CUTTING ELEMENTS COMPRISING WAVEFORMS AND RELATED TOOLS AND METHODS

• US 20190309578A1
• Filed: 05/20/2019
• Published: 10/10/2019
• Est. Priority Date: 05/02/2017
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes, a GE Company, LLC (Baker Hughes Company)
• Inventors: Borge, Richard Wayne
• Granted Patent: US 10,914,124 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: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: C22C 26/00 Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: C22C 29/10 based on titanium carbide
• CPC Class Codes: E21B 10/44 Bits with helical conveying portion, e.g. screw type bits; Augers with leading portion or with detachable parts E21B10/42 takes precedence
• CPC Class Codes: E21B 10/46 characterised by wear resisting parts, e.g. diamond inserts
• CPC Class Codes: E21B 10/5673 having a non planar or non circular cutting face
• CPC Class Codes: E21B 10/5676 having a cutting face with different segments, e.g. mosaic-type inserts
• CPC Class Codes: E21B 10/573 characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element

Abstract

Cutting elements for earth-boring tools may include a polycrystalline, superabrasive material secured to an end of a substrate. The polycrystalline superabrasive material may include a first transition surface and a second transition surface. A waveform may extend around a circumference of the second transition surface, a surface of the waveform tapered toward from the substrate and extending radially from the second transition surface toward the central axis. The surface of the waveform may extend from the second transition surface to a planar surface of the polycrystalline located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

Claims

1. A cutting element for an earth-boring tool, comprising:

a polycrystalline, superabrasive material secured to an end of a substrate, the polycrystalline superabrasive material comprising;

a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of the substrate;

a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and

a surface of a waveform extending around a circumference of the second transition surface, the surface of the waveform tapered toward the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline, superabrasive material located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

2. The cutting element of claim 1, wherein a frequency of the waveform is between one every 180°

and ten every 90°

.

3. The cutting element of claim 1, wherein a maximum thickness of the second transition surface as measured in a direction parallel to the central axis is between 0.01 inch and 0.05 inch.

4. The cutting element of claim 1, wherein the second transition surface is curved.

5. The cutting element of claim 1, wherein peaks of the waveform are positioned to contact an underlying earth formation before any other portion of the polycrystalline, superabrasive material.

6. The cutting element of claim 1, wherein a roughness of the planar surface is different from a roughness of other exposed surfaces of the polycrystalline, superabrasive material.

7. The cutting element of claim 6, wherein the planar surface is rougher than the other exposed surfaces of the polycrystalline, superabrasive material.

8. The cutting element of claim 1, wherein a diameter of the planar surface is between about 10% and about 50% of a maximum diameter of the superabrasive, polycrystalline material.

9. The cutting element of claim 1, wherein a shape of the second transition surface between the first transition surface and the waveform is sinusoidal.

10. The cutting element of claim 1, wherein the waveform is configured to induce a beneficial stress state within the polycrystalline, superabrasive material.

11. An earth-boring tool, comprising:

a body; and

a cutting element secured to the body, the cutting element comprising;

a polycrystalline, superabrasive material secured to an end of a substrate, the polycrystalline superabrasive material comprising;

a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of the substrate;

a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and

a surface of a waveform extending around a circumference of the second transition surface, the surface of the waveform tapered toward the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline, superabrasive material located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

12. The earth-boring tool of claim 11, wherein a frequency of the waveform is between one every 180°

and ten every 90°

.

13. The earth-boring tool of claim 11, wherein a maximum thickness of the second transition surface as measured in a direction parallel to the central axis is between 0.01 inch and 0.05 inch.

14. The earth-boring tool of claim 11, wherein the second transition surface is curved.

15. The earth-boring tool of claim 11, wherein a roughness of the planar surface is different from a roughness of other exposed surfaces of the polycrystalline, superabrasive material.

16. The cutting element of claim 11, wherein a diameter of the planar surface is between about 10% and about 50% of a maximum diameter of the superabrasive, polycrystalline material.

17. A method of removing an earth formation, comprising:

rotating a body of an earth-boring tool; and

removing an earth material in contact with a polycrystalline, superabrasive material of a cutting element secured to the body, the polycrystalline, superabrasive material comprising;

a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of the substrate;

a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and

a waveform extending around a circumference of the second transition surface, a surface of the waveform tapered toward from the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

18. The method of claim 17, wherein removing the earth material in contact with the polycrystalline, superabrasive material comprises contacting the earth material with peaks of the waveform before any other portion of the polycrystalline, superabrasive material.

19. The method of claim 17, further comprising inducing a beneficial stress state within the polycrystalline, superabrasive material utilizing the waveform.

20. The method of claim 17, further comprising breaking a chip of the earth material when the earth material reaches an intersection between the waveform and the planar surface.