Cutting elements comprising waveforms and related tools and methods

Patent metadata

Field	Value
Publication number	US-10914124-B2
Application number	US-201916417206-A
Country	US
Kind code	B2
Filing date	May 20, 2019
Priority date	May 2, 2017
Publication date	Feb 9, 2021
Grant date	Feb 9, 2021

Abstract

Cutting elements for earth-boring tools may include a polycrystalline, superabrasive material secured to an end of a substrate. The polycrystalline, superabrasive material may include a first transition surface and a second transition surface. A waveform may extend around a circumference of the second transition surface, a surface of the waveform tapered toward from the substrate and extending radially from the second transition surface toward the central axis. The surface of the waveform may extend from the second transition surface to a planar surface of the polycrystalline located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

First claim

What is claimed is:

1. A cutting element for an earth-boring tool, comprising:
a polycrystalline, superabrasive material secured to an end of a substrate, the polycrystalline, superabrasive material comprising:
a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of the substrate;
a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and
a surface of a waveform extending around a circumference of the second transition surface, the surface of the waveform tapered toward the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline, superabrasive material located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

2. The cutting element of claim 1 , wherein a frequency of the waveform is between one every 180° and ten every 90°.

3. The cutting element of claim 1 , wherein a maximum thickness of the second transition surface as measured in a direction parallel to the central axis is between 0.01 inch and 0.05 inch.

4. The cutting element of claim 1 , wherein the second transition surface is curved.

5. The cutting element of claim 1 , wherein peaks of the waveform are positioned to contact an underlying earth formation before any other portion of the polycrystalline, superabrasive material.

6. The cutting element of claim 1 , wherein a roughness of the planar surface is different from a roughness of other exposed surfaces of the polycrystalline, superabrasive material.

7. The cutting element of claim 6 , wherein the planar surface is rougher than the other exposed surfaces of the polycrystalline, superabrasive material.

8. The cutting element of claim 1 , wherein a diameter of the planar surface is between 10% and 50% of a maximum diameter of the polycrystalline, superabrasive material.

9. The cutting element of claim 1 , wherein a shape of the second transition surface between the first transition surface and the waveform is sinusoidal.

10. The cutting element of claim 1 , wherein the waveform is configured to reduce peak tensile stress within the polycrystalline, superabrasive material by between about 15% and about 50%.

11. An earth-boring tool, comprising:
a body; and
a cutting element secured to the body, the cutting element comprising:
a polycrystalline, superabrasive material secured to an end of a substrate, the polycrystalline, superabrasive material comprising:
a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of the substrate;
a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and
a surface of a waveform extending around a circumference of the second transition surface, the surface of the waveform tapered toward the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline, superabrasive material located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

12. The earth-boring tool of claim 11 , wherein a frequency of the waveform is between one every 180° and ten every 90°.

13. The earth-boring tool of claim 11 , wherein a maximum thickness of the second transition surface as measured in a direction parallel to the central axis is between 0.01 inch and 0.05 inch.

14. The earth-boring tool of claim 11 , wherein the second transition surface is curved.

15. The earth-boring tool of claim 11 , wherein a roughness of the planar surface is different from a roughness of other exposed surfaces of the polycrystalline, superabrasive material.

16. The cutting element of claim 11 , wherein a diameter of the planar surface is between 10% and 50% of a maximum diameter of the polycrystalline, superabrasive material.

17. A method of removing an earth formation, comprising:
rotating a body of an earth-boring tool; and
removing an earth material in contact with a polycrystalline, superabrasive material of a cutting element secured to the body, the polycrystalline, superabrasive material comprising:
a first transition surface located proximate to a periphery of the polycrystalline, superabrasive material, the first transition surface extending oblique to a central axis of a substrate;
a second transition surface located adjacent to the first transition surface, the second transition surface extending oblique to the central axis; and
a waveform extending around a circumference of the second transition surface, a surface of the waveform tapered toward from the substrate and extending radially from the second transition surface toward the central axis, the surface of the waveform extending from the second transition surface to a planar surface of the polycrystalline located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

18. The method of claim 17 , wherein removing the earth material in contact with the polycrystalline, superabrasive material comprises contacting the earth material with peaks of the waveform before any other portion of the polycrystalline, superabrasive material.

19. The method of claim 17 , further comprising mitigating tensile stress within the polycrystalline, superabrasive material utilizing the waveform.

20. The method of claim 17 , further comprising breaking a chip of the earth material when the earth material reaches an intersection between the waveform and the planar surface.

Assignees

• Baker Hughes A Ge Co Llc

Inventors

• Borge Richard Wayne

Classifications

• E21B10/44

  Bits with helical conveying portion, e.g. screw type bits; Augers with leading portion or with detachable parts (E21B10/42 takes precedence) · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B22F7/062

  involving the connection or repairing of preformed parts · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title

• E21B10/5676 Primary

  having a cutting face with different segments, e.g. mosaic-type inserts · CPC title