Cutting element apparatuses, drill bits including same, methods of cutting, and methods of rotating a cutting element

• US 7,987,931 B2
• Filed: 09/04/2009
• Issued: 08/02/2011
• Est. Priority Date: 10/11/2005
• Status: Active Grant

• Current Assignee: US Synthetic Corporation (ChampionX Corporation)
• Original Assignee: US Synthetic Corporation (ChampionX Corporation)
• Inventors: Cooley, Craig H., Sexton, Timothy N.
• Primary Examiner(s): Stephenson; Daniel P
• Application Number:
  US12/554,797
• Publication Number:
  US 20090324348A1
• Time in Patent Office: 697 Days
• Field of Search: 175/342, 175/426, 175/383, 175/432
• US Class Current: 175/432
• CPC Class Codes: B23B 27/12 with a continuously-rotated circular cutting edge; Holders therefor
• CPC Class Codes: E21B 10/567 with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
• 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: Y10T 407/221 Adjustable tool
• CPC Class Codes: Y10T 407/27 comprising tool of specific chemical composition
• CPC Class Codes: Y10T 83/04 Processes

Abstract

A rotary drill bit for drilling a subterranean formation may comprise a bit body, a cutting element coupled to the bit body, and a torque-generating assembly configured to apply torque, either continuously or periodically, to the cutting element. The torque-generating assembly may be powered by the rotary motion of the rotary drill bit or may be hydraulically or electrically powered. The cutting element may comprise a substrate, a table of superabrasive material disposed on an end of the substrate, and at least one impelling feature formed along the exterior surface of the substrate. In addition, a method of rotating a cutting element coupled to a drill bit for drilling a subterranean formation may comprise providing a cutting element comprising a table bonded to a substrate, coupling the substrate of the cutting element to a drill bit body, and applying torque to the substrate of the cutting element.

Claims

1. A rotary cutting tool comprising:

a body;

a plurality of discrete cutting elements coupled with the body, wherein the plurality of discrete cutting elements comprise natural diamond, tungsten carbide, or a polycrystalline diamond;

at least one torque generating assembly coupled with the plurality of discrete cutting elements and configured to selectively displace each of the plurality of discrete cutting elements relative to the body.

2. The rotary cutting tool of claim 1, wherein at least one discrete cutting element of the plurality of discrete cutting elements includes a superabrasive table bonded to a substrate.

3. The rotary cutting tool of claim 2, wherein the superabrasive table comprises polycrystalline diamond and the substrate comprises cemented tungsten carbide.

4. The rotary cutting tool of claim 2, wherein the at least one discrete cutting elements exhibits a substantially cylindrical geometry.

5. The rotary cutting tool of claim 2, wherein the at least one discrete cutting element includes at least one helical groove formed into at least a portion of an exterior surface of the substrate.

6. The rotary cutting tool of claim 2, wherein the at least one discrete cutting element includes at least one impelling feature formed into at least a portion of an exterior surface of the substrate.

7. The rotary cutting tool of claim 1, wherein the at least one torque generating assembly comprises at least one actuator assembly.

8. The rotary cutting tool of claim 7, wherein the torque-generating assembly comprises:

a pump in fluid communication with the at least one actuator; and

a structural assembly coupling the at least one actuator to a rotatable drive shaft affixed to a portion of at least one discrete cutting element of the plurality of discrete cutting elements.

9. The rotary cutting tool claim 8, wherein the actuator comprises:

a chamber in fluid communication with the pump;

a piston disposed within the chamber, the piston moveable between a first position and a second position; and

a piston rod coupled to the piston.

10. The rotary cutting tool of claim 9, wherein the structural assembly comprises:

a rack coupled to the piston rod; and

a pinion coupled to the drive shaft and operably coupled to the rack.

11. The rotary cutting tool of claim 7, wherein the at least one actuator includes a plurality of actuators, each actuator of the plurality being associated with at least one of the plurality of discrete cutting elements.

12. The rotary cutting tool of claim 1, wherein the at least one actuator includes a push rod configured to engage at least one engagement feature formed in at least one discrete cutting element of the plurality of discrete cutting elements.

13. The rotary cutting tool of claim 12, wherein the push rod is flexible and is biased toward the at least one engagement feature.

14. The rotary cutting tool of claim 1, wherein the at least one torque generating assembly comprises electric motor.

15. The rotary cutting tool of claim 1, wherein the at least one torque generating assembly comprises a hydraulic actuator.

16. The rotary cutting tool of claim 1, wherein the at least one torque generating assembly includes a cam assembly.

17. The rotary cutting tool of claim 1, wherein the at least one actuator is configured to continuously or periodically apply torque at least one discrete cutting element of the plurality of discrete cutting elements.

18. A rotary cutting tool comprising:

a body;

a plurality of discrete cutting elements coupled with the body;

at least one torque generating assembly coupled with the plurality of discrete cutting elements and configured to selectively displace each of the plurality of discrete cutting elements relative to the body, wherein the at least one torque generating assembly is configured to rotate at least one discrete cutter of the plurality more than 90°

.

19. A method of cutting a material, the method comprising:

rotating a body of a cutting tool relative to the material;

engaging the material with at least one discrete cutting element coupled with the body; and

selectively rotating the at least one discrete cutting element relative to the body of the cutting tool from a first position to a second position, the second position being more than 90°

from the first position.

20. The method according to claim 19, wherein engaging the material with at least one discrete cutting element comprises performing a lathe operation, a drilling operation, or a planing operation.

21. The method according to claim 19, wherein engaging the material with at least one discrete cutting element comprises machining the material.

22. The method according to claim 21, wherein machining the material comprises machining a rock formation or a metal.

23. The method according to claim 19, wherein engaging the material with at least one discrete cutting element includes engaging the material with a plurality of discrete cutting elements coupled with the body of the cutting tool.

24. The method according to claim 23, wherein selectively rotating the at least one cutting element relative to a bit body further comprises selectively rotating each of the plurality of discrete cutting elements relative to the body of the cutting tool.