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

Patent metadata

Field	Value
Publication number	US-2022112773-A1
Application number	US-202117560409-A
Country	US
Kind code	A1
Filing date	Dec 23, 2021
Priority date	Mar 11, 2014
Publication date	Apr 14, 2022
Grant date	—

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 at a central axis of the ultrahard layer, wherein the modified region along the major dimension comprises a concave cross-sectional shape; 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, the top surface having a portion extending laterally away from the cutting crest having a lesser height than a peak of the cutting crest,
wherein the cutting crest extends along a major dimension of the cutting crest from a peripheral edge of the top surface and wherein the portion of the top surface extending laterally away from the cutting crest to the peripheral edge of the top surface is, adjacent to the peripheral edge, non-perpendicular to a longitudinal axis of the cutting element, and
wherein, in a plane orthogonal to the major dimension of the cutting crest and extending through both the major dimension of the cutting crest and the peripheral edge, the top surface defines a shape consisting of at least one linear shape, at least one convex shape, or at least one linear shape and at least one convex shape, from the peripheral edge to the cutting crest.

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 and the cutting edge portion to another portion of the peripheral edge adjacent to a recessed region 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 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 a profile of the cutting crest along its length includes at least one concave region.

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

16 . 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; and
one or more secondary crests arranged in a lateral space between the cutting crest and the recessed region.

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

18 . The cutting element of claim 16 , wherein the one or more secondary crests extends less than 90% of a length of the cutting crest along the major dimension

19 . The cutting element of claim 16 , wherein the one or more secondary crests have a curvature bowing towards the peripheral edge.

20 . The cutting element of claim 16 , comprising one or more elongated valleys, wherein each elongated valley is arranged in the lateral space between the cutting crest and a respective 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