US2010089661A1PendingUtilityA1

Drill bit with continuously sharp edge cutting elements

40
Assignee: BAKER HUGHES INCPriority: Oct 13, 2008Filed: Oct 13, 2008Published: Apr 15, 2010
Est. expiryOct 13, 2028(~2.2 yrs left)· nominal 20-yr term from priority
Inventors:Robert M. WelchEric E. McclainL. Allen Sinor
E21B 10/43
40
PatentIndex Score
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Cited by
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References
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Claims

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.

Claims

exact text as granted — not AI-modified
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 design of the blades is optimized to manage a wear flat area of the drill bit.   
   
   
       2 . The method as set forth in  claim 1 , wherein the blades are designed to minimize the wear flat area of the drill bit. 
   
   
       3 . The method as set forth in  claim 1 , wherein a shape of the blades is optimized to manage the wear flat area of the drill bit. 
   
   
       4 . The method as set forth in  claim 1 , wherein a shape of the blades is optimized to minimize the wear flat area of the drill bit. 
   
   
       5 . The method as set forth in  claim 1 , wherein a shape of the blades is optimized to maximize the useful life of the drill bit. 
   
   
       6 . The method as set forth in  claim 1 , wherein the blades are designed to encourage exposed blade wear. 
   
   
       7 . The method as set forth in  claim 1 , wherein each blade has primary and secondary face cutting elements. 
   
   
       8 . The method as set forth in  claim 7 , wherein the blades are designed to encourage exposed blade wear once one of the primary cutting elements fails, thereby more rapidly exposing one of the secondary cutting elements. 
   
   
       9 . The method as set forth in  claim 1 , wherein the blades are designed for low abrasion resistance to ensure that the blades wear faster than the cutting elements. 
   
   
       10 . The method as set forth in  claim 1 , wherein the blades are designed for high strength and low abrasion resistance to ensure that the blades wear faster than the cutting elements. 
   
   
       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 design of the blades is optimized to manage a wear flat area of the drill bit.   
   
   
       12 . The drill bit as set forth in  claim 11 , wherein the blades are designed to minimize the wear flat area of the drill bit. 
   
   
       13 . The drill bit as set forth in  claim 11 , wherein a shape of the blades is optimized to manage the wear flat area of the drill bit. 
   
   
       14 . The drill bit as set forth in  claim 11 , wherein a shape of the blades is optimized to minimize the wear flat area of the drill bit. 
   
   
       15 . The drill bit as set forth in  claim 11 , wherein a shape of the blades is optimized to maximize the useful life of the drill bit. 
   
   
       16 . The drill bit as set forth in  claim 11 , wherein the blades are designed to encourage exposed blade wear. 
   
   
       17 . The drill bit as set forth in  claim 11 , wherein each blade has primary and secondary face cutting elements. 
   
   
       18 . The drill bit as set forth in  claim 17 , wherein the blades are designed to encourage exposed blade wear once one of the primary cutting elements fails, thereby more rapidly exposing one of the secondary cutting elements. 
   
   
       19 . The drill bit as set forth in  claim 11 , wherein the blades are designed for low abrasion resistance to ensure that the blades wear faster than the cutting elements. 
   
   
       20 . The drill bit as set forth in  claim 11 , wherein the blades are designed for high strength and low abrasion resistance to ensure that the blades wear faster than the cutting elements. 
   
   
       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 design of the cutting elements is optimized to manage a wear flat area of the cutting elements.   
   
   
       22 . The method as set forth in  claim 21 , wherein the cutting elements are designed to minimize the wear flat area of the drill bit. 
   
   
       23 . The method as set forth in  claim 21 , wherein a shape of the cutting elements is optimized to manage the wear flat area of the drill bit. 
   
   
       24 . The method as set forth in  claim 21 , wherein a size of the cutting elements is optimized to manage the wear flat area of the drill bit. 
   
   
       25 . The method as set forth in  claim 21 , wherein each blade has primary and secondary cutting elements. 
   
   
       26 . The method as set forth in  claim 25 , wherein the primary cutting elements are designed to fail rapidly once failure begins, thereby more rapidly exposing one of the secondary cutting elements. 
   
   
       27 . The method as set forth in  claim 21 , wherein the cutting elements comprise a diamond cutting table and a substrate. 
   
   
       28 . The method as set forth in  claim 27 , wherein the substrate of the cutting elements is designed for low abrasion resistance to minimize the wear flat area of the drill bit. 
   
   
       29 . The method as set forth in  claim 27 , wherein the substrate of the cutting elements is designed for high strength and low abrasion resistance to minimize the wear flat area of the drill bit. 
   
   
       30 . The method as set forth in  claim 27 , wherein the substrate comprises a tungsten carbide layer backed by a steel body. 
   
   
       31 . 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 design of the cutting elements is optimized to manage a wear flat area of the cutting elements.   
   
   
       32 . The drill bit as set forth in  claim 31 , wherein the cutting elements are designed to minimize the wear flat area of the drill bit. 
   
   
       33 . The drill bit as set forth in  claim 31 , wherein a shape of the cutting elements is optimized to manage the wear flat area of the drill bit. 
   
   
       34 . The drill bit as set forth in  claim 31 , wherein a size of the cutting elements is optimized to manage the wear flat area of the drill bit. 
   
   
       35 . The drill bit as set forth in  claim 31 , wherein each blade has primary and secondary cutting elements. 
   
   
       36 . The drill bit as set forth in  claim 35 , wherein the primary cutting elements are designed to fail rapidly once failure begins, thereby more rapidly exposing one of the secondary cutting elements. 
   
   
       37 . The drill bit as set forth in  claim 31 , wherein the cutting elements comprise a diamond cutting table and a substrate. 
   
   
       38 . The drill bit as set forth in  claim 37 , wherein the substrate of the cutting elements is designed for low abrasion resistance to minimize the wear flat area of the drill bit. 
   
   
       39 . The drill bit as set forth in  claim 37 , wherein the substrate of the cutting elements is designed for high strength and low abrasion resistance to minimize the wear flat area of the drill bit. 
   
   
       40 . The drill bit as set forth in  claim 37 , wherein the substrate comprises a tungsten carbide layer backed by a steel body.

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