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

• US 8,931,582 B2
• Filed: 09/20/2013
• Issued: 01/13/2015
• 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., Peterson, S. Barrett, Lund, Jeffrey, Johnson, Christopher F.
• Primary Examiner(s): Stephenson, Daniel P
• Application Number:
  US14/033,262
• Publication Number:
  US 20140020956A1
• Time in Patent Office: 480 Days
• Field of Search: 166/291, 166/292, 166/155, 166/177.4, 166/84.1, 175/342, 175/383, 175/426, 175/432, 175/331, 175/369
• US Class Current: 175/432
• CPC Class Codes: B23B 27/12 with a continuously-rotated circular cutting edge; Holders therefor
• CPC Class Codes: E21B 10/08 Roller bits E21B10/26 takes precedence; roller core bits E21B10/06; characterised by wear resisting parts E21B10/50
• CPC Class Codes: E21B 10/55 with preformed cutting elements
• 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: E21B 10/633 independently detachable

Abstract

A subterranean drilling system may include a drill string and a rotary drill bit coupled to the drill string. The rotary drill bit may include a bit body and a cutting element coupled to the bit body, with the cutting element being structured to rotate in response to torque applied to the cutting element. The system also may include a cam assembly coupled to the drill string, a cam follower assembly in contact with a cam surface of the cam assembly, and a torque-applying structure coupled to the cam follower assembly. The torque-applying structure may be configured to apply torque to the cutting element in response to relative rotation between the cam assembly and the cam follower assembly.

Claims

1. A rotary drill bit for drilling a subterranean formation, the rotary drill bit comprising:

a bit body having an external surface, the external surface including a gage portion that is configured to engage a subterranean formation;

at least one cutting element rotatably coupled to the bit body such that at least a portion of the at least one coffin element protrudes from the external surface of the bit body;

at least one clutch mechanism associated with the at least one cutting element, the at least one clutch mechanism configured to selectively permit or inhibit the application of torque to the at least one cutting element, wherein the at least one clutch mechanism and the at least one cutting element are structured to effect rotation of the at least one cutting element relative to the external surface of the bit body when sufficient torque is applied to the at least one cutting element.

2. The rotary drill bit of claim 1, wherein the at least one cutting element comprises a superabrasive table bonded to a substrate.

3. The rotary drill bit of claim 1, wherein the at least one clutch mechanism includes a first portion and a second portion mechanically coupled to the first portion, wherein the second portion is structured to decouple from the first portion when a torque developed between the first and second portions exceeds a selected magnitude.

4. The rotary drill bit of claim 3, wherein the second portion comprises a friction material structured to engage a friction material of the first portion.

5. The rotary drill bit of claim 3, wherein the second portion includes a surface that mechanically engages with a surface of the first portion.

6. The rotary drill bit of claim 3, wherein the first portion of the at least one clutch mechanism is integrally formed with the at least one cutting element.

7. The rotary drill bit of claim 1, further comprising a torque-generating assembly configured to apply torque to the at least one cutting element via the at least one clutch mechanism.

8. The rotary drill bit of claim 1, further comprising a limiting mechanism associated with the at least one cutting element configured to enable rotation of the at least one cutting element about an axis in a first direction and inhibit rotation of the at least one cutting element about the axis in a second, opposite direction.

9. The rotary drill bit of claim 8, wherein the limiting mechanism includes a ratcheting mechanism.

10. The rotary drill bit of claim 9, wherein a portion of the ratcheting mechanism in integrally formed with the at least one cutting element.

11. The rotary drill bit of claim 9, wherein the ratcheting mechanism is configured to incrementally rotate the at one cutting element through a defined angle.

12. The rotary drill bit of claim 1, wherein the external surface includes a face of the bit body.

13. The rotary drill bit of claim 1, wherein the external surface includes a blade of the bit body.

14. The rotary drill bit of claim 1, wherein the at least one cutting element is disposed within a pocket formed within the bit body.

15. The rotary drill bit of claim 1, wherein:

the at least one cutting element includes a plurality of cutting elements;

the at least one clutch mechanism includes a plurality of clutch mechanisms, each clutch mechanism of the plurality being associated with one of the plurality of cutting elements.

16. The rotary drill bit of claim 1, wherein the at least one cutting element is configured to rotate about a first axis relative to the external surface, and wherein the bit body is configured to rotate about a second axis when engaged with the subterranean formation, the first axis being different from the second axis.

17. A rotary drill bit for drilling a subterranean formation, the rotary drill bit comprising:

a bit body having an external surface, the external surface including a gage portion that is configured to engage a subterranean formation;

at least one cutting element rotatably coupled to the bit body such that at least a portion of the at least one cutting element protrudes from the external surface of the bit body;

at least one limiting mechanism associated with the at least one cutting element configured to enable rotation of the at least one cutting element relative to the external surface about a first axis in a first direction and inhibit rotation of the cutting element about the first axis in a second, opposite direction.

18. The rotary drill bit of claim 17, wherein the at least one cutting element comprises a superabrasive table bonded to a substrate.

19. The rotary drill bit of claim 17, wherein the at least one limiting mechanism includes a ratcheting mechanism.

20. The rotary drill bit of claim 19, wherein a portion of the ratcheting mechanism in integrally formed with the at least one cutting element.

21. The rotary drill bit of claim 19, wherein the ratcheting mechanism is configured to incrementally rotate the at least one cutting element through a defined angle.

22. The rotary drill bit of claim 17, further comprising a clutch mechanism configured to selectively permit or inhibit the application of torque to the cutting element, wherein the clutch mechanism and the at least one cutting element are structured to enable rotation of the at least one cutting element relative to the bit body when sufficient torque is applied to the at least one cutting element.

23. The rotary drill bit of claim 22, further comprising a torque-generating assembly configured to apply torque to the at least one cutting element.

24. The rotary drill bit of claim 17, wherein the external surface includes a face of the bit body.

25. The rotary drill bit of claim 17, wherein the external surface includes a blade of the bit body.

26. The rotary drill bit of claim 17, wherein the at least one cutting element is disposed within a pocket formed within the bit body.

27. The rotary drill bit of claim 17, wherein:

the at least one cutting element includes a plurality of cutting elements;

the at least one limiting mechanism includes a plurality of limiting mechanisms, each limiting mechanism of the plurality being associated with one of the plurality of cutting elements.

28. The rotary drill bit of claim 17, wherein the bit body is configured to rotate about a second axis when engaged with the subterranean formation, the second axis being different from the first axis.