Rotating cutting elements for pdc bits

Abstract

A drill bit has a bit body, a plurality of blades extending radially from the bit body, at least one rolling cutter pocket disposed on the plurality of blades, and at least one rolling cutter, wherein each rolling cutter is disposed in one of the rolling cutter pockets, and wherein a side surface of the rolling cutter pocket and an outer circumferential surface of the rolling cutter have at least one mating lip and channel formed therein. Further, the rolling cutter may include a cavity extending at least partially along a rotational axis through the rolling cutter, from a bottom surface of the rolling cutter, and a retention pin disposed within the cavity.

1 . A drill bit, comprising:
 a bit body;   a plurality of blades extending radially from the bit body;   at least one rolling cutter pocket disposed on the plurality of blades, each rolling cutter pocket comprising a side surface;   at least one rolling cutter, wherein each rolling cutter is disposed in one of the rolling cutter pockets, and wherein each rolling cutter comprises:
 a cavity extending at least partially along a rotational axis through the rolling cutter, from a bottom surface of the rolling cutter: and 
   a retention pin disposed within the cavity;   wherein the side surface of the rolling cutter pocket and an outer circumferential surface of the rolling cutter comprise at least one mating lip and channel formed therein.   
     
     
         2 . The drill bit of  claim 1 , wherein the retention pin is integral with the blade. 
     
     
         3 . The drill bit of  claim 1 , wherein the retention pin further extends through a hole the blade, from the rolling cutter pocket to a trailing face of the blade. 
     
     
         4 . The drill bit of  claim 1 , wherein the side surface of the rolling cutter pocket comprises an arc less than or equal to 180 degrees. 
     
     
         5 . The drill bit of  claim 1  any of the preceding claims, wherein the rolling cutter pocket comprises at least one channel formed in the side surface and the rolling cutter comprises at least one lip on the outer circumferential surface. 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The drill bit of  claim 1 , wherein the rolling cutter pocket comprises at least one lip on the side surface and the rolling cutter comprises at least one channel formed in the outer circumferential surface. 
     
     
         11 . The drill bit of  claim 1 , wherein the cavity extends along the rotational axis from the bottom surface to a cutting face of the rolling cutter. 
     
     
         12 . The drill bit of  claim 11 , wherein the retention pin extends entirely through the cavity from the back face to the cutting face. 
     
     
         13 . The drill bit of  claim 11 , wherein the retention pin extends partially through the cavity from the back face of the rolling cutter. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The drill bit of  claim 1 , wherein at least a portion of the side surface of the rolling cutter pocket is formed by a partial sleeve insert. 
     
     
         17 . A method of manufacturing a drill bit, comprising:
 forming a bit body comprising a threaded pin end and a cutting end, wherein at least one blade extends radially from the bit body, and wherein the blade has at least one rolling cutter pocket formed therein; and   placing a rolling cutter into the rolling cutter pocket, wherein the rolling cutter comprises an outer circumferential surface and a cavity extending at least partially along a rotational axis from a bottom surface of the rolling, cutter through the rolling cutter;   wherein a side surface of the rolling cutter pocket and the outer circumferential surface of the rolling cutter comprise at least one mating lip and channel formed therein; and   wherein the rolling cutter is retained in the rolling cutter pocket by a retention pin disposed within the cavity.   
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . The method of  claim 17 , wherein the rolling cutter is placed in the rolling cutter pocket prior to inserting the retention pin within the cavity. 
     
     
         24 . The method of  claim 23 , further comprising attaching the retention pin to blade by a threaded connection. 
     
     
         25 . The method of  claim 23 , further comprising, inserting the retention pin through the blade and screwing a bolt to the retention pin to attach the retention pin to the blade. 
     
     
         26 . (canceled) 
     
     
         27 . The method of  claim 17 , wherein the rolling cutter is placed in a partial sleeve insert prior to placing the rolling cutter with the partial sleeve insert in the rolling cutter pocket. 
     
     
         28 . The method of  claim 27 , wherein the retention pin is integrally formed with the rolling cutter pocket. 
     
     
         29 . A cutting tool, comprising:
 a tool body;   a plurality of blades extending from the tool body;   at least one cutter pocket formed in the plurality of blades;   at least one cutter assembly disposed in the at least one cutter pocket, the at least one cutter assembly comprising:
 a partial sleeve; 
 a rolling cutter having a groove or protrusion formed in an outer circumferential surface thereof and disposed adjacent to a side surface of the partial sleeve; and 
 at least one component interfacing at least a portion of the groove or the protrusion to limit axial movement of the rolling cutter with respect to the partial sleeve, 
 wherein a combination of the partial sleeve and cutter pocket extends greater than 180 degrees around the circumference of the rolling cutter to radially retain in the rolling cutter within the cutter pocket. 
   
     
     
         30 . The cutting tool of  claim 29 , wherein the at least one component comprises a channel formed in the side surface of the partial sleeve, and wherein the rolling cutter comprises at least one lip on the outer circumferential surface that mates with the channel. 
     
     
         31 . The cutting tool of  claim 29 , wherein the at least one component comprises a lip formed on the side surface of the partial sleeve, and wherein the rolling cutter comprises at least one channel in the outer circumferential surface that mates with the lip. 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . (canceled) 
     
     
         35 . The cutting tool of  claim 31 , wherein the partial sleeve further comprises at least one channel formed in the side surface and the rolling cutter further comprises at least one lip in the outer circumferential surface that mates with the channel.