CUTTING ELEMENTS HAVING NON-PLANAR SURFACES AND TOOLS INCORPORATING THE SAME

• US 20190071933A1
• Filed: 09/05/2018
• Published: 03/07/2019
• Est. Priority Date: 09/05/2017
• Status: Active Grant

• Current Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Original Assignee: Smith International Incorporated (Schlumberger NV)
• Inventors: Gan, Xiaoge, Dong, Anjie, Johnson, Gerard, Azar, Michael George, Song, Huimin, Zhang, Youhe, Karuppiah, Venkatesh
• Granted Patent: US 11,098,532 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: E21B 10/55 with preformed cutting elements
• CPC Class Codes: E21B 10/5671 with chip breaking arrangements
• CPC Class Codes: E21B 10/5676 having a cutting face with different segments, e.g. mosaic-type inserts

Abstract

A cutting element includes a body, a non-planar cutting face formed on a first end of the body, and an edge formed around a perimeter of the cutting face. The cutting face includes a central raised portion, and the edge has an edge angle defined between the cutting face and a side surface of the body. The edge angle varies around the perimeter of the cutting face and includes an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting angle. The portion of the edge defining the acute edge angle may be directly adjacent: a side surface of the cutting element; a bevel of the cutting element; or a flat region at the perimeter of the cutting element or bevel.

Claims

1. A cutting element, comprising:

a body;

a non-planar cutting face formed at a first end of the body, the cutting face including a central raised region; and

an edge formed around a perimeter of the cutting face, the edge having an edge angle defined between the cutting face and a side surface of the body, the edge angle varying around the perimeter of the cutting face, and the edge including an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting edge.

2. The cutting element of claim 1, the central raised region including a ridge extending between opposite sides of the perimeter of the cutting face.

3. The cutting element of claim 1, the central raised region being a distance from the entire perimeter of the cutting face.

4. The cutting element of claim 1, a cross-sectional profile of the cutting face having a sinusoidal shape on a plane extending along and intersecting a central longitudinal axis of the cutting element.

5. The cutting element of claim 1, the body including a cutting layer on a substrate, the cutting face formed on the cutting layer opposite the interface.

6. The cutting element of claim 1, the acute edge angle defined by an inclined portion of the cutting face, an area of a different edge angle being positioned between the inclined portion and a bevel of the edge.

7. The cutting element of claim 6, the inclined portion being a first inclined portion and the area of the different edge angle being a second inclined portion having a greater acute edge angle than the first inclined portion.

8. A cutting element, comprising:

a body;

a non-planar cutting face coupled to the body;

a height measured between a base surface of the body and the non-planar cutting face; and

an edge extending around a perimeter of the non-planar cutting face, the height of the edge varying around the perimeter, such that a first portion of the edge extends higher than a second portion of the edge, and an edge angle defined between the non-planar cutting face and a side surface of the body is less than 90°

in at least one section of the first portion of the edge and greater than 90°

at the second portion of the edge.

9. The cutting element of claim 8, the at least one section of the first portion of the edge having a concave profile.

10. The cutting element of claim 8, the second portion of the edge having a convex profile.

11. The cutting element of claim 8, the at least one section of the first portion of the edge including at least two sections, a first of the at least two sections being nearer the perimeter of the non-planar cutting face and having a greater edge angle than a second of the at least two sections.

12. The cutting element of claim 11, the first of the at least two sections having an edge angle between 75°

and 90°

.

13. The cutting element of claim 12, the second of the at least two sections having an edge angle between 60°

and 75°

.

14. A cutting element, comprising:

a substrate; and

a cutting layer on the substrate, the cutting layer defining a cutting edge, a non-planar cutting face opposite the substrate, and at least one impact resistant feature at an interface between the cutting edge and the non-planar cutting face.

15. The cutting element of claim 14, the at least one impact resistant feature being located between a high portion of the cutting edge and an inclined portion of the non-planar cutting face, the inclined portion defining an acute angle with a side surface of the cutting layer.

16. The cutting element of claim 15, the cutting edge further including a low portion, the low portion corresponding to a convex portion of the non-planar cutting face defining an obtuse angle with the side surface of the cutting layer.

17. The cutting element of claim 14, the impact resistant feature including at least one flat region defining a planar portion of the cutting face.

18. The cutting element of claim 17, the at least one flat region having a radial length that is between 5% and 10% of a width of the cutting layer.

19. The cutting element of claim 18, the at least one flat region including at least two flat regions having a variable radial length, the at least two flat regions collectively extending around between 20% and 50% of a perimeter of the cutting edge.

20. The cutting element of claim 14, the non-planar cutting face including at least two raised portions including:

a central raised portion; and

two raised edge portions, the two raised edge portions including first and second sections having different edge angles, with the edge angle of a portion nearest the cutting edge being larger, the portion nearest the cutting edge forming at least a portion of the impact resistant feature.