Cutting elements, earth-boring tools including the cutting elements, and methods of forming the earth-boring tools

Patent metadata

Field	Value
Publication number	US-11920409-B2
Application number	US-202217810802-A
Country	US
Kind code	B2
Filing date	Jul 5, 2022
Priority date	Jul 5, 2022
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

Abstract

A cutting element includes a substrate and a cutting table secure to the substrate. The cutting table includes a first surface, a cutting surface, a first transition surface, and a second transition surface. The cutting surface at least substantially surrounds an outer boundary of the first surface and is angled relative to a longitudinal centerline of the cutting table. The first and second transition surfaces are between the cutting surface and an outer lateral edge of the cutting table. The first and second transition surfaces are oriented at a first angle and a second different angle, respectively, relative to the longitudinal centerline of the cutting table. An earth-boring tool and method of forming an earth-boring tool are also described.

First claim

What is claimed is:

1. A cutting element, comprising:
a substrate; and
a cutting table secured to the substrate at an interface, the cutting table comprising a superabrasive material, the cutting table comprising:
a first surface including an outer boundary;
a cutting surface at least substantially surrounding the outer boundary of the first surface, the cutting surface angled relative to a longitudinal centerline of the cutting table;
a plurality of first transition surfaces between the cutting surface and an outer lateral edge of the cutting table, each of the plurality of first transition surfaces oriented at a first angle relative to the longitudinal centerline of the cutting table;
a plurality of second transition surfaces between the cutting surface and the outer lateral edge of the cutting table, each of the plurality of second transition surfaces oriented at a second angle, different than the first angle, relative to the longitudinal centerline of the cutting table, the plurality of second transition surfaces positioned in an alternating circumferential sequence with the plurality of first transition surfaces; and
a cutting edge defined by an interface between the cutting surface and each of: the plurality of first transition surfaces; and the plurality of second transition surfaces.

2. The cutting element of claim 1 , wherein each of the plurality of first transition surfaces is larger than each of the plurality of second transition surfaces.

3. The cutting element of claim 1 , wherein the plurality of first transition surfaces occupies a surface area within a range of from about 5% and about 20% of a total surface area of a cutting face of the cutting element.

4. The cutting element of claim 1 , wherein the first surface occupies a surface area within a range of from about 20% to about 80% of a total surface area of a cutting face of the cutting element.

5. The cutting element of claim 1 , wherein a central portion of the cutting table is recessed relative to a surrounding portion of the cutting table such that a first section of the first surface is recessed relative to a second section of the first surface.

6. The cutting element of claim 1 , wherein each of the plurality of first transition surfaces exhibits a concave surface profile from a first edge to a second edge thereof, the second edge opposite the first edge.

7. The cutting element of claim 1 , wherein the first surface is substantially planar.

8. An earth-boring tool, comprising:
a bit body;
a blade extending radially outward from and further extending in a direction parallel to a central longitudinal axis of the bit body, the blade comprising a rotationally leading portion; and
a cutting element secured to the blade proximate the rotationally leading portion of the blade, the cutting element comprising:
a substrate; and
a cutting table secured to the substrate at an interface, the cutting table comprising a superabrasive material, the cutting table comprising:
a first surface including an outer boundary;
a cutting surface at least substantially surrounding the outer boundary of the first surface, the cutting surface oriented at a first angle relative to a longitudinal centerline of the cutting table;
a plurality of first transition surfaces between the cutting surface and an outer lateral edge of the cutting table, each of the plurality of first transition surfaces oriented at a second angle relative to the longitudinal centerline of the cutting table;
a plurality of second transition surfaces between the cutting surface and the outer lateral edge of the cutting table, each of the plurality of second transition surfaces oriented at a third angle relative to the longitudinal centerline of the cutting table, the third angle different than the second angle, the plurality of second transition surfaces positioned in an alternating circumferential sequence with the plurality of first transition surfaces; and
a cutting edge defined by an interface between the cutting surface and each of: the plurality of first transition surfaces; and the plurality of second transition surfaces.

9. The earth-boring tool of claim 8 , wherein the substrate of the cutting element is at least partially disposed within a cutting element pocket of the bit body.

10. The earth-boring tool of claim 8 , wherein the first angle is greater than the second angle, and the second angle is greater than the third angle.

11. The earth-boring tool of claim 8 , wherein the second angle is greater than the third angle.

12. The earth-boring tool of claim 8 , wherein the first angle is within a range of from about 60 degrees to about 80 degrees.

13. The earth-boring tool of claim 8 , wherein the second angle is within a range of from about 45 degrees to about 75 degrees.

14. The earth-boring tool of claim 8 , wherein the third angle is within a range of from about 35 degrees to about 55 degrees.

15. A method of forming an earth-boring tool, the method comprising:
securing a cutting element within a pocket of an unfinished earth-boring tool, the cutting element comprising a cutting table, comprising:
a first surface;
a cutting surface surrounding the first surface and angled relative to a central longitudinal axis of the cutting table;
a plurality of first transition surfaces and a plurality of second transition surfaces positioned in an alternating circumferential sequence, the plurality of first transition surfaces angled differently relative to the central longitudinal axis of the cutting table than the plurality of second transition surfaces; and
a cutting edge defined by an interface between the cutting surface and each of: the plurality of first transition surfaces; and the plurality of second transition surfaces.

16. The method claim 15 , further comprising grinding the first surface to form a uniform chamfered section angled within a range of from about 65 degrees to about 75 degrees relative to the central longitudinal axis of the cutting table.

Assignees

• Baker Hughes Oilfield Operations Llc

Inventors

• Russell Steven Craig
• Ricks Gregory L
• Duffy Stephen

Classifications

• E21B10/5673 Primary

  having a non planar or non circular cutting face · CPC title

• E21B10/55

  with preformed cutting elements · CPC title