Increased point of contact Tungsten Carbide insert for fixed rotary drill bit

Abstract

A fixed rotary drill bit, especially the type rotary drill bits incorporating a plurality of spaced polycrystalline diamond compact (PDC) cutters or cutting elements on a plurality of radial blades, includes multiple tungsten carbide inserts (TCI) spaced between the PDC cutters or cutting elements, each TCI providing a mitigation to vibration for the drill bits, rapidly adapting the TCIs by wear from the intermediary formation ridges created from drilling resulting in the creation of a unique kerf in each TCI, thus increasing stability of the bit from lateral instability, making the drill bit more efficient, and promoting a continual steady state of drilling.

What is claimed is: 
     
         1 . An improvement to a fixed rotary drill bit defining a singular cast body forming a lower threaded end, lateral rounded margins, and an upper surface defining a plurality of fixed blades, each blade forming a plurality of spaced cutting element sockets, each cutting element socket containing an individual cutting element, said improvement comprising:
 a plurality of intermittent tungsten carbide insert sockets cast or milled within each blade between a rotational pathway of a plurality of paired sets of cutting elements, each tungsten carbide insert socket containing a singular tungsten carbide insert (TCI), each said tungsten carbide insert located equidistant between a cutting profile of each paired cutting element providing an enhanced and increased point of contact tungsten carbide insert in a polycrystalline diamond compact (PDC) fixed rotary drill bit, the improvement further providing a secondary form of stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize the drill bit.   
     
     
         2 . The improvement to a fixed rotary drill bit, as disclosed in  claim 1 , further comprising:
 each said cutting element is a polycrystalline diamond compact (PDC) cutter affixed within each said cutting element socket by brazing and/or adhesive;   each said TCIs is attached within each respective said tungsten carbine insert socket by brazing and/or adhesive; and   each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top forming a unique wear kerf conforming to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.   
     
     
         3 . The improvement to a fixed rotary drill bit, as disclosed in  claim 1 , further comprising:
 each said TCI includes a cylindrical cross-sectional profile and each respective said tungsten carbide insert socket is cylindrical.   
     
     
         4 . The improvement to a fixed rotary drill bit, as disclosed in  claim 1 , further comprising:
 each said TCI includes a cross-sectional profile selected from a semi-rounded shape, including an oval, oblique or egg-shape and each respective said tungsten carbide insert socket is shaped to strictly conform to the shape of said TCI.   
     
     
         5 . The improvement to a fixed rotary drill bit, as disclosed in  claim 1 , further comprising:
 each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top defining a preformed wear kerf which further conforms during wear to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.   
     
     
         6 . The improvement to a fixed rotary drill bit, as disclosed in  claim 1 , further comprising:
 each of said plurality of TCIs are located between each advancing said paired plurality of said cutting elements, not in-line with any preceding cutting element, each said TCI extending above said blade to a height no greater than an exposure height of said cutting elements and having no interfering effect on said cutting profile of each said advancing paired cutting elements, each said cutting element traveling along a defined individual radial cutting pathway, with a radial pathway of each said TCI equidistant between each said individual radial cutting pathway of said advancing cutting elements.   
     
     
         7 . An improvement to a fixed rotary drill bit defining a singular cast body forming a lower threaded end, lateral rounded margins, and an upper surface defining a plurality of fixed blades, each blade forming a plurality of spaced cutting element sockets, each cutting element socket containing an individual cutting element, said improvement comprising:
 a plurality of intermittent tungsten carbide insert sockets cast or milled within each blade between paired rotational pathways of advancing paired sets of cutting elements, each said tungsten carbide insert socket containing a singular tungsten carbide insert (TCI), each said tungsten carbide insert further located equidistant between a cutting profile of each of said paired cutting element; and   each of said plurality of TCIs, not in-line with any preceding cutting element, extending above said blade at a height no greater than an exposure height of said advancing cutting element and having no effect on a cutting profile of said cutting elements, with said radial pathway of each said TCI equidistant between each said individual radial cutting pathway of said advancing cutting elements, said TCIs providing an increased secondary form of stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize the drill bit.   
     
     
         8 . The improvement to a fixed rotary drill bit, as disclosed in  claim 7 , further comprising:
 each said cutting element is a polycrystalline diamond compact (PDC) cutter affixed within each said cutting element socket by brazing and/or adhesive;   each said TCIs is attached within each respective said tungsten carbine insert socket by brazing and/or adhesive; and   each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top forming a unique wear kerf conforming to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.   
     
     
         9 . The improvement to a fixed rotary drill bit, as disclosed in  claim 7 , further comprising:
 each said TCI includes a cylindrical cross-sectional profile and each respective said tungsten carbide insert socket is cylindrical.   
     
     
         10 . The improvement to a fixed rotary drill bit, as disclosed in  claim 7 , further comprising:
 each said TCI includes a cross-sectional profile selected from a semi-rounded shape, including an oval, oblique or egg-shape and each respective said tungsten carbide insert socket is shaped to strictly conform to the shape of said TCI.   
     
     
         11 . The improvement to a fixed rotary drill bit, as disclosed in  claim 7 , further comprising:
 each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top defining a preformed wear kerf which further conforms during wear to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.   
     
     
         12 . The improvement to a fixed rotary drill bit, as disclosed in  claim 7 , further comprising:
 each of said plurality of TCIs are located between each advancing said paired plurality of said cutting elements, not in-line with any preceding cutting element, each said TCI extending above said blade to a height no greater than an exposure height of said cutting elements and having no effect on said cutting profile of said cutting elements, each said cutting element travels along an individual radial cutting pathway, with a radial pathway of each said TCI equidistant between each said individual radial cutting pathway of said advancing cutting elements.   
     
     
         13 . An improvement to a fixed rotary drill bit defining a singular cast body forming a lower threaded end, lateral rounded margins, and an upper surface defining a plurality of fixed blades, each blade forming a plurality of spaced cutting element sockets, each cutting element socket containing an individual cutting element, said improvement comprising:
 a plurality of intermittent tungsten carbide insert sockets cast or milled within each blade between paired rotational pathways of advancing paired sets of cutting elements, each said tungsten carbide insert socket containing a singular tungsten carbide insert (TCI), each said tungsten carbide insert further located equidistant between a cutting profile of each of said paired cutting element and each said TCI extending above said blade at a height no greater than an exposure height of said advancing cutting elements and having no effect on a cutting profile of each said cutting element, with said radial pathway of each said TCI equidistant between each said individual radial cutting pathway of said advancing paired sets of cutting elements, and each said TCI further defining a rounded top exposed above said blade, said rounded top forming by intended and unique wear kerf conforming to said cutting profile of said respective advancing paired cutting elements, said improvement providing a secondary stabilizing forces to said improved fixed rotary bit to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize the drill bit.   
     
     
         14 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each said cutting element is a polycrystalline diamond compact (PDC) cutter affixed within each said cutting element socket by brazing and/or adhesive; and   each said TCIs is attached within each respective said tungsten carbide insert socket by brazing and/or adhesive.   
     
     
         15 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each said TCI includes a cylindrical cross-sectional profile and each respective said tungsten carbide insert socket is cylindrical.   
     
     
         16 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each said TCI includes a cross-sectional profile selected from a semi-rounded shape, including an oval, oblique or egg-shape and each respective said tungsten carbide insert socket is shaped to strictly conform to the shape of said TCI.   
     
     
         17 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top defining a preformed wear kerf which further conforms during wear to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.   
     
     
         18 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each of said plurality of TCIs are located between each advancing said paired plurality of said cutting elements, not in-line with any preceding cutting element, each said TCI extending above said blade to a height no greater than an exposure height of said cutting elements and having no effect on a cutting profile of said cutting elements, each said cutting element travels along an individual radial cutting pathway, with a radial pathway of each said TCI equidistant between each said individual radial cutting pathway of said advancing cutting elements.   
     
     
         19 . The improvement to a fixed rotary drill bit, as disclosed in  claim 13 , further comprising:
 each said cutting element is a polycrystalline diamond compact (PDC) cutter affixed within each said cutting element socket by brazing and/or adhesive;   each said TCIs is attached within each respective said tungsten carbine insert socket by brazing and/or adhesive; and   each said TCI further including a rounded top exposed above said respective blade and between each said respective rotational pathway of each said respective plurality of paired sets of cutting elements, said rounded top forming a unique wear kerf conforming to a profile of said respective advancing paired sets of cutting elements, each said wear kerf further engaging one of a plurality of radial formation ridges which form within a bottom of a borehole during steady state drilling and during initial restarting of rotation of said fixed rotary drill bit until said fixed rotary drill bit recommences its steady state speed of drilling, further providing greater secondary stability to mitigate vibration from starting, stopping and steady state drilling to maintain and stabilize said fixed rotary drill bit.