutting element body comprising a periphery comprising at least two but no more than three single curvature sections along a plane generally perpendicular to the longitudinal axis, wherein each section has a different radius of curvature from an adjacent section, said single curvature sections defining the entire periphery, and

an ultra hard material layer formed over the cutting element body, the ultra hard material layer having a periphery, wherein the ultra hard material layer periphery comprises at least two but no more than three single curvature sections along a plane generally perpendicular to the longitudinal axis.

14. A bit as recited in claim 13 wherein the cutting element body and the ultra hard material layer peripheries each comprise three single curvature sections wherein each cutting element body periphery section abuts two adjacent body periphery sections and wherein each of the ultra hard material periphery section abuts two adjacent ultra hard material periphery sections.

15. A bit as recited in claim 14 wherein each section has a different radius of curvature than an abutting section.

16. A bit as recited in claim 15 wherein two abutting sections have the same radius of curvature.

17. A bit as recited in claim 13 wherein the cutting element body and the ultra hard material layer peripheries each consist of two sections, wherein the two cutting element body periphery sections abut each other and wherein the two ultra hard material layer periphery sections abut each other.

18. A bit as recited in claim 13 wherein each ultra hard material periphery section is aligned with a corresponding cutting element body periphery section and wherein corresponding ultra hard material periphery and cutting element body periphery sections have the same radii of curvature.

19. A bit as recited in claim 13 wherein said ultra hard material sections define the entire periphery of the ultra hard material layer.

20. A bit as recited in claim 13 wherein each of said cutting element body and ultra hard material layer peripheries comprise at least two but no more than three single curvature sections along a plane generally perpendicular to the longitudinal axis.

21. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is different from the diameter of the first pocket;

a first cutting element mounted on the first pocket; and

a second cutting element mounted on the second pocket, wherein each cutting element comprises a curved surface for contacting earth formations during drilling, wherein the curved surface of the first cutting element has a diameter that is the same as the diameter of the curved surface of the second cutting element.

22. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is different from the diameter of the first pocket;

a first cutting element mounted on the first pocket, the first cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second diameter portions have diameters different from the diameters of the first diameter portions, wherein the body first diameter portion is brazed to the first pocket; and

a second cutting element mounted on the second pocket, the second cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second cutting element second diameter portions have diameters different from the diameters of the second cutting element first diameter portions, wherein the second cutting element body first diameter portion is brazed to the second pocket, and wherein the diameter of the second diameter portion of the second cutting element is the same as the diameter of the second diameter portion of the first cutting element.

23. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is different from the diameter of the first pocket;

a first cutting element mounted on the first pocket; and

a second cutting element mounted on the second pocket, wherein each cutting element comprises a curved surface for contacting earth formations during drilling, wherein the curved surface of the first cutting element has a diameter that is different from a diameter of the curved surface of the second cutting element, and wherein the difference between the diameters of the two pockets is different from the difference of the diameters of the two curved surfaces.

24. The bit body as recited in claim 23 wherein the difference between the diameters of the first and second pockets is greater than the difference between the diameters of the two curved surfaces.

25. The bit body as recited in claim 23 wherein the difference between the diameters of the first and second pockets is less than the difference between the diameters of the two curved surfaces.

26. A bit body comprising:

a first pocket having a diameter;

a second pocket having a diameter that is different from the diameter of the first pocket;

a first cutting element mounted on the first pocket, the first cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second diameter portions have diameters different from the diameters of the first diameter portions, wherein the body first diameter portion is brazed to the first pocket; and

a second cutting element mounted on the second pocket, the second cutting element having a body and a cutting layer each having a first diameter portion and a second diameter portion, wherein the second cutting element second diameter portions have diameters different from the diameters of the second cutting element first diameter portions, wherein the second cutting element body first diameter portion is brazed to the second pocket, and wherein the diameter of the second diameter portion of the second cutting element is different from the diameter of the second diameter portion of the first cutting element.

27. The bit body as recited in claim 26 wherein the difference between the diameters of the first and second pockets is greater than the difference between the diameter of the second diameter portion of the second cutting element and the diameter of the second diameter portion of the first cutting element.

28. The bit body as recited in claim 26 wherein the difference between the diameters of the first and second pockets is less than the difference between the diameter of the second diameter portion of the second cutting element and the diameter of the second diameter portion of the first cutting element.