Drill bit with continuously sharp edge cutting elements

Abstract

A method of optimizing drill bit design and an optimized drill bit for drilling a well into an earth formation comprising a bit body; a number of blades spaced around the bit body, each blade having a curved outer edge and a forward face; a first row of cutter pockets recessed into the face along the outer edge of each blade; a second group of cutter pockets recessed into the face of each blade offset from the first row; and a plurality of cutting elements, each cutting element being brazed into a different one of the cutter pockets.

1 . A method of optimizing a drill bit, such as for drilling a well into an earth formation, the method comprising the steps of:
 forming a bit body with a plurality of blades, each blade having a face with a row of individual cutter pockets at least partially recessed therein; and   securing a cutting element at least partially within each of the pockets;   wherein a wear flat area of the drill bit is managed by maintaining a minimum abrasion resistance ratio of the cutting element to the bit body.   
   
   
       2 . The method as set forth in  claim 1 , wherein the bit body is made from a body material having a body abrasion resistance and the cutting element is made from a cutting material having a cutting abrasion resistance, such that the cutting abrasion resistance is greater than the body abrasion resistance by at least the minimum abrasion resistance ratio. 
   
   
       3 . The method as set forth in  claim 2 , wherein the materials are selected in order to maintain the minimum abrasion resistance ratio. 
   
   
       4 . The method as set forth in  claim 1 , each cutting element having a cutting table and a substrate. 
   
   
       5 . The method as set forth in  claim 4 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       6 . The method as set forth in  claim 5 , wherein the substrate abrasion resistance is between the cutting abrasion resistance and the body abrasion resistance. 
   
   
       7 . The method as set forth in  claim 1 , wherein the drill bit is designed such that the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the bit body. 
   
   
       8 . The method as set forth in  claim 7 , wherein the drill bit is designed such that each cutting element has a cutting table and a substrate. 
   
   
       9 . The method as set forth in  claim 8 , wherein the drill bit is designed such that the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       10 . The method as set forth in  claim 1 , wherein the drill bit is designed such that the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the substrate. 
   
   
       11 . A drill bit, such as for drilling a well into an earth formation, the drill bit comprising:
 a bit body with a plurality of blades, each blade having a face with a row of individual cutter pockets at least partially recessed therein; and   a cutting element secured at least partially within each of the pockets;   wherein a wear flat area of the drill bit is managed by maintaining a minimum abrasion resistance ratio of the cutting element to the bit body.   
   
   
       12 . The method as set forth in  claim 11 , wherein the bit body is made from a body material having a body abrasion resistance and the cutting element is made from a cutting material having a cutting abrasion resistance, such that the cutting abrasion resistance is greater than the body abrasion resistance by at least the minimum abrasion resistance ratio. 
   
   
       13 . The method as set forth in  claim 12 , wherein the materials are selected in order to maintain the minimum abrasion resistance ratio. 
   
   
       14 . The method as set forth in  claim 11 , each cutting element having a cutting table and a substrate. 
   
   
       15 . The method as set forth in  claim 14 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       16 . The method as set forth in  claim 15 , wherein the substrate abrasion resistance is between the cutting abrasion resistance and the body abrasion resistance. 
   
   
       17 . The method as set forth in  claim 11 , wherein the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the bit body. 
   
   
       18 . The method as set forth in  claim 17 , wherein each cutting element has a cutting table and a substrate. 
   
   
       19 . The method as set forth in  claim 18 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       20 . The method as set forth in  claim 19 , wherein the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the substrate. 
   
   
       21 . A method of optimizing a drill bit, such as for drilling a well into an earth formation, the method comprising the steps of:
 forming a bit body with a plurality of blades, each blade having a face with a row of individual cutter pockets at least partially recessed therein; and   securing a cutting element at least partially within each of the pockets;   wherein a wear flat area of the drill bit is managed by selecting the materials in order to ensure the abrasion resistance of the cutting element is higher than the abrasion resistance of the body.   
   
   
       22 . The method as set forth in  claim 21 , wherein the bit body is made from a body material having a body abrasion resistance and the cutting element is made from a cutting material having a cutting abrasion resistance, such that the cutting abrasion resistance is greater than the body abrasion resistance. 
   
   
       23 . The method as set forth in  claim 22 , wherein the materials are selected in order to maintain a minimum abrasion resistance ratio. 
   
   
       24 . The method as set forth in  claim 21 , each cutting element having a cutting table and a substrate. 
   
   
       25 . The method as set forth in  claim 24 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       26 . The method as set forth in  claim 25 , wherein the substrate abrasion resistance is between the cutting abrasion resistance and the body abrasion resistance. 
   
   
       27 . The method as set forth in  claim 21 , wherein the drill bit is designed such that the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the bit body. 
   
   
       28 . The method as set forth in  claim 27 , wherein the drill bit is designed such that each cutting element has a cutting table and a substrate. 
   
   
       29 . The method as set forth in  claim 28 , wherein the drill bit is designed such that the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       30 . The method as set forth in  claim 21 , wherein the drill bit is designed such that the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the substrate. 
   
   
       31 . A drill bit, such as for drilling a well into an earth formation, the drill bit comprising:
 forming a bit body with a plurality of blades, each blade having a face with a row of individual cutter pockets at least partially recessed therein; and   securing a cutting element at least partially within each of the pockets;   wherein a wear flat area of the drill bit is managed by selecting the materials in order to ensure the abrasion resistance of the cutting element is higher than the abrasion resistance of the body.   
   
   
       32 . The drill bit as set forth in  claim 31 , wherein the bit body is made from a body material having a body abrasion resistance and the cutting element is made from a cutting material having a cutting abrasion resistance, such that the cutting abrasion resistance is greater than the body abrasion resistance. 
   
   
       33 . The drill bit as set forth in  claim 32 , wherein the materials are selected in order to maintain a minimum abrasion resistance ratio. 
   
   
       34 . The drill bit as set forth in  claim 31 , each cutting element having a cutting table and a substrate. 
   
   
       35 . The drill bit as set forth in  claim 34 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       36 . The drill bit as set forth in  claim 35 , wherein the substrate abrasion resistance is between the cutting abrasion resistance and the body abrasion resistance. 
   
   
       37 . The drill bit as set forth in  claim 31 , wherein the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the bit body. 
   
   
       38 . The drill bit as set forth in  claim 37 , wherein each cutting element has a cutting table and a substrate. 
   
   
       39 . The drill bit as set forth in  claim 38 , wherein the bit body is made from a body material having a body abrasion resistance, the cutting table is made from a cutting material having a cutting abrasion resistance, and the substrate is made from a substrate material having a substrate abrasion resistance. 
   
   
       40 . The drill bit as set forth in  claim 31 , wherein the earth formation has an abrasiveness between an abrasion resistance of the cutting element and an abrasion resistance of the substrate.