Cutter geometry for high ROP applications
First Claim
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1. A polycrystalline diamond compact (“
- PDC”
) cutter comprising;
a cylindrical body formed from a substrate material;
an ultrahard layer disposed on the cylindrical body; and
a cutting face perpendicular to a longitudinal axis of the cylindrical body, the cutting face including three lobes that form a planar surface that is perpendicular to the longitudinal axis of the cylindrical body, the three lobes defined by three substantially concave portions and three convex portions with respect to the longitudinal axis of the cylindrical body,wherein the radius of at least one lobe is between 50 and 90 percent of the radius of the cylindrical body,wherein the ultrahard layer comprises a transition section having a non-circular cross -section, the transition section extending from a circular cross-section of the cylindrical body to a non-circular cross-section of the cutting face, wherein the transition section comprises a smooth profile along the axial length and along a perimeter of the transition section from the circular cross-section of the cylindrical body to the non-circular cross-section of the cutting face, and wherein the cross-sectional area of the transition section decreases with axial distance from the interface along a majority of the axial length of the transition section.
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Abstract
A polycrystalline diamond compact (“PDC”)cutter includes a cylindrical body formed from a substrate material, an ultrahard layer disposed on the cylindrical body, and a cutting face perpendicular to an axis of the cylindrical body, wherein the cutting face includes two or more lobes and wherein the radius of at least one lobe is between 50 and 90 percent of the radius of the cylindrical body. A PDC cutter includes a substrate, and a cutting face perpendicular to an axis of the substrate, wherein the cross-section of the cutting face comprises multiple lobes, and the cross-section of the substrate is substantially circular.
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Citations
16 Claims
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1. A polycrystalline diamond compact (“
- PDC”
) cutter comprising;a cylindrical body formed from a substrate material; an ultrahard layer disposed on the cylindrical body; and a cutting face perpendicular to a longitudinal axis of the cylindrical body, the cutting face including three lobes that form a planar surface that is perpendicular to the longitudinal axis of the cylindrical body, the three lobes defined by three substantially concave portions and three convex portions with respect to the longitudinal axis of the cylindrical body, wherein the radius of at least one lobe is between 50 and 90 percent of the radius of the cylindrical body, wherein the ultrahard layer comprises a transition section having a non-circular cross -section, the transition section extending from a circular cross-section of the cylindrical body to a non-circular cross-section of the cutting face, wherein the transition section comprises a smooth profile along the axial length and along a perimeter of the transition section from the circular cross-section of the cylindrical body to the non-circular cross-section of the cutting face, and wherein the cross-sectional area of the transition section decreases with axial distance from the interface along a majority of the axial length of the transition section. - View Dependent Claims (2, 3, 4)
- PDC”
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5. A PDC cutter comprising:
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a cylindrical body formed from a substrate material; an ultrahard layer disposed on the cylindrical body; and a cutting face perpendicular to a longitudinal axis of the cylindrical body having at least two lobes forming an irregular cross-section, wherein a chord of at least one lobe, defined by two transition points between a concave portion and two convex portions, is smaller than a corresponding chord of the cylindrical body, wherein the ultrahard layer comprises a transition section extending from an interface between the cylindrical body and the ultrahard layer to the cutting face, and wherein a cross-sectional area of the transition section decreases with axial distance from the interface along an entire axial length of the transition section. - View Dependent Claims (6, 7, 8, 9)
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10. A PDC cutter comprising:
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a substrate; an ultrahard layer disposed on the substrate; and a cutting face formed at a distal end of the ultrahard layer, wherein a perimeter of the cutting face comprises at least two lobes forming at least two convex portions and at least two concave portions with respect to a longitudinal axis of the substrate, wherein the cutting face is perpendicular to the longitudinal axis of the substrate, wherein the ultrahard layer comprises a transition section extending from an interface between the substrate and the ultrahard layer to the cutting face, and wherein a cross-sectional area of the transition section decreases with axial distance from the interface along an entire axial length of the transition section. - View Dependent Claims (11, 12, 13, 14)
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15. A PDC cutter comprising:
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a substrate; a cutting face perpendicular to a longitudinal axis of the substrate, wherein the cross-section of the cutting face comprises multiple lobes defined by at least two convex portions and at least two concave portions with respect to the longitudinal axis of the substrate, and the cross-section of the substrate is substantially circular, and a transition section extending from the circular cross-section of the substrate to a non -circular cross-section of the cutting face, wherein the transition section comprises a smooth profile along the axial length and along a perimeter of the transition section from the circular cross-section of the substrate to the non-circular cross-section of the cutting face, and wherein the cross-sectional area of the transition section decreases with axial distance from the interface along a majority of the axial length of the transition section. - View Dependent Claims (16)
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Specification