Cutting elements having non-planar surfaces and downhole cutting tools using such cutting elements

Patent metadata

Field	Value
Publication number	US-12031384-B2
Application number	US-202117560409-A
Country	US
Kind code	B2
Filing date	Dec 23, 2021
Priority date	Mar 11, 2014
Publication date	Jul 9, 2024
Grant date	Jul 9, 2024

Abstract

A cutting element may include a substrate and an ultrahard layer. A top surface of the ultrahard layer includes a peripheral edge extending around the cutting element, a cutting crest extending across a major dimension of the cutting element from a cutting edge at a first portion of the peripheral edge to a modified region at a central axis of the ultrahard layer, and a lateral portion extending across a minor dimension of the cutting element from the peripheral edge to the modified region. The modified region along the major dimension includes a concave cross-sectional shape. The lateral portion along the minor dimension from the peripheral edge to the modified region includes one or more of a linear shape and a convex shape, and the modified region along the minor dimension includes a planar shape perpendicular to the central axis.

First claim

What is claimed is:

1. A cutting element, comprising:
a substrate comprising an upper surface; and
an ultrahard layer on the upper surface, a top surface of the ultrahard layer comprising:
a peripheral edge of the top surface extending around the cutting element;
a cutting crest extending across a major dimension of the cutting element from a cutting edge at a first portion of the peripheral edge to a modified region, wherein the modified region is located at a central axis of the ultrahard layer, wherein the modified region along the major dimension comprises a concave cross-sectional shape that extends along the length of the major dimension and across the central axis; and
a lateral portion extending across a minor dimension of the cutting element from the peripheral edge to the modified region, wherein the lateral portion along the minor dimension from the peripheral edge to the modified region comprises a linear shape, a convex shape, or the linear shape and the convex shape, and the modified region along the minor dimension comprises a planar shape perpendicular to the central axis.

2. The cutting element of claim 1 , wherein the major dimension is orthogonal to the minor dimension.

3. The cutting element of claim 1 , wherein the cutting crest extends across the major dimension of the cutting element from the cutting edge at a first portion of the peripheral edge to the modified region, and from the modified region to a second portion of the peripheral edge opposite the first portion.

4. The cutting element of claim 1 , wherein the cutting element comprises a cylindrical substrate.

5. The cutting element of claim 1 , wherein the peripheral edge decreases in height in a direction away from the cutting crest and the cutting edge portion to the lateral portion of the peripheral edge adjacent to a recessed region of the ultrahard layer.

6. The cutting element of claim 1 , wherein the cutting crest comprises a spacing greater than 0.03 inches between the peripheral edge and the concave cross-sectional shape.

7. The cutting element of claim 1 , wherein at least a portion of the cutting crest has a radius of curvature ranging from 0.06 to 0.18 inches.

8. The cutting element of claim 1 , comprising one or more protrusions on the top surface to form a chip breaker.

9. A cutting element comprising:
a substrate comprising an upper surface; and
an ultrahard layer on the upper surface, a top surface of the ultrahard layer comprising:
a cutting crest extending along at least a portion of a diameter of the cutting element, wherein the cutting crest comprises a peak and a length;
a sloped region of the top surface extending laterally away from the cutting crest, wherein the sloped region comprises a gradually decreasing height relative to the peak of the cutting crest as the sloped region extends laterally away from the cutting crest toward a peripheral edge of the top surface;
wherein the cutting crest extends along the portion of the diameter from the peripheral edge of the top surface and wherein the sloped region adjacent to the peripheral edge is non-perpendicular to a longitudinal axis of the cutting element,
wherein a profile of the cutting crest along its length includes at least one concave region and wherein the at least one concave region extends across the central longitudinal axis of the cutting element.

10. The cutting element of claim 9 , wherein the peripheral edge of the top surface extends around the cutting element and a cutting edge portion of the peripheral edge is adjacent the cutting crest, and wherein the peripheral edge decreases in height in a direction away from the cutting crest with the sloped region of the top surface of the ultrahard layer.

11. The cutting element of claim 9 , wherein the top surface comprises a plurality of cutting crests extending from a peripheral edge radially inwards to intersect at a central region.

12. The cutting element of claim 9 , wherein the cutting crest varies in height from the peak to form a continuous curve along its length.

13. The cutting element of claim 9 , wherein at least a portion of the cutting crest has a radius of curvature ranging from 0.06 to 0.18 inches.

14. The cutting element of claim 9 , wherein the profile of the cutting crest along its length includes at least two concave regions.

15. A cutting element, comprising:
a substrate comprising an upper surface; and
an ultrahard layer on the upper surface, a top surface of the ultrahard layer comprising:
a peripheral edge of the top surface extending around the cutting element;
a longitudinal axis extending perpendicular to a base plane of the ultrahard layer;
a cutting crest extending across a major dimension of the cutting element from the peripheral edge of the top surface, wherein the peripheral edge decreases in height relative to the base plane in a direction away from the cutting crest to a lateral portion of the peripheral edge adjacent to a recessed region of the ultrahard layer, wherein the major dimension of the cutting element extends between a maximally distanced pair of opposite points of the peripheral edge across the longitudinal axis; and
a secondary crest arranged in a lateral space between the cutting crest and the recessed region, wherein the secondary crest comprises a first end, a second end, and a secondary crest axis extending between the first end and the second end, wherein the secondary crest axis is substantially parallel to the cutting crest.

16. The cutting element of claim 15 , wherein the cutting crest has a constant height relative to a base plane perpendicular to a longitudinal axis of the cutting element.

17. The cutting element of claim 15 , wherein the secondary crest extends less than 90% of a length of the cutting crest along the major dimension, wherein the secondary crest extends to less than the peripheral edge.

18. The cutting element of claim 15 , wherein the secondary crest axis comprises a curvature bowing towards the lateral portion of the peripheral edge.

19. The cutting element of claim 15 , comprising one or more elongated valleys, wherein each elongated valley is arranged in the lateral space between the cutting crest and the secondary crest.

Assignees

• Schlumberger Technology Corp

Inventors

• Chen Chen
• Song Huimin
• Zhao Liang
• Zhang Youhe
• Azar Michael G
• Gan Xiaoge
• Keshavan Madapusi K
• Lin Zhijun
• Durairajan Bala
• Stewart Michael L

Classifications

• E21B10/5735

  Interface between the substrate and the cutting element · CPC title

• E21B10/56

  Button-type inserts (E21B10/52 takes precedence) · CPC title

• E21B10/5673 Primary

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