Cutting elements for earth-boring tools, earth-boring tools including such cutting elements, and related methods

Patent metadata

Field	Value
Publication number	US-2016130882-A1
Application number	US-201514980653-A
Country	US
Kind code	A1
Filing date	Dec 28, 2015
Priority date	Apr 22, 2011
Publication date	May 12, 2016
Grant date	—

Abstract

Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

First claim

1 . A cutting element for an earth-boring tool, comprising:
a substrate; a volume of superabrasive material disposed on the substrate, the volume of superabrasive material having a front cutting face and a lateral side surface; and at least one of a recess extending into the volume of superabrasive material from the front cutting face and a protrusion extending outward from the front cutting face of the volume of superabrasive material; and a recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material.

2 . The cutting element of claim 1 , wherein the recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material extends circumferentially around an entire lateral periphery of the volume of superabrasive material.

3 . A method of forming a shaped cutting element for an earth-boring tool, comprising:
disposing a volume of superabrasive material on a substrate; forming a non-planar front cutting face and a lateral side surface on the volume of superabrasive material; and forming at least one of a recess extending into the volume of superabrasive material from the front cutting face and a protrusion extending outward from the front cutting face of the volume of superabrasive material.

4 . The method of claim 3 , wherein forming the non-planar front cutting face comprises forming the non-planar front cutting face to have a dome shape.

5 . The cutting element of claim 1 , wherein the recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material has an arcuate shape when viewed in a cross-sectional plane extending along a longitudinal axis of the cutting element.

6 . The cutting element of claim 1 , wherein the recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material has one or more linear profile segments when viewed in a cross-sectional plane extending along a longitudinal axis of the cutting element.

7 . The cutting element of claim 1 , wherein the recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material includes a portion extending into a lateral side surface of the substrate.

8 . The cutting element of claim 1 , wherein the front cutting face of the volume of superabrasive material is substantially planar.

9 . The cutting element of claim 1 , wherein the at least one of a recess extending into the volume of superabrasive material from the front cutting face and a protrusion extending outward from the front cutting face of the volume of superabrasive material comprises a recess extending into the volume of superabrasive material from the front cutting face, the recess having an annular configuration.

10 . The cutting element of claim 8 , wherein the recess extending into the volume of superabrasive material from the front cutting face comprises a substantially planar surface recessed from the front cutting face of the volume of superabrasive material.

11 . The cutting element of claim 1 , wherein:
the at least one of a recess extending into the volume of superabrasive material from the front cutting face and a protrusion extending outward from the front cutting face of the volume of superabrasive material comprises a recess extending into the volume of superabrasive material from the front cutting face; and the volume of superabrasive material comprises a lip extending radially from the recess extending into the volume of superabrasive material from the lateral side surface of the volume of superabrasive material, the lip extending longitudinally from the recess extending into the volume of superabrasive material from the front cutting face.

12 . The cutting element of claim 11 , wherein the lip is configured to concentrate shear stresses in a region of subterranean earth formation material adjacent the lip during use of the cutting element in an earth-boring operation.

13 . The method of claim 4 , wherein forming at least one of a recess extending into the volume of superabrasive material from the front cutting face and a protrusion extending outward from the front cutting face of the volume of superabrasive material comprises forming a recess extending into the volume of superabrasive material from the front cutting face, the recess having an annular configuration.

14 . The method of claim 13 , wherein the recess has an arcuate, concave profile when viewed in a cross-sectional plane extending along a longitudinal axis of the cutting element.

15 . The method of claim 14 , further comprising forming a chamfered a peripheral edge of the volume of superabrasive material.

16 . The method of claim 15 , wherein forming a non-planar front cutting face on the volume of superabrasive material further comprises forming a portion of the front cutting face located radially between the chamfered peripheral edge and the recess, the portion having a rounded, convex profile in a cross-sectional plane extending along the longitudinal axis of the cutting element.

17 . The method of claim 16 , wherein the profile of the portion of the front cutting face located radially between the chamfered peripheral edge and the recess and a profile of the recess together comprise a sinusoidal profile when viewed in a cross-section plane extending along the longitudinal axis of the cutting element.

Assignees

• Baker Hughes Inc
• Element Six Ltd

Inventors

• Digiovanni Anthony A
• Kadioglu Yavuz
• Scott Danny E
• Meiners Matthew J
• Pessier Rudolf Carl
• Lyons Nicholas J
• Van Der Riet Clement D
• Herschell Donald Royceton
• Jonker Cornelis Roelof
• Nilen Roger William
• Dolan Gerard Peter

Classifications

• E21B10/5673 Primary

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

• E21B10/60

  characterised by conduits or nozzles for drilling fluids (for roller bits E21B10/18; for percussion drill bits E21B10/38) · CPC title

• E21B10/573

  characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element · CPC title

• E21B10/567 Primary

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title

• E21B10/55 Primary

  with preformed cutting elements · CPC title