Baker Hughes Corporation

Baker Hughes, a Ge Compnay, LLC

Konrad Thomas Izbinski

Nicholas J Lyons

Suresh G Patel

Xu Huang

Alejandro Flores

Richard Wayne Borge

Danny Eugene Scott

Anthony Albert DiGiovanni

Chaitanya K Vempati

Marc William Bird

Aaron J Dick

David A Stockey

Jarod DeGeorge

A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a first transition surface extending from an outer peripheral edge of the polycrystalline, superabrasive material and in a first direction oblique to a center longitudinal axis of the substrate and a curved, stress-reduction feature located on at least the first transition surface. Additionally, the stress-reduction feature may include an undulating edge formed in at least the first transition surface and a waveform extending from the undulating edge formed in at least the first transition surface toward the center longitudinal axis of the cutting element.

Cutting elements configured to reduce impact damage related tools and methods&#x2014;alternate configurations

A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a curved, stress-reduction feature located at least on the first transition surface. The cutting element includes at least one recess defined in the curved, stress-reduction feature of the polycrystalline, superabrasive material. The at least one recess includes sidewalls intersecting with a front surface of the stress-reduction feature of the polycrystalline, superabrasive material and extending to a base wall within the polycrystalline, superabrasive material. The curved, stress-reduction feature includes an undulating edge formed proximate a peripheral edge of the polycrystalline, superabrasive material and a waveform extending from the undulating edge toward the center longitudinal axis of the cutting element.

Cutting elements configured to reduce impact damage and mitigate polycrystalline, superabrasive material failure earth-boring tools including such cutting elements, and related methods

A cutting element comprises a cutting table of a polycrystalline hard material including a cutting face, a sidewall, and at least one peripheral cutting edge portion between the cutting face and the sidewall. A radius of curvature of the peripheral cutting edge portion is greater than a radius of curvature of at least another peripheral edge portion between the cutting face and the sidewall. An earth-boring tool may include one or more such cutting elements.

Cutting elements, earth-boring tools including cutting elements, and methods of forming cutting elements

A cutting element configured to mitigate spalling on a front cutting face thereof. The cutting element include a diamond table having the front cutting face defined thereon and at least one recess defined on the front cutting face of the diamond table. The at least one recess has a width within a range of 25.0 &#x3bc;m to 650 &#x3bc;m and a depth within a range of 25.0 &#x3bc;m to 600 &#x3bc;m. Methods of forming a cutting element configured to mitigate spalling on the front cutting face thereof. The methods including forming at least one recess on a front cutting face of a diamond table to have a width within a range of 25.0 &#x3bc;m to 650 &#x3bc;m and a depth within a range of 25.0 &#x3bc;m to 600 &#x3bc;m. Method of using a cutting element configured to mitigate spalling on the front cutting face thereof.

Cutting elements configured to mitigate diamond table failure, earth-boring tools including such cutting elements, and related methods

Methods of evaluating prototype cutting elements for earth-boring tools may involve generating first and second sets of virtual representations of cutting elements from first and second sets of used cutting elements. First and second sets of measures of damage corresponding to damage for each of the first and second sets set of virtual representations of cutting elements may be determined. A best-performing set of cutting elements from the first and second sets of used cutting elements according to the first and second sets of measures of damage may be identified by performing a statistical analysis.

Methods of evaluating performance of cutting elements for earth-boring tools

Cutting elements for earth-boring tools may include a superhard, polycrystalline material and a substrate adjacent to and secured to the superhard, polycrystalline material at an interface. The substrate may include a first region exhibiting a first coefficient of thermal expansion and a second region exhibiting a second, different coefficient of thermal expansion. The first region may be spaced from the superhard, polycrystalline material. The second region may extend from laterally adjacent to at least a portion of the first region to longitudinally between the first region and the superhard, polycrystalline material.

Methods of reducing stress in cutting elements for earth-boring tools and resulting cutting elements

A method of forming a cutting element for an earth-boring tool includes forming a table of superabrasive material over a substrate in an HTHP environment such that the table of superabrasive material is bonded to the substrate. The table of superabrasive material and the substrate form a cutting element. The method includes removing the cutting element from the HTHP environment, ascertaining predictable residual stresses within the table of superabrasive material, and marking the cutting element with at least one mark. The at least one mark provides indication of a region of the table of superabrasive material having a maximum or minimum residual stress therein. An additional method includes obtaining such a marked cutting element and affixing the cutting element on an earth-boring tool in a preferential orientation as indicated at least partially by the mark.

Methods of forming cutting elements and earth-boring tools carrying such cutting elements

A drilling system that includes a bit body that has a longitudinal axis, a blade of a selected length on a side of the bit body and substantially along the longitudinal axis, and a movable member associated with the blade that extends from a retracted position to a selected extended position along the longitudinal axis, thereby effectively extending the length of the blade when the movable member is in the selected extended position.

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The Woodlands, TX, United States of America

Konrad Thomas Izbinski