Earth-boring tools having cutting elements with cutting faces exhibiting multiple coefficients of friction, and related methods
View Patent ↗An earth-boring tool having at least one cutting element with a multi-friction cutting face provides for the steering of formation cuttings as the cuttings slide across the cutting face. The multi-friction cutting element includes a diamond table bonded to a substrate of superabrasive material. The diamond table has a cutting face formed thereon with a cutting edge extending along a periphery of the cutting face. The cutting face has a first area having an average surface finish roughness less than an average surface finish roughness of a second area of the cutting face, the two areas separated by a boundary having a proximal end proximate a tool crown and a distal end remote from the tool crown.
1. An earth-boring tool, comprising:
a tool crown; and
at least one cutting element attached to the tool crown, the at least one cutting element comprising a superabrasive material having a cutting face and a cutting edge extending along a periphery of the cutting face, a first area of the cutting face having a first average surface roughness and a second area of the cutting face having a second average surface roughness greater than the first average surface roughness, wherein a boundary between the first area and the second area extends from a location on the cutting face proximate a profile of the tool crown to an area remote from the tool crown, and the first area of the cutting face, the second area of the cutting face, and the boundary are in combination located and oriented to steer a formation cutting severed by a portion of the cutting edge in contact with a formation in a direction laterally away from a center of the cutting face as the formation cutting contacts the cutting face.
2. The earth-boring tool of claim 1 , wherein the first area has a first substantially constant surface roughness and the second area has a second substantially constant surface roughness.
3. The earth-boring tool of claim 2 , further comprising a chamfer interposed between the cutting edge and a side surface of a table of superabrasive material, wherein the first area of the cutting face lies adjacent to a first chamfer surface, the first chamfer surface having a surface roughness substantially equivalent to the first substantially constant surface roughness, wherein the second area of the cutting face lies adjacent to a second chamfer surface, wherein the second chamfer surface has a surface roughness substantially equivalent to the second substantially constant surface roughness.
4. The earth-boring tool of claim 2 , wherein the first area and the second area of the cutting face are relatively configured and located to cause the second area to impart a greater sliding friction force than a friction force imparted by the first area to a subterranean formation chip moving over the cutting face to urge the chip laterally away from the center of the cutting face.
5. The earth-boring tool of claim 1 , wherein the boundary is oriented at least substantially perpendicular to the tool crown at a location of attachment of the at least one cutting element to the tool crown.
6. The earth-boring tool of claim 1 , wherein the boundary is oriented at an acute angle to the perpendicular at a location of attachment of the at least one cutting element to the tool crown.
7. The earth-boring tool of claim 6 , wherein the acute angle is in a range extending from about zero degrees to about sixty degrees.
8. The earth-boring tool of claim 1 , wherein the first area and the second area of the cutting face are relatively configured and located to cause the second area to impart a greater sliding friction force than a friction force imparted by the first area to a subterranean formation chip moving over the cutting face to urge the chip laterally away from the center of the cutting face.
9. The earth-boring tool of claim 1 , wherein the first area of the cutting face has a surface roughness of about 0.1 to about 2 microinches.
10. The earth-boring tool of claim 1 , wherein the second area of the cutting face has a surface roughness of about 10 to about 400 microinches.
11. The earth-boring tool of claim 1 , wherein a surface area of the first area of the cutting face is substantially equivalent to a surface area of the second area of the cutting face.
12. The earth-boring tool of claim 11 , wherein the boundary between the first area and the second area is at least substantially linear.
13. The earth-boring tool of claim 12 , wherein the boundary is oriented at an angle to the perpendicular at a location of attachment of the at least one cutting element to the tool crown of between about zero degrees and about sixty degrees.
14. The earth-boring tool of claim 1 , wherein the boundary is arcuate.
15. The earth-boring tool of claim 1 , wherein the second area comprises two or more portions separated by the first area.