Shaped cutter arrangements

Patent metadata

Field	Value
Publication number	US-12031383-B2
Application number	US-201917309838-A
Country	US
Kind code	B2
Filing date	Mar 7, 2019
Priority date	Mar 7, 2019
Publication date	Jul 9, 2024
Grant date	Jul 9, 2024

Abstract

A device includes a drill bit body defining an axis of rotation, a plurality of drill blades on the drill bit body, and a shaped cutter secured to at least one of the plurality of drill blades. The shaped cutter including an engagement surface having an exposed partially flattened boundary, wherein a contact point of the engagement surface during drilling is off-centered with respect to a center of the exposed partially flattened boundary.

First claim

What is claimed is:

1. A device comprising:
a drill bit body defining an axis of rotation;
a plurality of drill blades on the drill bit body, including a first drill blade; and
a shaped cutter secured to the first drill blade at a tilt angle, the shaped cutter having a generally cylindrical like shape with a longitudinal axis, one end of the cylindrical like shape configured to be an engagement surface to encounter material during drilling, the engagement surface, prior to use, having a first boundary section and a second boundary section, the second boundary section separate from the first boundary section, the first boundary section having a first curvature, the second boundary section including an exposed partially flattened boundary having a second curvature, the second curvature less than the first curvature, the shaped cutter having a shaped cutter axis of rotation normal to the engagement surface and parallel to the longitudinal axis of the shaped cutter, the exposed partially flattened boundary having a center point that bisects the exposed partially flattened boundary, such that there is a shaped cutter centerline from the center point to the shaped cutter axis of rotation that is normal to the axis of rotation,
the shaped cutter secured to the first drill blade at a tilt angle about the axis of rotation, such that when the drill bit is first put in use the shaped cutter is configured to have a contact point on the exposed partially flat boundary, separate from the center point, that is positioned to first encounter a material being drilled,
wherein there is a cutter reference vector that is normal to the shaped cutter axis of rotation and that intersects the contact point, and
wherein the cutter reference vector intersects the shaped cutter centerline at the shaped cutter axis of rotation, wherein the angle between the cutter reference vector and the shaped cutter centerline is approximately equal to the tilt angle.

2. The device of claim 1 , wherein the shaped cutter is a leading shaped cutter and the contact point is a leading contact point, wherein the device of claim 1 further comprises a trailing shaped cutter secured to the first drill blade, the trailing shaped cutter comprising a trailing engagement surface, wherein a trailing contact point of the trailing engagement surface is at a different axial position from the leading contact point.

3. The device of claim 2 , wherein the leading contact point is at an upper end of the leading shaped cutter with respect to the axis of rotation defined by the drill bit body and the trailing contact point is at a lower end of the trailing shaped cutter with respect to the axis of rotation defined by the drill bit body.

4. The device of claim 1 , wherein the shaped cutter is a first shaped cutter, and wherein the exposed partially flattened boundary is a first exposed partially flattened boundary, and wherein the device of claim 1 further comprises:
a second shaped cutter attached to the drill bit body, the second shaped cutter comprising a second exposed partially flattened boundary, wherein the second shaped cutter has a second cutter centerline that is perpendicular to and bisects the second exposed partially flattened boundary; and
a third shaped cutter attached to the drill bit body, the third shaped cutter comprising a third exposed partially flattened boundary, wherein the third shaped cutter has a third cutter centerline that is perpendicular to and bisects the third exposed partially flattened boundary, and wherein at least a portion of the third shaped cutter is at a different axial position along the axis of rotation defined by the drill bit body, and wherein a distance from the axis of rotation defined by the drill bit body to the second shaped cutter is equal to a distance from the axis of rotation defined by the drill bit body to the third shaped cutter.

5. The device of claim 1 , wherein the tilt angle is greater than or equal to 5 degrees.

6. The device of claim 1 , wherein the shaped cutter centerline is at an angle of at least 5 degrees offset from the cutter reference vector.

7. The device of claim 1 , wherein the engagement surface comprises a polycrystalline diamond compact bit material.

8. In a drill bit body defining an axis of rotation and a plurality of drill blades that rotate around the axis of rotation, a method of installing a shaped cutter in one of the drill blades, the method comprising:
determining an initial position for securing the shaped cutter to the drill blade, the initial position establishing a first initial contact point on an exposed partially flattened boundary of an engagement surface of the shaped cutter, the first initial contact point the position on the exposed partially flattened boundary that first encounters a material being drilled when the shaped cutter is first used secured in the initial position;
selecting a second initial contact point on the exposed partially flattened boundary of the engagement surface of the shaped cutter, wherein the second initial contact point is not the first initial contact point;
determining whether an off-centering distance of the second initial contact point is less than an off-centering threshold, wherein the off-centering distance is a distance along the exposed partially flattened boundary from the second initial contact point to a center of the exposed partially flattened boundary; and
in response to a determination that the off-centering distance is less than an off-centering threshold, rotating the shaped cutter by the off-centering distance to expose the second initial contact point as the position on the exposed partially flattened boundary that first encounters a material being drilled when the shaped cutter is first used secured in the drill blade as rotated.

9. The method of claim 8 , wherein rotating the shaped cutter comprises rotating the shaped cutter until the off-centering distance is greater than or equal to the off-centering threshold.

10. The method of claim 8 , wherein the second initial contact point comprises a leading contact point, and wherein the method further comprises rotating a trailing shaped cutter to a trailing tilt angle, and wherein the trailing shaped cutter comprises a trailing contact point, and wherein at least a portion of the trailing shaped cutter is at a same axial position as the trailing shaped cutter, and wherein the trailing contact point is at a different axial position than the leading contact point.

11. The method of claim 8 , wherein rotating the shaped cutter comprises rotating the shaped cutter by an angle greater than 5 degrees around an axis of rotation extending through the engagement surface.

12. A system comprising:
a drill pipe in a borehole;
a drill bit body defining an axis of rotation, wherein the drill bit body is in the borehole and attached to the drill pipe;
a plurality of drill blades on the drill bit body, including a first drill blade; and
a shaped cutter secured to the first drill blade at a tilt angle, the shaped cutter having a generally cylindrical like shape with a longitudinal axis, one end of the cylindrical like shape configured to be an engagement surface to encounter material during drilling, the engagement surface having, prior to use, a first boundary section and a second boundary section, the second boundary section separate from the first boundary section, the first boundary section having a first curvature, the second boundary section including an exposed partially flattened boundary having a second curvature, the second curvature less than the first curvature, the shaped cutter having a shaped cutter axis of rotation normal to the engagement surface a

Assignees

• Halliburton Energy Services Inc

Inventors

• Maouche Zakaria
• Chen Shilin

Classifications

• E21B10/5673

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

• E21B10/43 Primary

  characterised by the arrangement of teeth or other cutting elements · CPC title