US20100101750A1 - Two piece mold used in manufacture of PDC drill bits and method of using same - Google Patents
Two piece mold used in manufacture of PDC drill bits and method of using same Download PDFInfo
- Publication number
- US20100101750A1 US20100101750A1 US12/288,889 US28888908A US2010101750A1 US 20100101750 A1 US20100101750 A1 US 20100101750A1 US 28888908 A US28888908 A US 28888908A US 2010101750 A1 US2010101750 A1 US 2010101750A1
- Authority
- US
- United States
- Prior art keywords
- core
- shell
- mold
- cavity
- graphite
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims description 11
- 238000004519 manufacturing process Methods 0.000 title description 10
- 239000011159 matrix material Substances 0.000 claims abstract description 18
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 10
- 239000010439 graphite Substances 0.000 claims abstract description 10
- 238000003801 milling Methods 0.000 claims abstract description 9
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000000843 powder Substances 0.000 claims description 6
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims 4
- 239000002245 particle Substances 0.000 claims 3
- 229910052759 nickel Inorganic materials 0.000 claims 2
- 238000002844 melting Methods 0.000 claims 1
- 230000008018 melting Effects 0.000 claims 1
- 238000003825 pressing Methods 0.000 claims 1
- 229910000990 Ni alloy Inorganic materials 0.000 abstract description 5
- 238000005553 drilling Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910003460 diamond Inorganic materials 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 230000000284 resting effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/06—Casting in, on, or around objects which form part of the product for manufacturing or repairing tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/42—Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits
Definitions
- This invention relates generally to the manufacture of fixed cutter drill bits used to drill oil and gas wells.
- Bits typically used for drilling boreholes in the oil and gas industry include roller cone bits and fixed cutter bits.
- Cutting structures on bits vary depending on the type of bit and the type of formation being cut.
- Roller cone cutting structures typically include milled steel teeth, tungsten carbide inserts, or diamond enhanced inserts.
- Cutting structures for fixed cutter bits typically include polycrystalline diamond compacts, commonly referred to as “PDC” cutters.
- PDC polycrystalline diamond compacts
- Fixed cutter drill bits also referred to as fixed head bits or drag bits, are generally more expensive than mill tooth roller cone drill bits and are considered to offer less aggressive cutting structures than roller cone drill bits. However, in several applications, fixed cutter bits can be used to drill longer well segments in a single run and can be rebuilt and reused multiple times to provide an overall economic benefit that outweighs the higher cost. Fixed cutter bits which include PDC cutters are typically referred to as PDC bits.
- FIG. 1 of the drawings illustrates a conventional single piece graphite mold which is known in the prior art for manufacturing the carbide matrix body for a PDC drill bit.
- FIG. 1 is a pictorial, isometric view of a graphite mold known in the prior art used for manufacturing a carbide matrix body for PDC drill bits;
- FIGS. 2A , 2 B and 2 C respectively illustrate an exploded view of the two piece mold in accordance with the present invention
- FIG. 3A illustrates another view of the elements illustrated in FIGS. 2A , 2 B and 2 C, as assembled, after the drill bit has been at least partially milled in accordance with invention
- FIG. 3B is a schematic view, partially in cross section, illustrating the assembled two piece mold and the gauge ring which is used as a funnel, illustrated in FIG. 2C , resting on top of the two piece mold illustrated in FIGS. 2A and 2B ;
- FIG. 4A is an elevated, schematic view, in cross section, illustrating the mold core illustrated in FIG. 2 mounted within the mold shell illustrated in FIG. 2A and having the gauge ring illustrated in FIG. 2 sitting on top of the mold part shown in FIG. 2B ;
- FIG. 4B is a top plan, schematic view of the embodiment illustrated in FIG. 4A , but without its top portion illustrated;
- FIG. 5 is a side view, in cross section of the mold shell illustrated in FIG. 2A in accordance with the invention.
- FIG. 6 is a side view, in cross section, illustrating the mold core illustrated in FIG. 2B , which in operation resides within the mold shell illustrated in FIG. 5 ;
- FIG. 7 is a pictorial, isometric view of the assembled two piece mold illustrated in FIGS. 2A and 2B , and having a drill bit residing within the interior of the mold core in FIG. 2B in accordance with the invention.
- FIG. 8 illustrates the equipment used in milling the drill bit within the mold core illustrated in FIG. 2B while resting on a fixture to support the mold core illustrated in FIG. 2B .
- FIG. 1 is a pictorial, isometric view of the one piece mold which is commonly used in the PDC drill bit industry to manufacture PDC bits.
- the mold 10 has a lower portion 12 and an upper ring 14 which contains a cavity which is used as the mold for manufacturing the PDC bit body.
- the mold is first partially filled with a tungsten carbide powder to which is then applied a metal alloy, such as a nickel alloy. Upon heating, the nickel alloy will mix with the molten tungsten carbide, which upon cooling results in a carbide matrix which forms the bit body in the prior art.
- a conventional milling process such as is illustrated in FIG. 8 having milling device 16 is then used to mill out the various components of the matrix body to result in a finished PDC matrix body.
- the mold 10 is removed from the molded graphite 18 , typically by breaking the mold 10 with a hammer, a crowbar or the like. This results in a lot of wasted material because the mold 10 cannot be reused because of its broken condition.
- FIGS. 2A , 2 B and 2 C there is illustrated a mold shell 30 and a mold core 32 which is illustrated in FIG. 2B .
- the mold core 32 is sized to closely fit within the cavity 34 illustrated in FIG. 2A which allows the mold core 32 to be easily removed from the shell 30 after the molding process has been completed.
- the mold shell 30 is not broken and can be reused several times in the molding process.
- the milling process has been used to at least partially complete the milling of the matrix body to result in a matrix drill bit body.
- Gauge ring 36 which sits on top of the mold shell 30 , surrounds the cavity in the mold core 32 , all is illustrated in FIG. 4A .
- the funnel 38 through which the nickel alloy and the tungsten carbide powder is filled, allows the tungsten carbide powder and the nickel alloy to go into the cavity within the mold core 32 as illustrated in FIG. 2B .
- Sitting atop the funnel 38 is a top end piece 42 .
- the end cap 42 can be threaded onto the top of the funnel 38 or can merely sit on top of the funnel as desired.
- the drill bit parts are illustrated schematically, such as the nozzles 44 and the other components such as the cutter pockets 46 which will eventually house the PDC cutters once all the molding process has been completed. All of these parts of the conventional PDC bit are well known in the art and need no further description herein.
- FIG. 4B illustrates a top plan view of the mold shell, mold core and gauge ring, as well as carbide matrix which has been milled to accept the various components of the finished drill bit in accordance with the invention.
- FIG. 7 is a pictorial, isometric view of the two piece mold according to the invention, is much like the embodiment of FIG. 3A , but having the milling process further completed for forming the various components of the PDC drill bit.
- the core 32 is easily removed from the mold shell 30 , without any need to break the mold shell 30 , all as contemplated by the present invention.
- the matrix body for the drill bit can then be removed from the mold core, with breaking of the mold core as may be necessary. It allows a mold shell to be used several times without a need to break the shell as done in the prior art single piece molds.
- the use of the two piece mold enables the manufacture of several sized PDC bit bodies from a single size mold shell which cannot be done in the prior art because the one piece mold is broken with a single use and does not allow the manufacture of different sized drill bit bodies to be made from a one piece mold, or even a repetition of the process for the same sized bits using the same shell.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mining & Mineral Resources (AREA)
- Geology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Earth Drilling (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
Abstract
Description
- This invention relates generally to the manufacture of fixed cutter drill bits used to drill oil and gas wells.
- Various types of drill bits have been developed and found useful in different drilling environments. Bits typically used for drilling boreholes in the oil and gas industry include roller cone bits and fixed cutter bits. Cutting structures on bits vary depending on the type of bit and the type of formation being cut. Roller cone cutting structures typically include milled steel teeth, tungsten carbide inserts, or diamond enhanced inserts. Cutting structures for fixed cutter bits typically include polycrystalline diamond compacts, commonly referred to as “PDC” cutters. The selection of a bit type and cutting structure for a given drilling application depends on many factors including the formation type to be drilled, rig equipment capabilities, and the time and cost associated with drilling.
- It is common in the art of manufacturing PDC, fixed cutter drill bits, to manufacture the carbide matrix body of the drill bit in a graphite mold. Such a mold known in the prior art is typically made with a single mold manufactured from graphite.
- Fixed cutter drill bits, also referred to as fixed head bits or drag bits, are generally more expensive than mill tooth roller cone drill bits and are considered to offer less aggressive cutting structures than roller cone drill bits. However, in several applications, fixed cutter bits can be used to drill longer well segments in a single run and can be rebuilt and reused multiple times to provide an overall economic benefit that outweighs the higher cost. Fixed cutter bits which include PDC cutters are typically referred to as PDC bits.
-
FIG. 1 of the drawings illustrates a conventional single piece graphite mold which is known in the prior art for manufacturing the carbide matrix body for a PDC drill bit. -
FIG. 1 is a pictorial, isometric view of a graphite mold known in the prior art used for manufacturing a carbide matrix body for PDC drill bits; -
FIGS. 2A , 2B and 2C respectively illustrate an exploded view of the two piece mold in accordance with the present invention; -
FIG. 3A illustrates another view of the elements illustrated inFIGS. 2A , 2B and 2C, as assembled, after the drill bit has been at least partially milled in accordance with invention; -
FIG. 3B is a schematic view, partially in cross section, illustrating the assembled two piece mold and the gauge ring which is used as a funnel, illustrated inFIG. 2C , resting on top of the two piece mold illustrated inFIGS. 2A and 2B ; -
FIG. 4A is an elevated, schematic view, in cross section, illustrating the mold core illustrated inFIG. 2 mounted within the mold shell illustrated inFIG. 2A and having the gauge ring illustrated inFIG. 2 sitting on top of the mold part shown inFIG. 2B ; -
FIG. 4B is a top plan, schematic view of the embodiment illustrated inFIG. 4A , but without its top portion illustrated; -
FIG. 5 is a side view, in cross section of the mold shell illustrated inFIG. 2A in accordance with the invention; -
FIG. 6 is a side view, in cross section, illustrating the mold core illustrated inFIG. 2B , which in operation resides within the mold shell illustrated inFIG. 5 ; -
FIG. 7 is a pictorial, isometric view of the assembled two piece mold illustrated inFIGS. 2A and 2B , and having a drill bit residing within the interior of the mold core inFIG. 2B in accordance with the invention; and -
FIG. 8 illustrates the equipment used in milling the drill bit within the mold core illustrated inFIG. 2B while resting on a fixture to support the mold core illustrated inFIG. 2B . - Referring now to the drawings in more detail,
FIG. 1 is a pictorial, isometric view of the one piece mold which is commonly used in the PDC drill bit industry to manufacture PDC bits. Themold 10 has alower portion 12 and anupper ring 14 which contains a cavity which is used as the mold for manufacturing the PDC bit body. In the process of using the prior art mold illustrated inFIG. 1 , the mold is first partially filled with a tungsten carbide powder to which is then applied a metal alloy, such as a nickel alloy. Upon heating, the nickel alloy will mix with the molten tungsten carbide, which upon cooling results in a carbide matrix which forms the bit body in the prior art. A conventional milling process such as is illustrated inFIG. 8 havingmilling device 16 is then used to mill out the various components of the matrix body to result in a finished PDC matrix body. - In using the single piece mold of the prior art illustrated in
FIG. 1 , as soon as the process has been finished as illustrated inFIG. 1 , themold 10 is removed from themolded graphite 18, typically by breaking themold 10 with a hammer, a crowbar or the like. This results in a lot of wasted material because themold 10 cannot be reused because of its broken condition. - Referring now to
FIGS. 2A , 2B and 2C, there is illustrated amold shell 30 and amold core 32 which is illustrated inFIG. 2B . Themold core 32 is sized to closely fit within thecavity 34 illustrated inFIG. 2A which allows themold core 32 to be easily removed from theshell 30 after the molding process has been completed. Themold shell 30 is not broken and can be reused several times in the molding process. As illustrated inFIG. 2B , the milling process has been used to at least partially complete the milling of the matrix body to result in a matrix drill bit body.Gauge ring 36 which sits on top of themold shell 30, surrounds the cavity in themold core 32, all is illustrated inFIG. 4A . - The
funnel 38 through which the nickel alloy and the tungsten carbide powder is filled, allows the tungsten carbide powder and the nickel alloy to go into the cavity within themold core 32 as illustrated inFIG. 2B . Sitting atop thefunnel 38 is atop end piece 42. Theend cap 42 can be threaded onto the top of thefunnel 38 or can merely sit on top of the funnel as desired. InFIG. 4A , the drill bit parts, are illustrated schematically, such as thenozzles 44 and the other components such as the cutter pockets 46 which will eventually house the PDC cutters once all the molding process has been completed. All of these parts of the conventional PDC bit are well known in the art and need no further description herein. -
FIG. 4B illustrates a top plan view of the mold shell, mold core and gauge ring, as well as carbide matrix which has been milled to accept the various components of the finished drill bit in accordance with the invention. -
FIG. 7 is a pictorial, isometric view of the two piece mold according to the invention, is much like the embodiment ofFIG. 3A , but having the milling process further completed for forming the various components of the PDC drill bit. Assuming that the milling process is completed, thecore 32 is easily removed from themold shell 30, without any need to break themold shell 30, all as contemplated by the present invention. The matrix body for the drill bit can then be removed from the mold core, with breaking of the mold core as may be necessary. It allows a mold shell to be used several times without a need to break the shell as done in the prior art single piece molds. The use of the two piece mold enables the manufacture of several sized PDC bit bodies from a single size mold shell which cannot be done in the prior art because the one piece mold is broken with a single use and does not allow the manufacture of different sized drill bit bodies to be made from a one piece mold, or even a repetition of the process for the same sized bits using the same shell.
Claims (8)
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/288,889 US20100101750A1 (en) | 2008-10-24 | 2008-10-24 | Two piece mold used in manufacture of PDC drill bits and method of using same |
| PCT/US2009/005742 WO2010047802A1 (en) | 2008-10-24 | 2009-10-22 | Two piece mold used in manufacture of pdc drill bits and method of using same |
| US12/590,561 US20100101747A1 (en) | 2008-10-24 | 2009-11-10 | Mold used in manufacture of drill bits and method of forming same |
| US12/806,704 US20110056751A1 (en) | 2008-10-24 | 2010-08-19 | Ultra-hard matrix reamer elements and methods |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/288,889 US20100101750A1 (en) | 2008-10-24 | 2008-10-24 | Two piece mold used in manufacture of PDC drill bits and method of using same |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US12/590,561 Continuation-In-Part US20100101747A1 (en) | 2008-10-24 | 2009-11-10 | Mold used in manufacture of drill bits and method of forming same |
Related Child Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US12/590,429 Continuation-In-Part US8561725B2 (en) | 2008-10-24 | 2009-11-06 | Ultra-hard drill collar |
| US12/590,561 Continuation-In-Part US20100101747A1 (en) | 2008-10-24 | 2009-11-10 | Mold used in manufacture of drill bits and method of forming same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20100101750A1 true US20100101750A1 (en) | 2010-04-29 |
Family
ID=42116354
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US12/288,889 Abandoned US20100101750A1 (en) | 2008-10-24 | 2008-10-24 | Two piece mold used in manufacture of PDC drill bits and method of using same |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20100101750A1 (en) |
| WO (1) | WO2010047802A1 (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4140170A (en) * | 1977-09-06 | 1979-02-20 | Baum Charles S | Method of forming composite material containing sintered particles |
| US5839329A (en) * | 1994-03-16 | 1998-11-24 | Baker Hughes Incorporated | Method for infiltrating preformed components and component assemblies |
| US6655481B2 (en) * | 1999-01-25 | 2003-12-02 | Baker Hughes Incorporated | Methods for fabricating drill bits, including assembling a bit crown and a bit body material and integrally securing the bit crown and bit body material to one another |
| US20080028891A1 (en) * | 2006-04-28 | 2008-02-07 | Calnan Barry D | Molds and methods of forming molds associated with manufacture of rotary drill bits and other downhole tools |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5355750A (en) * | 1991-03-01 | 1994-10-18 | Baker Hughes Incorporated | Rolling cone bit with improved wear resistant inserts |
| US7044243B2 (en) * | 2003-01-31 | 2006-05-16 | Smith International, Inc. | High-strength/high-toughness alloy steel drill bit blank |
-
2008
- 2008-10-24 US US12/288,889 patent/US20100101750A1/en not_active Abandoned
-
2009
- 2009-10-22 WO PCT/US2009/005742 patent/WO2010047802A1/en not_active Ceased
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4140170A (en) * | 1977-09-06 | 1979-02-20 | Baum Charles S | Method of forming composite material containing sintered particles |
| US5839329A (en) * | 1994-03-16 | 1998-11-24 | Baker Hughes Incorporated | Method for infiltrating preformed components and component assemblies |
| US6655481B2 (en) * | 1999-01-25 | 2003-12-02 | Baker Hughes Incorporated | Methods for fabricating drill bits, including assembling a bit crown and a bit body material and integrally securing the bit crown and bit body material to one another |
| US20080028891A1 (en) * | 2006-04-28 | 2008-02-07 | Calnan Barry D | Molds and methods of forming molds associated with manufacture of rotary drill bits and other downhole tools |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2010047802A1 (en) | 2010-04-29 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: ENCORE BITS, LLC,TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:TOMCZAK, MICHAEL M.;SALVO, VINCENTE S.;RIOS, JUAN;REEL/FRAME:021856/0194 Effective date: 20081111 |
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| AS | Assignment |
Owner name: OMNI LP LTD.,TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ENCORE BITS, LLC;REEL/FRAME:024051/0140 Effective date: 20100304 |
|
| AS | Assignment |
Owner name: OMNI IP LTD.,VIRGIN ISLANDS, BRITISH Free format text: ADDRESS CHANGE AND CORRECTION R/F 024051/0140;ASSIGNOR:OMNI IP LTD.;REEL/FRAME:024534/0647 Effective date: 20100304 |
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| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |