Cutting elements having non-planar surfaces and tools incorporating the same

Patent metadata

Field	Value
Publication number	US-2019071933-A1
Application number	US-201816121694-A
Country	US
Kind code	A1
Filing date	Sep 5, 2018
Priority date	Sep 5, 2017
Publication date	Mar 7, 2019
Grant date	—

Abstract

A cutting element includes a body, a non-planar cutting face formed on a first end of the body, and an edge formed around a perimeter of the cutting face. The cutting face includes a central raised portion, and the edge has an edge angle defined between the cutting face and a side surface of the body. The edge angle varies around the perimeter of the cutting face and includes an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting angle. The portion of the edge defining the acute edge angle may be directly adjacent: a side surface of the cutting element; a bevel of the cutting element; or a flat region at the perimeter of the cutting element or bevel.

First claim

What is claimed is:

1 . A cutting element, comprising:
a body; a non-planar cutting face formed at a first end of the body, the cutting face including a central raised region; and an edge formed around a perimeter of the cutting face, the edge having an edge angle defined between the cutting face and a side surface of the body, the edge angle varying around the perimeter of the cutting face, and the edge including an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting edge.

2 . The cutting element of claim 1 , the central raised region including a ridge extending between opposite sides of the perimeter of the cutting face.

3 . The cutting element of claim 1 , the central raised region being a distance from the entire perimeter of the cutting face.

4 . The cutting element of claim 1 , a cross-sectional profile of the cutting face having a sinusoidal shape on a plane extending along and intersecting a central longitudinal axis of the cutting element.

5 . The cutting element of claim 1 , the body including a cutting layer on a substrate, the cutting face formed on the cutting layer opposite the interface.

6 . The cutting element of claim 1 , the acute edge angle defined by an inclined portion of the cutting face, an area of a different edge angle being positioned between the inclined portion and a bevel of the edge.

7 . The cutting element of claim 6 , the inclined portion being a first inclined portion and the area of the different edge angle being a second inclined portion having a greater acute edge angle than the first inclined portion.

8 . A cutting element, comprising:
a body; a non-planar cutting face coupled to the body; a height measured between a base surface of the body and the non-planar cutting face; and an edge extending around a perimeter of the non-planar cutting face, the height of the edge varying around the perimeter, such that a first portion of the edge extends higher than a second portion of the edge, and an edge angle defined between the non-planar cutting face and a side surface of the body is less than 90° in at least one section of the first portion of the edge and greater than 90° at the second portion of the edge.

9 . The cutting element of claim 8 , the at least one section of the first portion of the edge having a concave profile.

10 . The cutting element of claim 8 , the second portion of the edge having a convex profile.

11 . The cutting element of claim 8 , the at least one section of the first portion of the edge including at least two sections, a first of the at least two sections being nearer the perimeter of the non-planar cutting face and having a greater edge angle than a second of the at least two sections.

12 . The cutting element of claim 11 , the first of the at least two sections having an edge angle between 75° and 90°.

13 . The cutting element of claim 12 , the second of the at least two sections having an edge angle between 60° and 75°.

14 . A cutting element, comprising:
a substrate; and a cutting layer on the substrate, the cutting layer defining a cutting edge, a non-planar cutting face opposite the substrate, and at least one impact resistant feature at an interface between the cutting edge and the non-planar cutting face.

15 . The cutting element of claim 14 , the at least one impact resistant feature being located between a high portion of the cutting edge and an inclined portion of the non-planar cutting face, the inclined portion defining an acute angle with a side surface of the cutting layer.

16 . The cutting element of claim 15 , the cutting edge further including a low portion, the low portion corresponding to a convex portion of the non-planar cutting face defining an obtuse angle with the side surface of the cutting layer.

17 . The cutting element of claim 14 , the impact resistant feature including at least one flat region defining a planar portion of the cutting face.

18 . The cutting element of claim 17 , the at least one flat region having a radial length that is between 5% and 10% of a width of the cutting layer.

19 . The cutting element of claim 18 , the at least one flat region including at least two flat regions having a variable radial length, the at least two flat regions collectively extending around between 20% and 50% of a perimeter of the cutting edge.

20 . The cutting element of claim 14 , the non-planar cutting face including at least two raised portions including:
a central raised portion; and two raised edge portions, the two raised edge portions including first and second sections having different edge angles, with the edge angle of a portion nearest the cutting edge being larger, the portion nearest the cutting edge forming at least a portion of the impact resistant feature.

Assignees

• Smith International

Inventors

• Gan Xiaoge
• Dong Anjie
• Johnson Gerard
• Azar Michael George
• Song Huimin
• Zhang Youhe
• Karuppiah Venkatesh

Classifications

• E21B10/43

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

• E21B10/55

  with preformed cutting elements · CPC title

• B22F2005/001

  Cutting tools, earth boring or grinding tool other than table ware · CPC title

• E21B10/42 Primary

  Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits (characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62) · CPC title

• E21B10/5676 Primary

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