Cutter with a lockable retention feature

Abstract

A cutter for a drill bit includes a substrate having opposing first and second ends and exhibiting a first diameter, a cutting layer attached to the substrate at the first end, and a lock member provided at the second end and including a body exhibiting a second diameter less than the first diameter, and at least one locking feature protruding radially from the body. The locking feature is engageable with a locking profile defined within a pocket of a drill bit body.

What is claimed is: 
     
         1 . A cutter for a drill bit, comprising:
 a substrate having opposing first and second ends and exhibiting a first diameter;   a cutting layer attached to the substrate at the first end; and   a lock member provided at the second end and including:
 a body exhibiting a second diameter less than the first diameter; and
 at least one locking feature protruding radially from the body, wherein the at least one locking feature is engageable with a locking profile defined within a pocket of a drill bit body. 
 
   
     
     
         2 . The cutter of  claim 1 , wherein the lock member is integral with the substrate. 
     
     
         3 . The cutter of  claim 1 , wherein the substrate and the lock member comprise separate component parts, the substrate providing a plug exhibiting a third diameter less than the first diameter, and the lock member providing a socket sized to receive the plug. 
     
     
         4 . The cutter of  claim 3 , wherein the plug is freely rotatable within the socket prior to brazing the substrate to the drill bit body. 
     
     
         5 . The cutter of  claim 3 , wherein the plug has a first cylindrical profile and the socket has a second cylindrical profile matable with the first cylindrical profile. 
     
     
         6 . The cutter of  claim 3 , wherein an end of the plug has a first beveled edge around an end face of the plug and a second beveled edge is provided on the socket. 
     
     
         7 . The cutter of  claim 1 , wherein the cutting layer provides a torque profile defined on a face of the cutting layer. 
     
     
         8 . The cutter of  claim 1 , wherein the at least one locking feature comprises four locking features angular spaced from each other about the body. 
     
     
         9 . A cutter for a drill bit, comprising:
 a substrate providing a first portion exhibiting a first outer diameter and plug protruding from the first portion and exhibiting a second outer diameter less than the first outer diameter;   a cutting layer disposed on the first portion; and   a lock member including:
 a socket portion including a socket sized to receive the plug; 
 a body protruding from the socket portion and exhibiting a third outer diameter less than the first outer diameter; and 
 at least one locking feature protruding radially from the body, wherein the at least one locking feature is engageable with a locking profile defined within a pocket of a drill bit body. 
   
     
     
         10 . The cutter of  claim 9 , wherein the plug has a first cylindrical profile and the socket has a second cylindrical profile matable with the first cylindrical profile. 
     
     
         11 . The cutter of  claim 9 , wherein an outer diameter of the socket portion is the same as the first outer diameter. 
     
     
         12 . The cutter of  claim 9 , wherein an end of the plug has a beveled edge around an end face of the plug. 
     
     
         13 . The cutter of  claim 9 , wherein the lock member further includes a first shoulder disposed around a periphery of an entrance of the socket, the first shoulder being engageable with a second shoulder of the first portion of the substrate. 
     
     
         14 . The cutter of  claim 9 , wherein the cutting layer provides a torque profile defined on a face of the cutting layer. 
     
     
         15 . The cutter of  claim 9 , wherein the plug is brazed to the socket. 
     
     
         16 . A drill bit, comprising:
 a bit body;   a blade forming part of the bit body;   a pocket formed in the blade and having a first portion and a second portion, the second portion including an insertion profile and a locking profile that has a plurality of locking surfaces; and   a cutter insertable into the pocket and including:
 a body; and 
 a lock member having a plurality of locking features extending radially from the body, 
   wherein the lock member is insertable into the pocket at a first rotational orientation such that the plurality of locking features are advanced through the insertion profile, and   wherein the lock member is rotatable to a second rotational orientation in which each locking feature is engaged with a corresponding one of the plurality of locking surfaces, thereby axially locking the cutter within the pocket.   
     
     
         17 . The drill bit of  claim 16 , wherein the lock member is integral with a substrate of the cutter. 
     
     
         18 . The drill bit of  claim 16 , wherein the lock member includes a socket configured to receive a plug extending from the substrate. 
     
     
         19 . The drill bit of  claim 16 , wherein the cutter includes a first portion and a second portion, the first portion including a plug and a cutting layer, and the second portion including the body, the lock member, and a socket portion extending from the body and defining a socket configured to receive the plug. 
     
     
         20 . The drill bit of  claim 16 , wherein the cutter includes a cutting layer and a substrate, and wherein the body is formed integrally with the substrate.