Self-Aligning Insert for Drill Bits

Abstract

The present invention is generally directed to various embodiments of a self-aligning insert for use with roller cone drill bits. In one illustrative embodiment, the insert comprises a generally cylindrical body, a cutting surface, a bottom surface, a tapered surface adjacent the cylindrical body, and a generally cylindrical section positioned between the bottom surface and the tapered surface. The inserts of the present invention may be installed in a roller cone of a roller cone drill bit.

1 . A rolling cutter insert, comprising: 
 a generally cylindrical body, a cutting surface, and a bottom surface;    a tapered surface adjacent said generally cylindrical body; and    a generally cylindrical section positioned between said bottom surface and said tapered surface.    
   
   
       2 . The device of  claim 1 , further comprising a radiused corner region adjacent said bottom surface, said radiused corner region being positioned between said bottom surface and said generally cylindrical section.  
   
   
       3 . The device of  claim 2 , wherein said generally cylindrical section is adjacent said radiused corner region.  
   
   
       4 . The device of  claim 1 , wherein said generally cylindrical body has a diameter that is greater than a diameter of said generally cylindrical section.  
   
   
       5 . The device of  claim 1 , further comprising a radiused region positioned between said tapered surface and said generally cylindrical section.  
   
   
       6 . The device of  claim 2 , wherein said radiused corner region defines a transition between said bottom surface and said generally cylindrical section.  
   
   
       7 . The device of  claim 5 , wherein said radiused region defines a transition between said cylindrical section and said tapered surface.  
   
   
       8 . The device of  claim 1 , wherein said tapered surface is formed at an angle of approximately 15 degrees relative to a longitudinal axis of said generally cylindrical body.  
   
   
       9 . The device of  claim 1 , wherein said radiused corner region has a radius of approximately 0.020 inches.  
   
   
       10 . The device of  claim 5 , wherein said radiused region has a radius of approximately 0.20 inches.  
   
   
       11 . The device of  claim 1 , wherein said generally cylindrical section has an axial length of approximately 0.020 inches.  
   
   
       12 . The device of  claim 1 , further comprising a roller cutter drill bit comprised of at least one roller cone, wherein said roller cutter insert is press fit into an opening formed in said roller cone.  
   
   
       13 . A rolling cutter insert, comprising: 
 a generally cylindrical body, a cutting surface, and a bottom surface;    a tapered surface adjacent said generally cylindrical body;    a radiused corner region adjacent said bottom surface; and    a generally cylindrical section positioned between said radiused corner region and said tapered surface, wherein said radiused corner region defines a transition between said bottom surface and said generally cylindrical section.    
   
   
       14 . The device of  claim 13 , wherein said generally cylindrical body has a diameter that is greater than a diameter of said generally cylindrical section.  
   
   
       15 . The device of  claim 13 , further comprising a radiused region positioned between said tapered surface and said generally cylindrical region.  
   
   
       16 . The device of  claim 15 , wherein said radiused region defines a transition between said generally cylindrical section and said tapered surface.  
   
   
       17 . The device of  claim 13 , wherein said tapered surface is formed at an angle of approximately 15 degrees relative to a longitudinal axis of said generally cylindrical body.  
   
   
       18 . The device of  claim 13 , further comprising a roller cutter drill bit comprised of at least one roller cone, wherein said roller cutter insert is press fit into an opening formed in said roller cone.  
   
   
       19 . A rolling cutter insert, comprising: 
 a generally cylindrical body, a cutting surface, and a bottom surface;    a tapered surface adjacent said generally cylindrical body;    a radiused corner region adjacent said bottom surface;    a generally cylindrical section positioned between said radiused corner region and said tapered surface, wherein said radiused corner region defines a transition between said bottom surface and said generally cylindrical section; and    a radiused region positioned between said tapered surface and said generally cylindrical section, wherein said radiused region defines a transition between said generally cylindrical section and said tapered surface.    
   
   
       20 . The device of  claim 19 , wherein said generally cylindrical body has a diameter that is greater than a diameter of said generally cylindrical section.  
   
   
       21 . The device of  claim 19 , wherein said tapered surface is formed at an angle of approximately 15 degrees relative to a longitudinal axis of said generally cylindrical body.  
   
   
       22 . The device of  claim 19 , further comprising a roller cutter drill bit comprised of at least one roller cone, wherein said roller cutter insert is press fit into an opening formed in said roller cone.  
   
   
       23 . A rolling cutter insert, comprising: 
 a generally cylindrical body, a cutting surface, and a bottom surface;    a tapered surface adjacent said generally cylindrical body; and    a region of material positioned between said bottom surface and said tapered surface, said region of material positioned outside of a volume defined, at least in part, by an intersection of a linear extension of said tapered surface with said bottom surface.    
   
   
       24 . The device of  claim 23 , further comprising a generally cylindrical section positioned between said tapered surface and said bottom surface, wherein at least a portion of said generally cylindrical section defines at least a part of said region of material.  
   
   
       25 . The device of  claim 24 , further comprising a radiused corner region between said generally cylindrical section and said bottom surface.  
   
   
       26 . The device of  claim 25 , wherein at least a portion of said radiused corner region defines at least part of said region of material.  
   
   
       27 . The device of  claim 25 , wherein said generally cylindrical section is adjacent said radiused corner region.  
   
   
       28 . The device of  claim 23 , further comprising a radiused corner region positioned adjacent said bottom surface, wherein at least a portion of said radiused corner region defines at least part of said region of material.  
   
   
       29 . The device of  claim 24 , wherein said generally cylindrical body has a diameter that is greater than a diameter of said generally cylindrical section.  
   
   
       30 . The device of  claim 24 , further comprising a radiused region positioned between said tapered surface and said generally cylindrical section.  
   
   
       31 . The device of  claim 25 , wherein said radiused corner region defines a transition between said bottom surface and said generally cylindrical section.  
   
   
       32 . The device of  claim 30 , wherein said radiused region defines a transition between said generally cylindrical section and said tapered surface.  
   
   
       33 . The device of  claim 23 , wherein said tapered surface is formed at an angle of approximately 15 degrees relative to a longitudinal axis of said generally cylindrical body.  
   
   
       34 . A rolling cutter insert, comprising: 
 a generally cylindrical body;    a cutting surface; and    a bottom portion extending from said generally cylindrical body, said bottom portion comprising a bottom surface and a tapered surface, said tapered surface being formed adjacent said generally cylindrical body, wherein said bottom portion is configured such that there is a region of material positioned between said bottom surface and said tapered surface, said region of material being positioned outside of a volume defined, at least in part, by an intersection of a linear extension of said tapered surface with said bottom surface.    
   
   
       35 . The device of  claim 34 , further comprising a generally cylindrical section positioned between said tapered surface and said bottom surface, wherein at least a portion of said generally cylindrical section defines at least a part of said region of material.  
   
   
       36 . The device of  claim 35 , further comprising a radiused corner region between said generally cylindrical section and said bottom surface.  
   
   
       37 . The device of  claim 36 , wherein at least a portion of said radiused corner region defines at least part of said region of material.  
   
   
       38 . The device of  claim 36 , wherein said generally cylindrical section is adjacent said radiused corner region.  
   
   
       39 . The device of  claim 34 , further comprising a radiused corner region positioned adjacent said bottom surface, wherein at least a portion of said radiused corner region defines at least part of said region of material.  
   
   
       40 . The device of  claim 35 , wherein said generally cylindrical body has a diameter that is greater than a diameter of said generally cylindrical section.  
   
   
       41 . The device of  claim 35 , further comprising a radiused region positioned between said tapered surface and said generally cylindrical section.  
   
   
       42 . The device of  claim 36 , wherein said radiused corner region defines a transition between said bottom surface and said generally cylindrical section.  
   
   
       43 . The device of  claim 41 , wherein said radiused region defines a transition between said generally cylindrical section and said tapered surface.  
   
   
       44 . The device of  claim 34 , wherein said tapered surface is formed at an angle of approximately 15 degrees relative to a longitudinal axis of said generally cylindrical body.