Hybrid plug drill-out bit

Abstract

A drill bit includes a cone section, a blade flank section, a blade shoulder section, and a plurality of blades connected to the bit body and extending away from the bit body. At least one cutting element is positioned on at least one of the plurality of blades. In addition, a plurality of thermally stable polycrystalline cutters is positioned on at least one of the plurality of blades in at least one of the cone section, the blade flank section, and the blade shoulder section of the at least one of the plurality of blades. The thermally stable polycrystalline cutters include a cutting edge that defines a line, wherein the line is substantially parallel to a tangent line of a radius line that extends from a center of the drill bit to the cutting edge.

1 . A drill bit comprising:
 a bit body having a first end and a second end spaced apart from the first end;   a connection for coupling the bit body to a drill string;   a cone section proximate the second end that extends a first radial distance from a centerline of the drill bit;   a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance;   a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit; and,   a plurality of blades connected to the bit body and extending away from the bit body,   at least one cutting element positioned on at least one of the plurality of blades; and,   a plurality of thermally stable polycrystalline cutters positioned on at least one of the plurality of blades in at least one of the cone section, the blade flank section, and the blade shoulder section of the at least one of the plurality of blades, and   wherein at least one of a) the at least one cutting element or b) the plurality of thermally stable polycrystalline cutters includes a sawtooth profile.   
     
     
         2 . The drill bit of  claim 1 , wherein the sawtooth profile includes at least two tips and at least one recess that separates the at least two tips. 
     
     
         3 . The drill bit of  claim 1 , wherein the at least one cutting element comprises a polycrystalline diamond compact. 
     
     
         4 . The drill bit of  claim 1 , wherein the at least one cutting element and the plurality of thermally stable polycrystalline cutters are positioned on the same blade of the plurality of blades. 
     
     
         5 . The drill bit of  claim 1 , wherein the plurality of thermally stable polycrystalline cutters are positioned on the at least one of the plurality of blades in the cone section and in the blade flank section and in the blade shoulder section. 
     
     
         6 . The drill bit of  claim 1 , wherein the plurality of thermally stable polycrystalline cutters are at least one of a) embedded in a tungsten carbide segment coupled to the at least one of the plurality of blades, b) embedded in a matrix that forms the plurality of blades, and c) brazed to the at least one of the plurality of blades. 
     
     
         7 . The drill bit of  claim 1 , wherein at least one of the cutting element and the plurality thermally stable polycrystalline cutters is a segmented portion of a polycrystalline diamond compact. 
     
     
         8 . The drill bit of  claim 1 , wherein at least a portion of at least one of the plurality of thermally stable polycrystalline cutters is triangular-shaped in cross-section. 
     
     
         9 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, wherein the line is substantially parallel to a tangential line of a radial line that extends from a center of the drill bit to the cutting edge. 
     
     
         10 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, wherein the line intersects a tangential line of a radial line that extends from a center of the drill bit to the cutting edge at an angle less than or equal to 20 degrees. 
     
     
         11 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a planar face and a horizontal line parallel to the planar face, wherein the horizontal line intersects a radial line that extends from a center of the drill bit to the horizontal line at an angle between greater than or equal to 70 degrees and less than or equal to 110 degrees. 
     
     
         12 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a side-rake angle in one of the ranges of a) from 70 degrees to 110 degrees and b) from −70 to −110 degrees. 
     
     
         13 . The drill bit of  claim 1 , further comprising at least one port through which a drilling fluid is capable of passing. 
     
     
         14 . The drill bit of  claim 13 , wherein the at least one port is a slot. 
     
     
         15 . The drill bit of  claim 1 , further comprising a junk slot that separates each of the plurality of blades from an adjacent blade. 
     
     
         16 . A method of making a drill bit, said method comprising:
 forming a bit body having a first end and a second end spaced apart from the first end;   forming a plurality of blades connected to and extending away from the bit body at least at the second end, the plurality of blades including:
 a cone section at the second end that extends a first radial distance from a centerline of the drill bit; 
 a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance; 
 a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit; 
   coupling at least one cutting element to at least one of the plurality of blades;   coupling a plurality of thermally stable polycrystalline cutters to at least one of the plurality of blades in at least one of the cone section, the blade flank section, and the blade shoulder section of the at least one of the plurality of blades, wherein at least one of a) the at least one cutting element orb) the plurality of thermally stable polycrystalline cutters includes a sawtooth profile; and,   forming a connection for coupling the bit body to a drill string on the bit body.   
     
     
         17 . The method of  claim 16 , wherein the sawtooth profile includes at least two tips and at least one recess that separates the at least two tips. 
     
     
         18 . The method of  claim 16 , wherein the at least one cutting element comprises a polycrystalline diamond compact. 
     
     
         19 . The method of  claim 16 , further comprising positioning the at least one cutting element and the plurality of thermally stable polycrystalline cutters on the same blade of the plurality of blades. 
     
     
         20 . The method of  claim 16 , further comprising positioning the plurality of thermally stable polycrystalline cutters on the at least one of the plurality of blades in the cone section and in the blade flank section and in the blade shoulder section. 
     
     
         21 . The method of  claim 16 , further comprising at least one of a) embedding the plurality of thermally stable polycrystalline cutters in a tungsten carbide segment and coupling the tungsten carbide segment to at least one of the plurality of blades, b) forming the plurality of blades from a matrix and embedding the plurality of thermally stable polycrystalline cutters in the matrix, and c) brazing the plurality of thermally stable polycrystalline cutters to at least one of the plurality of blades. 
     
     
         22 . The method of  claim 16 , further comprises segmenting a portion of a polycrystalline diamond compact to form at least one of the cutting element and the plurality of thermally stable polycrystalline cutters. 
     
     
         23 . The method of  claim 16 , wherein at least a portion of at least one of the plurality of thermally stable polycrystalline cutters is triangular-shaped in cross-section. 
     
     
         24 . The method of  claim 16 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, and wherein the method further comprises positioning the line substantially parallel to a tangential line of a radial line that extends from a center of the drill bit to the cutting edge. 
     
     
         25 . The method of  claim 16 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, and wherein the method further comprises positioning the line so as to intersect a tangential line of a radial line that extends from a center of the drill bit to the cutting edge at an angle less than or equal to 20 degrees. 
     
     
         26 . The method of  claim 16 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a planar face and a horizontal line parallel to the planar face, and wherein the method further comprises positioning the horizontal line so as to intersect a radial line that extends from a center of the drill bit to the horizontal line at an angle between greater than or equal to 70 degrees and less than or equal to 110 degrees. 
     
     
         27 . The method of  claim 16 , further comprising positioning at least one of the thermally stable polycrystalline cutters to have a side-rake angle in one of the ranges of a) from 70 degrees to 110 degrees and b) from −70 to −110 degrees. 
     
     
         28 . The method of  claim 16 , further comprising positioning at least one of the thermally stable polycrystalline cutters to have a side-rake angle in one of the ranges of a) from 70 degrees to 110 degrees and b) from −70 to −110 degrees. 
     
     
         29 . A drill bit comprising:
 a bit body having a first end and a second end spaced apart from the first end a connection for coupling the bit body to a drill string;   a cone section proximate the second end that extends a first radial distance from a centerline of the drill bit;   a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance;   a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit;   a plurality of blades connected to the bit body and extending away from the bit body, and,   at least one cutting element that includes a sawtooth profile, the at least one cutting element being positioned on at least one of the plurality of blades.   
     
     
         30 . The drill bit of  claim 29 , wherein the sawtooth profile includes at least two tips and at least one recess that separates the at least two tips. 
     
     
       What is claimed is: 
     
     
         1 . A drill bit comprising:
 a bit body having a first end and a second end spaced apart from the first end;   a connection for coupling the bit body to a drill string;   a cone section proximate the second end that extends a first radial distance from a centerline of the drill bit;   a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance;   a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit; and,   a plurality of blades connected to the bit body and extending away from the bit body, and,   at least one cutting element positioned on at least one of the plurality of blades;   a plurality of thermally stable polycrystalline cutters positioned on at least one of the plurality of blades in at least one of the cone section, the blade flank section, and the blade shoulder section of the at least one of the plurality of blades; and,   wherein at least one of a) the at least one cutting element or b) the plurality of thermally stable polycrystalline cutters includes a sawtooth profile.   
     
     
         2 . The drill bit of  claim 1 , wherein the at least one cutting element comprises a polycrystalline diamond compact. 
     
     
         3 . The drill bit of  claim 1 , wherein the at least one cutting element and the plurality of thermally stable polycrystalline cutters are positioned on the same blade of the plurality of blades. 
     
     
         4 . The drill bit of  claim 1 , wherein the plurality of thermally stable polycrystalline cutters are positioned on the at least one of the plurality of blades in the cone section and in the blade flank section and in the blade shoulder section. 
     
     
         5 . The drill bit of  claim 1 , wherein the plurality of thermally stable polycrystalline cutters are at least one of a) embedded in a tungsten carbide segment coupled to the at least one of the plurality of blades, b) embedded in a matrix that forms the plurality of blades, and c) brazed to the at least one of the plurality of blades. 
     
     
         6 . The drill bit of  claim 1 , wherein at least one of the cutting element and the plurality of thermally stable polycrystalline cutters is a shaped portion of a polycrystalline diamond compact. 
     
     
         7 . The drill bit of  claim 1 , wherein at least a portion of at least one of the plurality of thermally stable polycrystalline cutters is one of (a) triangular-shaped in cross-section, (b) sawtooth-shaped, (c) m-shaped, (d) w-shaped, and (e) star-shaped. 
     
     
         8 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, wherein the line is substantially parallel to a tangential line of a radial line that extends from a center of the drill bit to the cutting edge. 
     
     
         9 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, wherein the line intersects a tangential line of a radial line that extends from a center of the drill bit to the cutting edge at an angle less than or equal to 20 degrees. 
     
     
         10 . The drill bit of  claim 1 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a planar face and a horizontal line parallel to the planar face, wherein the horizontal line intersects a radial line that extends from a center of the drill bit to the horizontal line at an angle between greater than or equal to 70 degrees and less than or equal to 110 degrees. 
     
     
         11 . A drill bit comprising:
 a bit body having a first end and a second end spaced apart from the first end a connection for coupling the bit body to a drill string;   a cone section proximate the second end that extends a first radial distance from a centerline of the drill bit;   a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance;   a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit;   a plurality of blades connected to the bit body and extending away from the bit body, and,   at least one cutting element that includes a sawtooth profile, the at least one cutting element being positioned on at least one of the plurality of blades.   
     
     
         12 . The drill bit of  claim 11 , wherein the sawtooth profile includes at least two tips and at least one recess that separates the at least two tips. 
     
     
         13 . A method of making a drill bit, said method comprising:
 forming a bit body having a first end and a second end spaced apart from the first end;   forming a plurality of blades connected to and extending away from the bit body at least at the second end, the plurality of blades including:
 a cone section at the second end that extends a first radial distance from a centerline of the drill bit; 
 a blade flank section that extends from proximate the first radial distance to a second radial distance from the centerline that is greater than the first radial distance; 
 a blade shoulder section that extends from proximate the second radial distance to a third radial distance greater than the second radial distance, the third radial distance proximate a gauge radial distance that defines a maximum radius of the drill bit; 
   coupling at least one cutting element to at least one of the plurality of blades;   coupling a plurality of thermally stable polycrystalline cutters to at least one of the plurality of blades in at least one of the cone section, the blade flank section, and the blade shoulder section of the at least one of the plurality of blades, wherein at least one of a) the at least one cutting element orb) the plurality of thermally stable polycrystalline cutters includes a sawtooth profile; and,   forming a connection for coupling the bit body to a drill string on the bit body.   
     
     
         14 . The method of  claim 13 , further comprising positioning the at least one cutting element and the plurality of thermally stable polycrystalline cutters on the same blade of the plurality of blades. 
     
     
         15 . The method of  claim 13 , further comprising positioning the plurality of thermally stable polycrystalline cutters on the at least one of the plurality of blades in the cone section and in the blade flank section and in the blade shoulder section. 
     
     
         16 . The method of  claim 13 , further comprising at least one of a) embedding the plurality of thermally stable polycrystalline cutters in a tungsten carbide segment and coupling the tungsten carbide segment to at least one of the plurality of blades, b) forming the plurality of blades from a matrix and embedding the plurality of thermally stable polycrystalline cutters in the matrix, and c) brazing the plurality of thermally stable polycrystalline cutters to at least one of the plurality of blades. 
     
     
         17 . The method of  claim 13 , further comprises segmenting a portion of a polycrystalline diamond compact to form at least one of the cutting element and the plurality thermally stable polycrystalline cutters. 
     
     
         18 . The method of  claim 13 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, and wherein the method further comprises positioning the line substantially parallel to a tangential line of a radial line that extends from a center of the drill bit to the cutting edge. 
     
     
         19 . The method of  claim 13 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a cutting edge that defines a line, and wherein the method further comprises positioning the line so as to intersect a tangential line of a radial line that extends from a center of the drill bit to the cutting edge at an angle less than or equal to 20 degrees. 
     
     
         20 . The method of  claim 13 , wherein at least one of the plurality of thermally stable polycrystalline cutters further comprises a planar face and a horizontal line parallel to the planar face, and wherein the method further comprises positioning the horizontal line so as to intersect a radial line that extends from a center of the drill bit to the horizontal line at an angle between greater than or equal to 70 degrees and less than or equal to 110 degrees.