WHIPSTOCK ASSEMBLY
A method of manufacturing a whipstock assembly includes cutting a shape of a body plate from a flat metal plate; forming a concave surface in the body plate; and attaching a body core to the body plate in a mold.
1 . A method of manufacturing a whipstock assembly, comprising:
cutting a shape of a body plate from a flat metal plate;
forming a concave surface in the body plate; and
attaching a body core to the body plate in a mold.
2 . The method of claim 1 , wherein the shape of the body plate includes at least one tab.
3 . The method of claim 2 , further comprising bending the at least one tab.
4 . The method of claim 3 , wherein attaching the body core comprises:
attaching the body core to an inner surface of the body plate; and
at least partially disposing the at least one tab in the core body.
5 . The method of claim 2 , wherein the at least one tab includes a locking feature.
The method of claim 5 , wherein the anchoring feature comprises a hole formed in the tab.
6 . The method of claim 1 , wherein forming a concave surface in the body plate comprises using a pressing operation to form the concave surface.
7 . The method of claim 6 , wherein cutting the shape of the body plate is performed using a stamping process, a laser cutting process, or a water jet cutting process,
8 . The method of claim 1 , wherein the shape of the body plate includes a lug section.
9 . The method of claim 1 , wherein attaching the body core to the body plate comprises adding a filler material to the mold and allowing the filler material to solidify in the mold.
10 . The method of claim 9 , wherein adding the filler material comprises injecting a filler material into the mold.
11 . The method of claim 9 , wherein the filler material is selected from the group consisting of thermoset plastic, concrete, polyvinylidene fluoride polymers, and santoprene polymer.
12 . The method of claim 1 , further comprising forming a retrieval slot in the body core.
13 . The method of claim 1 , further comprising forming a communication channel in the body core.
14 . A whipstock assembly, comprising:
a body plate having a concave surface and a plurality of tabs; and
a body core attached to the body plate, wherein the body core is formed in a mold with the body plate.
15 . The whipstock assembly of claim 14 , wherein the plurality of tabs are at least partially disposed in the body core.
16 . The whipstock assembly of claim 14 , further comprising a communication channel formed in the body core.
17 . The whipstock assembly of claim 16 , wherein the body plate includes a hole for fluid communication with the communication channel.
18 . The whipstock assembly of claim 14 , wherein the body plate has a thickness from 0.1 inches to 2 inches.
19 . The whipstock assembly of claim 14 , wherein the body core comprises a filler material selected from the group consisting of thermoset plastic, concrete, polyvinylidene fluoride polymers, and santoprene polymer.
20 . The whipstock assembly of claim 14 , further comprising an adapter for connection to a downhole tool.
21 . The whipstock assembly of claim 20 , wherein the adapter is formed in the mold.
22 . A method of manufacturing a whipstock assembly, comprising:
cutting a shape of a body plate from a flat metal plate;
forming a concave surface in the body plate;
forming a body core in a mold;
removing the body core from the mold; and
attaching the body plate to the body core.